pre feasibility report for in

Pre Feasibility Report

for

Capacity Expansion

In

Grain & Molasses Based Distillery

From 120 KLD to 200 KLD

(Cogeneration Power Plant from 04 MW)

Through up-gradation

&

Addition of New Grain & Molasses Based unit of

300 KLD (Cogeneration Power Plant of 06 MW)

At

M/s Som Distilleries Pvt Limited

Village –Sehatganj

Tehsil- Raisen

Dist – Raisen (MP)

Proposed By

M/s Som Distilleries Pvt Limited

23 Zone- II – M.P. Nagar

Bhopal (MP) -462011

1. Identification of project and project proponent

M/s Som Distilleries Pvt Limited has engaged in RS/ENA/ IMFL production since

several years. The management has proposed to expand it’s capacity of grain &

molasses based distillery from 120 KLD to 200 KLD Through up-gradation of

existing plant & machineries and addition of new unit of grain & molasses based

distillery of 300 KLD for production of RS/ENA/-Ethanol/Glycol. Total capacity

of the Unit will 500 KLD and will have two units of 200 KLD and 300 KLD which

will be based on grain and molasses base as feed stock.

Som being a major bottler of IMFL and also having its own brands. SOM’s

management has decided to install world class Grain /Molasses based Distillery

unit to produce super fine alcohol (Extra Neutral Alcohol) and also Absolute

alcohol considering the local fuel ethanol demand

The company is having well defined board of directors followed by managerial and

technical team looking after entire operation. Shri B K Goel is the Sr. Vice

President of the company and shall be look after entire project under his

supervision.

Brief Description of Nature of the Project

M/s Som is operating grain & molasses based distillery having capacity of 120

KLD for production of RS/ENA along with 4 MW Co gen plant , CO2 generation

18,000 MT/Annum. Unit is also having IMFL bottling plant with capacity of

86,400 KL/Annum.

The present proposal is for expansion of grain & molasses based distillery from

120 KLD to 200 KLD through up-gradation of existing plant & machineries as well

as addition of new unit of grain & molasses based distillery of 300 KLD. After

expansion, total capacity of the Unit will 500 KLD and will have two units of 200

KLD and 300 KLD for production of RS/ENA/-Ethanol/Glycol at Village

Sehatganj , Tehsil- Raisen, Dist Raisen in the State of Madhya Pradesh. The

existing cost of the project 239.88 crores whereas for 200 KLD plant it will be Rs

243 ( Existing & Proposed). The project cost of 300 kLD plant will be Rs 855

Crores. Total cost after proposed expansion will be Rs 1098 Crores.

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

distillery operation is being continued from several years.

The Products will specified as RS/ENA/-Ethanol/Glycol for total configuration of

project. .The by product is identified as CO2 which will generate at about 75,000

MT/Annum, DWGS as 1250 TPD shall also be recovered from the proposed unit

wherever it will be operated grain basis.

The existing unit is facilitated with MEE, PCTP, and Slope fired boiler and

maintaining ZLD condition as per norms of SPCB and same status shall be

maintained with the proposed expansion also. . The proposed Industrial Complex

shall process waste and coarse grains as well as Molasses as its raw material to

produce ENA, R.S. Fusel oil, CO2 etc. :

Silent feature of the project

Plant can be operated on different Grain feedstock like broken rice, Corn,

Sorghum, Millet etc. and Molasses as per the availability of raw material

• 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

Imported Buhler makes Mill and efficient Grain handling system is considered.

Closed water recycles system and plant process is designed to minimize fresh

water requirement by recycling various effluents.

Drier is considered to dry distillery wet grain soluble (DWGS ), a mixture of spent

grain and evaporated thick slops:

C02 is discharged as a byproduct of the Fermentation process which in turn can

be utilized after further treatment (Co2 Plant) in industrial or food grade

application which further would contribute to enhance Revenue Generation.

Zero Effluent Discharge norms is applied while designing the plant

TABLE-2.3 – Existing and Proposed Project of 120 KLD

Particular For120 KLD Plant For 200 KLD plant

( 120+80 KLD)

For New Unit

of 300 KLD Plant

Total

Site Address Khasra No. 76/1,2,3 , 77/1,

77/2, 76/4 Village-

Sehatganj, Dist-

Raisen (M.P.)

Khasra No. 76/1,2,3 , 77/1, 77/2, 76/4

Village- Sehatganj,

Dist- Raisen (M.P.)

Khasra No. 76/1,2,3 ,

77/1, 77/2,

76/4 Village-

Sehatganj,

Dist- Raisen (M.P.)

-

Production Capacity 120 KLD of Total Spirit ( RS/ENA)

200 KLD of Total Spirit RS/ENA/-

Ethanol/Glycol

300 KLD of Total Spirit (

Glycol)

500 KLD RS / ENA /

Ethanol / Glycol

No of operation days 300 300 300 300

Cost of Project Rs 239.88 Cr Rs 243 Cr ( 239.88 + Rs 855 Cr 1098 Cr

3.15 Cr)

Grain Requirement 300 MT/day 500 MT/day

( 300 MT+200 MT)

750 MT/day 1250 MT/day

Molasses

Requirement

480 MT/day 800 MT/day 1200 MT/day 2000 MT/day

Boiler capacity at

MCR (100% Load)

40 TPH – 01 nos

25 TPH – 01 nos

Total = 65 TPH

40 TPH – 01 nos

25 TPH – 01 nos

Total = 65 TPH

(Existing)

75 TPH

40 TPH – 01 nos

25 TPH – 01 nos

75 TPH – 01 nos

Total = 140 TPH

Steam Requirement Molasses- 20 TPH Grain- 22.5 TPH

Molasses- 33 TPH Grain- 37.5 TPH

Molasses- 50 TPH

Grain- 56 TPH

Fuel Coal= 60 TPD Coal= 95 TPD Coal=125 TPD (95+125)=220

TPD

Net fresh Water

Requirement

1400 KL 2200 KL

(1400 + 700 KL)

3000 KL

2200 + 3000 KL

Source of water

supply

Borewell Borewell + Surface

Water

Borewell +

Surface Water

Borewell +

Surface Water

Raw Spent wash

Generation

(Molasses)

1200 KLD 2000 KLD 3000 KLD 5000 KLD

Power Requirement 3-3.5 MW 3.5-4.0 MW 6.0 MW 10 MW

Capacity of Co Gen

Plant

4.0 MW 4 MW 6MW 10 MW

Details of DG sets 06 nos x 500 KVA each = 3000 KVA

06 nos x 500 KVA each = 3000 KVA

06 nos x 500 KVA each =

3000 KVA

06 nos x 500 KVA each =

3000 KVA

Effluent Treatment

System

For Molasses Based

: Spent wash will

be concentrated

b y u s i n g multi

effect evaporator and concentrated

spent wash 58%

w/w will be fed to

Incineration Boiler.

P r o c e s s

C o n d e n s a t e T r e a t m e n t

P l a n t ( P C T P )

will treat spent

lees, and process

condensate.

For Grain Based : Spent wash will be

concentrated b y

u s i n g

I n t e g r a t e d

evaporator followed

by DWGS system

Same Same

Quantity of DWGS Generation

300 TPD 500 TPD 750 TPD 1250 TPD

Quantity of coal ash

generation

21 TPD 35 TPD 52 TPD 87 TPD

Quantity of ash from 40 TPD 66 TPD 99 TPD 165 TPD

slope fired boiler

Alternative Source of Power

TG- 4.0 MW TG- 4.0 MW TG- 06 MW Total TG 04+06 = 10 MW

Size of grain storage

silo

2000 MT x 03 nos 2000 MT x 03 nos 2000 MT x 06

nos

Coal & Husk Storage

area

730 sq. mtr 1100 sq. mtr 2000 sq. mtr

Number and

capacity of Molasses

storage tanks

16000 MT

02 No.

16000 MT

36000 MT 16000+36000

MT

No & Capacity of

spent wash holding

tank

1000 m³ 2200 m³ 1300 m³ 4500 m³

Direct employment generation

100 - 32 132

Land acquired

(owned)

160 Acre

Land required for

plant and building

89000 sq mtrs 89000 sq mtrs 242000 sq

mtrs

Existing area of

plantation 1,20,000 sq. mtr

-

1,20,000 sq. mtr

-

Proposed area for

plantation -

- 60,000 sq mtr 1, 80,000 sq mtr

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

The project will be an integrated grain/molasses -processing complex to process

about 1250 MT of grain as well as 2000 MT of molasses for total configuration of

unit as 500 KLD..

The existing and proposed unit will use either molasses or grain at a time as

feed stock. Molasses as by product of sugar industries shall be procured and is

traditional raw material for alcohol. Grain has about 60-68% of Starch will be

used for the manufacture of potable alcohol. The fibers, Protein, Fat, yeast sludge

etc will be utilized for manufacturing DDGS. And Effluent will be concentrated &

mix with dry solids in powder form.

(a) As a result of the integrated processing 100% utilization of input & output as a

raw material, the company will enjoy the unique advantage of being a low cost

of production with high quality.

(b) The required grain and ,molasses is easily available & purchase of such

magnitude would not result in any major fluctuations in prices.

(c) The proposed project may contribute to narrow the gap of demand/ supply of

Indian made foreign liquor. As project will base on modern technology, it will

have an edge over other competitors within & outside the state. Ethyl alcohol is

basically used for three purposes i.e.

Industrial alcohol for production of downstream chemicals,

Potable Alcohol for manufacture of alcoholic beverages (Country Liquor

and IMFL) and 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

Alcohol production in the country has been lagging behind around 1500-

1700million liters per annum. Ethyl Alcohol, Alcohol, Ethanol, Spirit, Denatured

Spirit etc, these are various descriptions for this agriculture-based product. It is a

globally traded commodity, and finds its way in pharmaceutical and chemical

industries, across the world.

The molasses based alcohol was largely used for potable & industrial purpose in

the past. Hence there was always surplus alcohol available in the market. The use

of agro-based alcohol for manufacture of Industrial Chemicals and Fuel Ethanol

depends upon the crude oil prices. The recent trend of increase in the crude oil

prices shows possibilities of greater use of agro based alcohol for various

applications. This clearly indicates that all over the globe there will be tremendous

demand for agro-based alcohol for industrial as well fuel purpose. The company

proposes to manufacture ENA from either grains or molasses which is primarily

used for manufacture of IMFL.

4. Demand –Supply Gap

Demand-Supply Situation of ENA In India

Demand Of Alcohol: Projections (In Million Ltrs.)

Sr. No.

Year

IMFL

Country Liquor

Industrial

Ethanol @ 5%

Other Usage

Total Demand

1 2008-09 461 765 1536 477 74 3312

2 2009-10 516 803 1613 506 77 3515

3 2010-11 578 843 1694 536 81 3731

4 2011-12 647 885 1778 568 85 3964

5 2012-13

6 2013-14

6

Estimated growths are considered as follows.

For IMFL @ 12% P.A. from 103 Mn cases /year.

For Country liquor @ 5 % P.A. from 208 Mn cases.

For Ethanol @ 6% P.A for 5% blending.

For Industrial Chemicals @ 5% P.A.

Demand And Supply Situation: Projected (In Million Ltrs.)

Sr.

No.

Year

Alcohol Production from TOTAL

Production

Total

Demand

Short

fall Molasses Grains Cane

1 2011-12 1677 55 30 1762 3123 1361

2 2012-13 1719 185 60 1964 3312 1348

3 2013-14 1823 370 90 2283 3515 1231

4 2014-15 1934 740 120 2794 3731 937

5 2015-16 2052 1300 150 3502 3964 462

Production of alcohol from molasses is considered @ 250-260 Ltrs / ton of

molasses for the corresponding estimated availability.

Projections for Alcohol production from Grain & Cane are based on market

information.

The estimated production of grain based alcohol in the year 2007 is likely to be

300 to 400 million liters per year and by 2011 it shall be around 1300 million

liters.

The shortfall can be met by increased capacities of grain-based alcohol

than the projected and also by import of alcohol to some extent for industrial

use.

The alcohol industry situation in India is characterized by continued demand

supply gap, despite capacity additions over the years.

Since MP is an molasses deficient State, Govt. of MP has planned to encourage

production of Grain Based Alcohol manufactured from grains only.

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 grain base RS/ENA 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 & Proposed Employment : 132 Nos.

Apart from that indirect employment generation is envisaged from the project.

Total manpower requirement

Sr no. Permanent Staff Existing Proposed for Total configuration of 500 KLD 1. Distillery manager 1 1

2. Production manager 4 4

3. ETP in-charge 1 1

4. Lab chemist 6 6

5. Operators 12 16

6. Project Engineer / Shift Engineer 6 10

7. Electrician 8 10

8. Mechanical fitters 14 18

9. Office Peon 6 8

10. Office assistant 4 6

11. Excise officer 2 2

12. Waterman/ Pump man 6 10

13. Other Contractual staff 30 40

14. Total 100 132

9 Project Description

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

No interlinked and interdependent project with the proposed plant. This existing

Co Gen Plant is 4.0 MW whereas proposed Co-gen plant of 06 MW is proposed.

Incineration Boiler of 75 TPH is also proposed for implementation of zero

discharge concept whenever [plant will be operated on Molasses base. CO2 will

also generate as by product from the fermentation process which is turn can be

utilized after further treatment at CO2 plant in industrial or food grade application.

It is also proposed Evaporation plant/ Slope fired Boilers 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 160 acres of land in village Sehatganj Tehsil, Raisen

Dist. – Raisen of MP. The latitude and longitude of the site is as below

1. 23°15' 18 "N- 77°38'05"E 2. 23°15' 24 "N- 77°37'55"E

3. 23°15' 27 "N- 77°38'01"E 4. 23°15' 11 "N- 77°37'59"E

A. Satellite Image of the Project area

B. Satellite Image of the Study area

C. Location Map

D. Topographical Base Map

iii. Details of Alternate Site:

The site is proposed on the piece of land where existing distillery unit 120 KLD is

already in operation. The total acquired land is about 160 acres. No additional

land is required for 200 KLD plant as it will be achieved through up gradation in

existing plant of 120 KLD, proposed unit of 300 KLD will require 90 acres of land.

Most of the infrastructure is already available. Therefore proposed site suitable for

the project configuration.

iv. Size Or Magnitude Of Operation:

M/s Som is operating grain & molasses based distillery having capacity of 120

KLD for production of RS/ENA along with 4.0 MW co gen plant , Co2 18,000

MT/Annum. Unit is also having IMFL bottling plant with capacity of 86,400

KL/Annum

The present proposal is for expansion of grain & molasses based distillery from

120 KLD to 200 KLD through up-gradation of existing plant & machineries as

well as addition of new unit of grain & molasses based distillery of 300 KLD .

After expansion, total capacity of the Unit will 500 KLD and will have two units of

200 KLD and 300 KLD for production of RS/ENA/Ethanol/Glycol

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 Rs/ENA/ Ethanol /

Glycol and co-products from grain and molasses .

PROCESS DESCRIPTION FOR GRAIN BASED OPERATION 1. Grain Storage Silos, Cleaning, Handling And Milling Section:

Grain is received from various sources and is pre-cleaned off Stones, husk, straws

and iron metals etc. and then Stored in specially designed Storage Silos. Grains

are continuously lifted from the bottom of the Silos and screened followed by

removal of stones in De-stoner and iron metals in Magnetic Separators. Cleaned

Grains are then milled using dry milling process in Hammer Mills. The flour is fed

through the bucket elevator and conveyed to the Batch Machine through a Screw

Conveyor.

2. Slurry Preparation / Liquefaction

Slurry from pre-masher is taken to Initial liquefaction tank where liquefying

enzyme is added. The mixture of slurry and steam is then passed through the

retention vessel (cook tube) having sufficient capacity to provide the desired

retention time at a given flow rate. The cooked mash is discharged to a flash tank

for liquefaction.

The gelatinized mash from the flash tank is further liquefied in a final liquefaction

tank where liquefying enzyme is added. Then the liquefied mash is passed through

plate heat exchanger and cooled slurry transferred to Fermentation section.

3. Fermentation Section

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

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

and Co2 is generated as by Product. 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 fermenter into Beer Well.

5. DistillationSection

Wash to ENA Multi-pressure: -

Pre-heated fermented wash is fed into a series of Distillation Columns to increase

the alcohol concentration and remove various impurities including Fusel oil as by

product .The columns are termed as below:

a. Analyzer

b. Degasifier

c. Pre Rectifier

d. Extractive Distillation

e. Rectifier cum Exhaust

f. Recovery

g. Simmering

ENA drawn from the Simmering Column is taken to the receiver after cooling in

ENA cooler.

5. Evaporation Section

The Spent Wash discharged from the Analyzer column bottom is taken to the

Decanter for separation of suspended solids then thin slop to evaporation section

for concentrating the slop up to 40%w/w solids. Treatment scheme is a series of

evaporation effects working on the principle of falling film Evaporation & Forced

circulation.

6. Dryer Section

The concentrated syrup is mixed with the wet cake from the decantation section

.This mixture is termed as DWGS which either sold as cattle feed or fed in Dryer to

reduce the moisture up to 10%. This by product is termed as DDGS which is in a

powder form.

7. Process Condensate Treatment Section

The process condensate from the evaporation section is partially recycled in

making Grain Slurry and balance qty treated in this unit and this treated

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

consumption.

Product Specification Extra Neutral Alcohol (ENA):

S.No Parameter Unit Value

1. Specific Gravity at 15.6 deg C 0.80692

2. Ethanol content at 20 deg C % v/v 96

3. Acid as acetic acid by GC Analysis ppm ≤ 3

4. Butanol ppm Nil 5. Diacetal ppb 200 max

6. Aldehyde as acetaldehyde, ppm <1

7. Esters as ethyl acetate ppm <1

8. Copper ppm Nil

9. Lead as Pb, ppm Nil

10. Methanol ppm <2

11. Furfural ppm Nil

12. N-Propanol & iso-Propanol ppm Nil 13. Dry Extract ppm Negligible

14. Permanganate Time at 15 Deg C IS 1049

minutes 50

Typical DWGS Product Specification

Crude Protein, wt. percent, dry basis, min 30.0

Crude Fat, wt. percent, dry basis, min 6.0

Crude Fiber, wt. percent, dry basis, min 8.5

Ruminant TDN, wt. percent, dry basis, min 88.0

Note: This may vary depending on the quality of raw material.

Process Flow Chart For Grain Based Operation

PROCESS DESCRIPTION FOR MOLASSES BASED OPERATION

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 270 C and 300 C and are

held a 320 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 350 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

400 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 Corporate Responsibility to achieve Zero Discharge in

Inland Surface Water. For 120/200/300 KLPD distillery plant nearly about 1200

, 2000, 3000 M3/Day Raw spent wash is/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

Process flow diagramme ( Molasses Based )

Existing & Proposed Co-generation Power Plant [4.0 & 6.0 MW]

Proposed 6 MW co-generation plant consists of high pressure AFBC water tube

steam boiler & back pressure steam turbine. Fuel in the steam boiler will be burnt

with the help of air in the boiler furnace. Water will be circulated in the boiler

drum and tubes thus getting heated by the flame burning in the boiler furnace.

Water comes out of the boiler drum located at the top of the boiler as steam. Flue

gases rise in the boiler furnace and come in contact with the steam coming out of

boiler drum. Steam after coming in contact with flue gases gets heated up further

thus getting superheated. Super heated steam leaves the boiler in a pipe. Flue

gases after super heating the steam pass through economizer where they pre-heat

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

pass through air pre-heaters where they heat the air which is fed to the boiler

furnace for burning the fuel. After air pre heaters flue gases pass through a bag

house filter where the dust particles are collected in filter bags & discharge from

the bottom of the bag house filter. Dust will be collected in the Ash Silo through

pneumatic conveying system.

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

and low pressure goes to Low pressure header, which is used for distillery. While

passing through the turbine, the high pressure and temperature steam rotates the

turbine rotor and an electric alternator mounted on the same shaft. Electric power

is generated by the alternator. This electric power generated is consumed in house

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

Process Flow Chart of Exiting project of 120 KLD (CPP)

Power

Steam

To MEE Plant

DWGS

To Distillation

To Hydro heater/Jet cooker

Working Pressure

3.5 Kg/Cm2

(g)

Working Pressure

3.5 Kg/Cm2

(g)

BOILER – 40 TPH

Pressure – 45 Kg/Cm2

(g)

Temp – 400º C ± 05º C

Turbine 4 MW

Exhaust Steam Header

Pressure 4.0 Kg/Cm2(g)

11 KV Voltage

Alternator

Sub Station Step down

Transformer

Power Control

Circuit Panel

Motor Control Circuit Panel

Field Equipment

Process Flow Chart of proposed project of 200 KLD (CPP)

Power

Steam

To MEE Plant

DWGS

To Distillation


Working Pressure

3.5 Kg/Cm2

(g)

Working Pressure

3.5 Kg/Cm2

(g)

BOILER – 40 TPH


(g)

Temp – 400º C ± 05º C

11 KV Voltage

Alternator


Transformer

Power Control

Circuit Panel

Turbine 4 MW




Field Equipment

Process Flow Chart of proposed project of 300 KLD (CPP)

Power

Steam

To MEE Plant

DWGS

To Distillation


Working Pressure

3.5 Kg/Cm2

(g)

Working Pressure

3.5 Kg/Cm2

(g)

Quantity of Raw Materials Required;

Raw Material Quantity Per Day Source

Mode of

Transportat

ion

For 120 KLD For 200 KLD

120+80 KLD

For 300

KLD Total

Grain / Flour

300 MT 500 MT 750 MT 1250

MT

Local Anaj

Mandi /

Private

Supplier

Trucks

Molasses 480 MT 800 MT 1200 MT 2000

MT

Sugar Mills By Road

Tankers

BOILER – 75 TPH


(g)

Temp – 400º C ± 05º C

Turbine 6 MW



11 KV Voltage

Alternator


Transformer

Power Control

Circuit Panel


Field Equipment

Coal 60 MT 95 MT 125 MT

220

MT

Local

supplier /

Private

Supplier

Trucks

Antifoam Agent In Mol-

200 kg/ltr

In Grain-

100 kg/ltr

In Mol-

333 kg/ltr

In Grain-

166 kg/ltr

In Mol-

500 kg/ltr

In Grain-

250 kg/ltr

Bhopal Tanker /

Drums or Barrels in

Trucks/Mini

Trucks

NaOH (50%) In Mol-

350 kg/ltr

In Grain-

350 kg/ltr

In Mol-

583 kg/ltr

In Grain-

583 kg/ltr

In Mol-

875 kg/ltr

In Grain-

875 kg/ltr

Bhopal Trucks /

Drums or

Barrels in Trucks/Mini

Trucks

Phosphoric acid

(75%0 - - -

Bhopal Mini Truck

Enzymes like

Liquizime Mol- Nil

Grain-100 kg

Mol- Nil

Grain-166 kg

Mol- Nil

Grain-250

kg

Enzymes like

Spzyme Mol- Nil Grain-120 kg

Mol- Nil Grain-200 kg

Mol- Nil

Grain-300 kg

Yeast (In Grain

Only) 40 kg 66 kg 100 kg

Bhopal Mini Truck

Urea (In Molasses) 375 Kg 625 Kg 937 Kg

Alcorise Biocide (In

Molasses) 9 kg 15 kg 22 kg

vii. Resource optimization/ recycling and reuse

Advantages of Grain Plant over the Molasses Plant

1. Water consumption is reduced by 30 to 40% % in the system adopted for MEE,

CPU and Slope fired boiler

2. Effluent generation is also reduced by 30% in the Grain based plant as

compare to Molasses based plant

3. Hydraulic Load is also reduced by 40-50%

4. By adaptation of such technology for production of ENA , reduction in pollution load

is proven fact..

• Centrifuge Decanter is used for separation of suspended solid from the spent wash

coming out of the distillation plant when plant is operated on grain basiselse MEE

followed by slope fired boiler will be used when plant will be operated on Molasses

basis.

• Wet cake has 30-35% w/w solids as removed from the bottom of the Decanter.

Thin slops coming out from decanter will be collected in a tank & transferred for

the partial recycling & remaining for Evaporation. The separated solid shall be

converted as DWGS, which is protein reach cattle feed having good market value.

The ash generated form incinerator boiler is rich in potash content and having

good value to be used as manure in the field.

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 16

TPH for spirit only 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

accesNos 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.

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

Water requirement:

Construction Phase – 20-30 kld

Operational Phase – Water requirement for the existing and proposed project is ass

follows :

Feed Stock Molasses Grain

S

No

Plat

Capacity

KLD

Description Water

Requirement

without

recycle in KLD

Water

Requirement

with recycle

in KLD

Water

Requirement

without

recycle in KLD

Water

Requirement

with recycle

in KLD

1 120 Process water 1075 200 728 12

Soft water 862 455 810 622

DM water 1232 278 1274 363

Total water 3169 933 2812 997

Water

Requirement

Kl/KL

26.4 7.8 23.4 8.3

2 200 Process water 1765 313 1175 11

Soft water 1430 771 1345 1026

DM water 2050 464 2120 604

Total water 5245 1548 4640 1641

Water

Requirement Kl/KL

26.2 7.7 23.2 8.2

3 300 Process water 2625 486 1736 8

Soft water 2140 1152 2013 1537

DM water 3072 691 3176 901

Total water 7837 2311 6925 2446

Water

Requirement

Kl/KL

26.1 7.7 23.1 8.15

ix. Power Requirement:

Construction Phase – 30 kw

During Operation Phase

Power Requirement for

Grain Base Plant

Existing 120 KLD 200 KLD 300 KLD

Operating

in kwh

Connected

in kwh

Operating

in kwh

Connected

in kwh

Operating

in kwh

Connected

in kwh

Pre-cleaning, Storage

Silo

Grain & Flour Handling 450 575 540 690 848 1083

Hammer Mills ( Buhler

Make)

Liquefaction Section 190 340 228 408 358 641

Fermentation Section 600 850 720 1020 1130 1601

Distillation Section 250 500 300 600 471 942

Decantation 225 275 270 330 424 518

Dryer

Integrated Evaporation Section 285 450 342 540 537 848

Utilities: Cooling Towers,

Instrument Air

Compressor and Yard

piping 950 1400 1140 1680 1790 2638

C02 Plant

Alcohol Storage

Process Condensate Treatment Plant 230 350 276 420 433 660

WTP

Boiler, Turbine

Total Power

requirement 3180 4740 3816 5688 5991 8931

Power Requirement for Molasses Based Plant

Existing 120 KLD 200 KLD 300 KLD

Operating in kwh

Connected in kwh

Operating in kwh

Connected in kwh

Operating in kwh

Connected in kwh

Fermentation 650 900 780 1080 1225 1696

Distillation 250 500 300 600 471 942

MSDH

Integrated RSW

evaporation 300 475 360 570 565 895

Process condensate

treatment plant 230 350 276 420 433 660

Alcohol storage

Utility (Cooling tower) 1150 1640 1380 1968 2167 3090

Instrument air

compressor

Total 2580 3865 3096 4638 4861 7283

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

power plant. Details of co gen plant and turbine is a s follws :

Turbine for Existing Co-Generation Power Plant of 4 MW for 120 KLD

Parameters Details

Turbine Back Pressure Type

Back Pressure 4.0 kg/cm²

Turbine RPM 7500

Capacity 4.0 MW

Alternator 4.0 MW

Turbine Efficiency 90 %

Alternator Efficiency 85 %

Turbine for Co-Generation Power Plant of 4 MW for 200 KLD

Parameters Details



Turbine RPM 7500

Capacity 4.0 MW

Alternator 4.0 MW



Turbine for Proposed Co-Generation Power Plant of 6 MW for 300 KLD

Parameters Details



Turbine RPM 7500

Capacity 4.0 MW

Alternator 4.0 MW



Existing DG set of 3000 KVA is kept as standby arrangement. For capacity

expansion same arrangements are proposed.

Details of DG

S. No. Details

Existing Proposed

1. Type of Fuel HSD HSD

2. Capacity 500 KVA X 6 NOS SAME

3. Stack Height 5 MTR 5 MTR

4. Pollution Control Equipment Measures

Adequate stack height/ Acoustic

Steam Requirement

S No Plant Capacity Description Molasses Grain

A 120 Steam Consumption

(kg/lit)

5.5 5.5

Steam Consumption TPH

27.5 27.5

Boiler Capacity TPH 35 32

B 200 Steam Consumption

(kg/lit)

5.5 5.5

Steam Consumption

TPH

45.8 45.8


B 300 Steam Consumption

(kg/lit)

5.5 5.5

Steam Consumption

TPH

68.8 68.8


Energy and Steam Balance (Existing & Proposed) Existing Balance for 120 & 200 KLD Plant -

To Dearator (0.7 TPH) To MPR (13.0 TPH) To Liquification (1.7 TPH) To MEE (1.5 TPH) To Dryer (2.8 TPH)

Consumed in Process Plant

Stand By- To Dearator (7.0 TPH) To Process (29.1 TPH) To Dryer (9.0 TPH)


Boiler

Generation - 25 TPH

Pressure - 45

Kg/Cm2(g)

Turbine

Low Pressure

Header

Flow – 25 TPH

Pressure – 3.5

Kg/Cm2(g) Power Generation

4.0 MW

Boiler

Generation - 40 TPH

Pressure - 67

Kg/Cm2(g)

Turbine

Low Pressure Header

Flow – 40 TPH

Pressure – 4.0

Kg/Cm2(g) Power Generation 4.0

MW

Proposed Balance for 300 KLD- To Dearator (7.0 TPH) To Process (29.1 TPH) To Dryer (9.0 TPH)


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

management/ disposal

For Liquid Waste

Following are details of spent wash and process condensate generation for

existing and proposed configuration .

Spent Wash Generation to MEE

S

No

Plant Capacity

KLD

Description Molassees Grain

A 120 Raw Spent

Wash/Thin Slop -

TPD

Raw Spent

wash : 1308

Conc Spent wash : 158

511

Solid In spent wash

-%w/w

14 7.77

Conc Product –TPD 305.2 113

Solid in Conc

product -% w/w

60 35

Evaporation duty

TPD

1002.8 398

B 200 Raw Spent

Wash/Thin Slop -TPD

Raw Spent

wash : 2179 Conc Spent

wash : 264

853

Solid In spent wash

-%w/w

14 7.77

Conc Product –TPD 508.4 189

Solid in Conc

product -% w/w

60 35

Evaporation duty

TPD

1670.6 664

C 300 Raw Spent Wash/Thin Slop -

TPD

Raw Spent wash : 3268

Conc Spent 3sh

: 396

1280

Solid In spent wash

-%w/w

14 7.76

Boiler

Generation - 75 TPH

Pressure - 67

Kg/Cm2(g)

Turbine

Low Pressure Header

Flow – 75 TPH

Pressure – 4.0

Kg/Cm2(g) Power Generation

6.0 MW

Conc Product –TPD 763 284

Solid in Conc

product -% w/w

60 35

Evaporation duty

TPD

2505 996

Process Condensate Plant

S

No

Plant Capacity

KLD

Description Molasses (TPD) Grain (TPD)

A 120 Feed to PCTP 723 138

Reject to Evaporation 108 21

Reject to Ferm 277 -

Recycle to CT 338 117

B 200 Feed to PCTP 1205 238




C 300 Feed to PCTP 1807 357




Treatment Scheme for Grain Based for Existing and Proposed Configuration

During operation, Grain Slops will be taken through Centrifuge Decanters for

separation of suspended solids.

Spent wash (720 M3 per day) will pass through centrifuge decanter for separation

of solid. The part of thin slope 576 M3 per day from centrifuge will be recycled to

process.

• The remaining slop will be concentrated through multi effect evaporator.

• The concentrated syrup will be mixed uniformly in the ribbon mixer to form DWGS

(300 MT per day). DDGS will be sold as cattle feed.

200 KLD

Spent wash (1224M3 per day) will pass through centrifuge decanter for separation

of solid. The part of thin slope 980 M3 per day) from centrifuge will be recycled to

process.




300 KLD

Spent wash (1836 M3 per day) will pass through centrifuge decanter for separation

of solid. The part of thin slope 1469 M3 per day) from centrifuge will be recycled to

process.




Treatment Scheme

Decantation Section

• Centrifuge Decanter is used for separation of suspended solid from the spent wash

coming out of the distillation plant.

• Wet cake has 30-35% w/w solids as removed from the bottom of the Decanter.

• Thin slops coming out from decanter will be collected in a tank & transferred for

the partial recycling & remaining for Evaporation.

Evaporation section

The suggested treatment scheme is a Multi Effect Evaporator with thermal

recompression for Thin Slops Evaporation. The following points will elucidate the

basic working principal:

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

the principal of Falling Film Evaporation.

• Analyzer vapors are fed to the 1st effect evaporator shell side at the given pressure

& temperature as the heating medium.

• The Feed is fed from the top of the 1st effect evaporator which is Falling Film

Evaporator-1

• Vapors generated in the 1st effect VLS (Vapour Liquid Separator) are used as heat

source in the 2nd effect. 3rd effect(finisher) is on steam.Vapours generated in the

2nd & 3rd effects VLS are condensed on shell side of Surface Condenser for

Evaporator.

• The Total Solid will be obtained at the outlet of the 3rd effect evaporator. A shell &

tube type multi pass surface condenser is employed for condensing the shell side

vapors.

• The operation of the plant will be under vacuum. Vacuum will be created with the

help of a water ring vaccum pump. Cooling water from the cooling tower is used

in the surface condensers for condensing the vapors.

• Lees of 100 m3/day is recycled back for Molasses dilution . Balance 100 m3/day

lees sent to CT make up after heat recovery. 600 m3/day of Process condensate is

fed to PCTP unit.

3. 510 m3/day treated water will return back to process for utilization in

liquefaction/fermentation/cooling tower etc.

4. Rainwater will be utilized to recharge the underground resource through

scientifically designed rainwater harvesting system.

5. 7 M3/day of boiler blow down will be sent for ash quenching.

Treatment Scheme for Molasses Based for Existing and Proposed

Configuration

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.

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.

The concentrated spent wash generated after entire process of evaporation is then

sprayed in a furnace with baggass as support fuel and is then burnt in a boiler. Som

proposes to employ spent wash Concentration and Incineration Technology,

simultaneously generating Steam and Power required for the Distillery process. With

effective utilization of such a technology, major hurdle of spent wash disposal will be

solved and the propose distillery will become a ZLD unit

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 the

entire 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

Solid And Hazardous Waste Management

Solid Waste Management

S

No

Plant Capacity

KLD

Description Molasses (TPD) Grain (TPD)

A 120 DWGS - 300

Boiler ash (Coal Ash) 21 45

Waste papers/Boxes

Yeast Sludge NIL NIL

Lime Sludge NIL NIL

WTP Sludge NIL NIL

ETP Sludge -

Incinerated Ash 40 -

B 200 DWGS - 500

Boiler ash (Coal Ash) 35

Waste papers/Boxes

Yeast Sludge NIL NIL

Lime Sludge NIL NIL

WTP Sludge NIL NIL

ETP Sludge

Incinerated Ash 66

C 300 DWGS - 800

Boiler ash (Coal Ash) 61 131

Waste papers/Boxes

Yeast Sludge NIL

Lime Sludge NIL

WTP Sludge NIL

ETP Sludge

Incinerated Ash 116

4.0 Site Analysis:

i. Connectivity

Location : Own land at Village Sehatganj

Tehsil –Sanchi, District- Raisen (MP)

Khasara No : 76/1,2,3 , 77/1, 77/2, 76/4

Details of Environmental Settings

S. No. Particulars Details

1. Locations

A. Village Sehatganj

B. Tehsil Sanchi

C. District Raisen

D. State Madhya Pradesh

Toposheet No. 55-E/11 & 55-E/12

2. General ground level 445-439m above MSL

3. Nearest National/ State Highway Bhopal- Sagar National Highway-86 – 0.01km- N

4. Nearest Railway Station Habibganj – 20km Bhadbhada Ghat – 16.50km

5. Nearest Airport Bhopal – 30.75km

6. Nearest Religious place Kankali Mandir- 6.25km- SW

7. Archaeological Important Place None within 10km radius

8. Ecological Sensitive Areas (Wild Life Sanctuaries)

None within 10km radius

9. Reserved / Protected Forest within 10km radius

Raisen RF - 0.50km - NE Goharganj RF - 0.25km - S Bilarkhoh PF - 0.75 km - W Bhopal RF - 5.00km - W

10. Nearest major city >50000 population

None

11. Nearest Town/City within 10km radius

Bhopal – 13.00 km

12. Dist. Head quarter Raisen- 15.50km

13. Other Industry within 10km radius Pipalkhiriya Industrial Area- 1.00km- E

14. Surrounding village within 1 km area of the project.

Sehatganj – 0.5km – N Pipalkhiriya – 0.75km- E

15. Nearest village Sehatganj – 0.5km – N

16. Nearest River Betwa River –4.25 km – SE Kubu Nadi – 5.25km- ESE Ajnar Nadi – 6.50km- W

17. Nearest Nalla/Lake/ Ponds No. of Seasonal nallas/gullies which flows rainy season Maniari Nalla – 6.25km- N Jogikhar Nalla – Adjacent – S Ajnal Dam – 6.50km- W

18. Surrounding features within 500m radius

N- NH- 86 S- Jogikhar Nalla E- Seasonal gullies W- Agricultural land

ii. Land Form, Land use and Land Ownership

Project Proponent is having 80 acres of land which is possession and diverted for

industrial purposes.

iii. Topography

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

iv. 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 & Proposed Unit

Land use Break-Up For Existing & Proposed Unit

Area In Sq mtrs

Particular Existing 120

KLD

Proposed

120+80 KLD

Proposed 500 Unit

( 120+80+300 KLD)

Built up Area of main

plant and machineries

33600 (roof

area included)

33900(roof area

included)

42545 (roof area included)

Road area 15590 15590 22550

Raw Material storage

area

5865 5865 16000

Fuel Storage Area 2050 2050 5600

Parking area 4000 4000 10900

Green Belt 1,20,000 1,20,000 180000

Total 181405 181405 277595

Open Land 142073 142073 46153

Total acquired area 3,23,748 3,23,748 3,23,748

v. Existing Infrastructure

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

State Highway is passing at 50 mtrs from the industry.

vi. Soil Classification

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

vii. Climate data from Secondary Source:

Meteorological data month of 15th March, 14 to 14th April, 2017

Date

Temperature OC Relative

Humidity %

Morning

km/hr 8.00hr

Evening

km/hr

17.00hr

Cloudiness

%

Max Avg Min Max Avg Min Wind Dirt

Wind Speed

Wind Dirt

Wind Speed

Mor Eve

15 35 27 18 64 48 32 SE 7.4 WNW 14.8 10 -

16 34 27 19 66 45 30 E 5.6 NE 9.3 - -

17 37 28 19 51 40 29 SE 14.8 WNW 24.1 - -

18 35 28 22 51 38 30 C 0 WSW 18.5 10 -

19 33 24 16 61 40 27 ENE 14.8 WNW 14.8 - -

20 34 26 17 55 36 23 SE 11.1 WNW 22.2 - 10

21 35 26 16 71 37 21 S 9.3 W 27.8 - -

22 34 25 16 64 43 28 WSW 7.4 NW 14.8 - -

23 36 26 17 61 41 30 NNW 3.7 WSW 3.7 10 -

24 36 28 19 55 39 20 SE 9.3 WSW 18.5 20 -

25 36 29 22 60 32 12 C 0 C 0 - 30

26 36 28 19 37 24 9 WNW 14.8 W 18.5 - -

27 38 29 21 41 27 11 SSE 7.4 WNW 22.2 - -

28 38 29 19 41 24 11 N 5.6 W 18.5 10 -

29 38 30 22 32 19 10 NW 14.8 WSW 20.4 - -

30 38 29 20 30 20 9 NW 14.8 W 18.5 - 10

31 37 29 21 48 23 11 ENE 18.1 W 18.5 - -

1 36 28 19 39 19 9 WNW 9.3 W 22.8 - -

2 36 28 19 27 18 10 W 18.5 WSW 11.1 - -

3 37 29 21 39 22 12 WNW 18.5 NNW 14.8 - -

4 37 29 22 35 22 12 C 0 NW 5.6 - -

5 39 30 21 38 20 7 S 14.8 WSW 11.1 10

6 39 30 21 33 18 11 NNW 14.8 WSW 22.8 -

7 38 30 23 30 21 12 C 0 C 0 -

8 37 29 22 33 25 13 C 0 C 0 -

9 37 29 21 47 22 8 E 5.6 WNW 18.5 -

10 37 28 19 33 18 10 NE 9.3 WSW 9.3 -

http://www.wunderground.com/history/airport/VANP/2011/12/15/DailyHistory.html

















11 37 28 19 35 19 10 NNE 7.4 SW 11.1 -

12 37 28 18 31 18 7 C 0 SSE 9.3 -

13 38 30 21 35 22 10 SE 7.4 SSW 5.6 - -

14 39 30 21 39 27 13 S 18.5 SW 9.3 - -

Meteorological data month of 15th April, to 14th May, 2017

Date


Humidity %

Morning km/hr

8.30hr

Evening km/hr

17.30hr

Cloudiness

%

Max Avg Min Max Avg Min Wind

Dirt

Wind

Speed

Wind

Dirt

Wind

Speed Mor Eve.

15 39 30 22 42 25 13 SW 7.4 W 9.3 - -

16 40 32 25 31 21 12 WSW 5.6 NNW 18.5 - -

17 39 31 24 48 29 15 C 0 C 0 - -

18 39 31 23 44 32 14 C 0 C 0 40 40

19 35 29 23 56 36 25 WSW 9.3 ENE 11.1 - -

20 36 29 22 56 35 19 NE 5.6 SSE 13.0 - -

21 37 29 22 49 30 17 SSE 9.3 W 7.4 - -

22 38 30 23 62 33 13 C 0 C 0 40 -

23 38 29 20 72 40 14 C 0 C 0 - 40

24 38 30 21 48 23 11 NNE 9.3 N 5.6 - -

25 41 31 22 40 21 9 E 7.4 WSW 9.3 - 10

26 42 33 24 25 16 7 NW 14.8 W 16.7 - -

27 42 33 24 24 16 6 NW 5.6 NNW 14.8 40 -

28 41 33 26 32 19 9 NE 11.1 NNW 18.5 - -

29 41 33 26 28 18 8 SE 11.1 SSE 9.3 - -

30 42 34 27 30 20 8 W 11.1 NNW 22.2 30 40

1 42 34 27 28 14 8 WNW 22.2 W 22.2 - -

2 42 33 25 20 13 6 WNW 22.2 W 22.2 - -

3 39 33 27 25 17 9 WNW 22.2 W 24.1 - -

4 38 31 24 29 21 10 W 14.8 SW 14.8 - -

5 39 31 23 38 25 13 WSW 22.2 WSW 22.2 10 -

6 38 30 23 45 26 13 S 7.4 SW 44.4 - 10

7 40 32 24 47 25 10 S 5.6 NW 14.8 - 20

8 41 33 26 45 30 14 SSW 9.3 NW 14.8 - -

9 38 32 27 47 27 11 C 0 C 0 40 -

10 40 32 24 30 16 7 WSW 18.5 W 29.6 - -

11 39 31 24 31 17 9 NW 27.8 W 22.2 - -

12 38 32 25 41 23 13 WNW 14.8 WNW 29.6 - -

13 38 32 26 31 21 10 WNW 35.2 WSW 9.3 40 -

14 37 31 24 57 32 16 C 0 C 0 40 -































Meteorological data month of 15th May, to 14th June, 2017

Date


Humidity %

Morning km/hr

8.30hr

Evening km/hr

17.30hr

Cloudiness

%

Max Avg Min Max Avg Min Wind

Dirt

Wind

Speed

Wind

Dirt

Wind

Speed Mor Eve.

15 39 30 22 58 30 11 C 0 C 0 - -

16 38 32 26 30 23 12 WNW 16.7 W 9.3 10 -

17 39 32 25 47 28 15 NW 24.1 NNW 22.2 - 20

18 39 32 26 39 24 15 WNW 22.2 NNW 9.3 - -

19 42 33 26 37 20 10 E 14.8 N 5.6 - 40

20 41 34 23 47 23 10 NNW 11.1 W 11.1 - -

21 41 34 28 26 15 7 NW 14.8 WNW 25.9 40 40

22 42 33 24 26 15 7 W 14.8 NNW 18.5 - -

23 42 34 28 19 14 9 WNW 22.2 S 9.3 20 40

24 42 36 28 21 16 12 C 0 C 0 10 -

25 39 33 27 36 27 18 C 0 C 0 20 -

26 39 33 28 64 36 21 C 0 C 0 - -

27 40 33 26 50 28 10 C 0 C 0 - -

28 42 34 26 46 23 10 S 11.1 NNW 18.5 - -

29 44 37 29 32 20 9 WNW 27.8 WNW 22.2 40 -

30 44 38 31 32 19 9 WNW 25.9 W 22.2 - -

31 44 36 28 37 21 13 W 29.6 W 11.1 - -

1 43 35 27 53 25 13 WSW 11.1 NNE 14.8 30 -

2 43 36 28 37 21 13 C 0 NNW 18.5 60 -

3 43 35 27 43 20 9 WBW 7.4 NNW 22.2 - -

4 44 36 28 33 18 9 W 11.1 NNE 14.8 - -

5 44 37 29 27 20 10 NW 25.9 NNE 22.2 10 -

6 45 38 30 34 24 13 NNW 22.2 NWN

W 18.5 - -

7 44 39 33 26 21 13 WNW 29.6 WNW 11.1 - 40

8 44 37 31 38 23 13 W 25.9 N 14.8 - 40

9 44 37 31 37 25 18 WNW 40.7 W 5.6 - 10

10 43 37 30 41 29 19 NNW 11.1 WNW 5.6 - -

11 43 37 28 47 31 14 WNW 11.1 WNW 5.6 - -

12 37 30 22 94 56 27 WNW 11.1 WNW 25.9 - -

13 38 32 26 56 36 21 W 18.5 W 25.9 - -

14 38 32 27 54 36 22 NNE 3.7 W - -

43

viii. Social Infrastructure available

Social infrastructure like community center, hospital and electricity is available

in Sehatganj as well as in Bhopal and Raisen. Industry has also developed

school, Hospital (Asha Mohan Trust) etc in Sehatganj Itself.

5.0 Planning Brief:

i. Planning Concept :

The grain/molasses base unit shall be installed after receiving environment

clearance and consent under air and water act from the MPPCB. Total

configuration shall be achieved within two years time.

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.

44

6.0 Proposed Infrastructure

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

Outline Technical Specifications for Molasses/Grain based 120+200 KLPD Ethanol plant

Storage & Handling:

Sr.No. Equipment Technical Specifications Qty. MOC

1 Raw Molasses transfer

pump

Type- Screw/Gear type Capacity-

60 MT/hr 2+1 CI

2 Day Molasses Tank Capacity- 900 MT 1 MS

3 Molasses Transfer

Pump


60 MT/hr 2+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-

5 MT

1 MS

6 Molasses Weighing

System

Type- Load Cell Capacity 10 MT

Per Trip 1 MS

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

200 MT

1 MS

8

Weighed Molasses

Transfer Pump with

Motor


45 MT/hr 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

Type - Cyl/Vert Shell, Jacketed

with Dished Ends. 1 AISI 304

45

4 Culture Vessel-III with Air Sparger

Type - Cyl/Vert Shell, Jacketed with Dished Ends. Capacity- 6 m3

1 AISI 304

5 Cell Mass Transfer Pump with Motor

Type- Centrifugal with Trolley Capacity- 20 m3

1

6 Fermenter with

Agitator, SG, LG

Type- Cyl/Vert. Shell with Conical

Top & Sloping Bottom, Capacity-

1600 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- 1250

m3/hr 4+1 CF8

9 Fermenter Wash Cooler Type- PHE 4 AISI 316

10

Pre-fermenter/Yeast

Activation Vessel with SG,LG


Top & Sloping Bottom, Capacity- 200 m3

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 AISI 316

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

1600 m3

1 MS Epoxy

15 Wash Transfer Pump Type- Centrifugal Capacity- 50

m3/hr 1+1 CF8

16 Air Filter Type- HEPA 1+1 MS

17 Air Blower with Motor Type- Watering Capacity- 420 A

m3/hr 1+1 CI

18 Nutrient Dosing Tank

with Agitator Capacity- 5 m3 1 AISI 304

19 Nutrient Dosing Pump Type- Centrifugal Capacity- 5 1+1 CI

46

m3/hr

20 Acid Dosing Tank Type- Cylindrical, Vertical Capacity- 2 m3

1 MS

21 Acid Dosing Pump Type- Centrifugal Capacity- 2

m3/hr 1+1 Alloy 20

22 Antifoam Dosing Tank Type- Cylindrical, Vertical

Capacity- 2 m3 1 MS

23 Antifoam Dosing Pump Type: Gear Capacity- 2 m3/hr 1+1 CI

24 CIP tank Type- Cylindrical, Vertical

Capacity- 25 m3 1+1 AISI304

25 CIP Pump Type- Centrifugal Capacity- 20

m3/hr 1+1 Alloy 20

26 Piping, Valves

Instrumentation As Per Standards Lot

Re boilers

1 Analyzer Column Reboiler

Shell & Tube Type AISI 304 2+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

Condensers & Coolers

5 DG Condenser I Shell & Tube Type AISI 304 1

6 DG Condenser II Shell & Tube Type AISI 304 1

7 Analyser Condenser I &

II Shell & Tube Type AISI 304 2

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

47

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

PHE's, Pumps

18 DM Water Preheater PHE, SS 316 Plates /MS Frame SS 1

19 Rectifier Feed Preheater PHE, SS 316 Plates /MS Frame SS 1

20 PR Feed Preheater PHE, SS 316 Plates /MS Frame SS 1

21 Analyser Bottom

Transfer Pump

Centrifugal Type, CF8 (Wetted

Parts Only) CF8 1+1

22 Rectifier Lees Pump Centrifugal Type, CF8 (Wetted

Parts Only) CF8 1+1

23 PR Lees Pump Centrifugal Type, CF8 (Wetted

Parts Only) CF8 1+1

24 Pre Rectifier Feed Pump Centrifugal Type, CF8 (Wetted Parts Only)

CF8 1+1

25 PR Refux Pump Centrifugal Type, CF8 (Wetted

Parts Only) CF8 1+1

26 Rectifier Reflux Pump Centrifugal Type, CF8 (Wetted

Parts Only) CF8 1+1

27 FO Washing Pump Centrifugal Type, CF8 (Wetted

Parts Only) CF8 1+1

28 ED Bottom Transfer

Pump


Parts Only) CF8 1+1

29 Alcohol Transfer Pump Centrifugal Type, CF8 (Wetted

Parts Only) CF8 1+1

48

30 Recovery Feed Pump Centrifugal Type, CF8 (Wetted

Parts Only) CF8 1+1

31 Steam Condensate

Pump Centrifugal Type CI 1+1

32 Vacuum Pump Water Ring Type CI 1+1

33 Emergency Water

Supply Set Standard 1

Others

Sr. Description Tech. Specs. Qty.

No.

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 Pump capacity 6 cu.m

For Recovery Column As Per Standard 1+1

7 TA Mixing Bottle As Per Standard 1

8 Pipes & Fittings, Valves

and Instrument As Per Standard Lot

SN Description Technical Specifications Qty. MOC

1 Absorber Bed AS per standard (Suitable) 2 AISI 304

2 Evaporator Column AS per standard (Suitable) 1 AISI 304

3 Evaporator Column Re

boiler AS per standard (Suitable) 1 AISI 304

4 Feed Preheater AS per standard (Suitable) 1 AISI 304

5 Regeneration Preheater AS per standard (Suitable) 1 AISI 304

6 Product Condenser AS per standard (Suitable) 1 AISI 304

7 Product Cooler AS per standard (Suitable) 1 AISI 304

8 Regeneration AS per standard (Suitable) 1 AISI 304

49

Condenser

9 Regeneration Cooler AS per standard (Suitable) 1 AISI 304

10 Super heater AS per standard (Suitable) 1 AISI 304

11 Regeneration Receiver AS per standard (Suitable) 1 AISI 304

12 Product Receiver AS per standard (Suitable) 1 AISI 304

13 Vacuum Educator AS per standard (Suitable) 1 AISI 304

14 Feed Pump with Motor AS per standard (Suitable) 1+1 AISI 304

15 Regeneration Pump

with Motor AS per standard (Suitable) 1+1 AISI 304

16 Product Pump with

Motor AS per standard (Suitable) 1+1 AISI 304

17 Filters 3 CS

18 RS Feed Tank Capacity : 200 m3 1 MS

19 Instrumentation Standard Lot

20 Piping and Valves Standard Lot

21 Electricals Standard Lot

Reveiver and Storage (W.H.):

Sr.No. Equipment Technical Specification MOC Qty.

1 RS Receivers Capacity: 210 m3 MS 3

2 IS Receivers Capacity: 25 m3 MS 1

3 Ethanol Receiver Capacity: 210 m3 MS 3

4

RS Storage Tank with

Vent Condenser &

Flame Arrestors

Capacity: 900 m3 MS 2

5 Ethanol Storage Tank with Vent Condenser &

Flame Arrestors


6

IS Bulk Storage Tank

with Vent Condenser & Flame Arrestors

Capacity: 400m3 MS 1

7 FO Storage Capacity: 40 m3 MS 1

50

8 Alcohol Pumps with

Flameproof Motor Centrifugal,Wetted Parts CF 8 CF8 1+1

9 Issue Measures PD Flow

meters Standard 3

10 Piping & Fittings Standard Standard 1 Lot

11 FO Purification Tank Capacity 25 KL CF8 2

Integrated

Evaporator:

Sr.No. Description Technical data Qty. M.O.C.

1 Multiple effect

evaporator Shell & Tube type, Falling Film 1 SS304

2 Vapor Separator Cylindrical 1 SS304

3 Surface condenser Sheet & Tube type 1 SS304

4 Circulation pump Double Mech Shaft 1 SS 304

5 Process Condensate

pump 1+1 SS 304

6 Concentrate Spent

wash transfer pump 1+1 SS 304

7 Condensate Pump 1+1 SS 304

8 Vacuum pump 1+1 SS 304

9 Piping & Valves Lot

10 Electrical &

Instrumentation Lot

Independent

Evaporator:

r. No Description Technical data Qty. M.O.C.

1 Feed and Product Tank Type:- Rectangular 2 SS304

2 Feed Pump & Spent wash pump

Type - Centrifugal type 1+1 SS 316

3 Evaporators Type : Forced circulation SS304

4 Vapor Liquid Separators Type : Gas liquid separator type SS304

5 Evaporation Pump Recirculation pump SS 316

51

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

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

10 Condensate Tank Capacity – Suitable 1 SS 304

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

12 Piping and Valve, Electrical and Instruments

Utilities:

Cooling

Tower:

Sr.No. Equipment Description

Specifications Qty.

1 Cooling tower for Fermentation plant

as per standard 1

2 Cooling tower for

Distillation as per standard 1

3 Cooling tower for Ethanol

as per standard 1

4 Cooling tower for evaporation

as per standard 1

5 CW Recirculation pump

for Fermentation Suitable. Centrifugal, 1+1


for Distillation Suitable. Centrifugal, 1+1


for evaporation Suitable. Centrifugal, 1+1


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

13 Liqufication Cooling standard Lot

52

Tower

Slop Fired Incinerator Boiler & Turbine:

Sr. No. Particulars Specification Qty.

1

Slop fired incinerator

boiler with coal as

supporting fuel

Capacity 40 TPH, working pressure

45 Kg/Cm2 (g) 1

2 Turbine

Capacity of 4 MW back pressure

with exhaust pressure of 4.5 Kg/Cm2(g)

1

Water Treatment Area Filtration Plant:

Sr. No. Particulars MOC Qty.

1 Multi grade Sand

Filter 1 No.

Pressure vessel

internally painted with

black bituminous and

externally with red

oxide primer

MS with epoxy coating 1 No.

Piping work with valves 1 No.

Graded filtering sand specifically selected and

graded

1 No.

2 Activated Carbon

Filter 1 No.

Pressure vessel

internally painted with black bituminous and

externally with red

oxide primer


Piping works with

valves 1 No.

3 Softener 1 No.

53

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 No.

1 Strong acid cation 1 No.

2 Degasser tower & pump 1 No.

3 Strong acid anion 1 No.

4 Mixed bed exchanger 1 No.

grain receipt & cleaning, milling & flour handling section:

I Section Grain Receipt / Cleaning Section Qty.

1. Receiving Hopper

Duty – To feed Grains to Chain Conveyor

1

Bags to be dumped manually in the hopper.

Safety Grill on the top

Manual Slide Gate at Bottom.

Provided with hood on top for

dedusting.

2. Bucket Elevator #1

Duty – For feeding grains to Pre-Cleaner 1

Capacity – 45 TPH

3. Bag Dump Station

Fitted on the receiving hopper to

avoid dusting in receiving area.

Filter bags and pulse valve for

1

54

cleaning

M.O.C. – M. S.

4. Chain Conveyer

Duty – For feeding grains to Pre-

Cleaner 1

Capacity – 45 TPH

5. Drum Cleaner

Duty – For screening the

impurities. 1

Capacity – 45 TPH


Duty – For Feeding Grains to Storage Silos

1

Capacity – 45 TPH MOC-Mild steel,

II Section Grain Storage Section Qty.

1. Bulk Storage GIC Silos

Galvanised Flat Bottom Silos

2+1

Capacity – 5000 MT with Level

Sensors, Aeration System, Sweep

Auger. Discharge Gates

III Section Common Systems For Section I

& III

1. Electrical

Starter Panel for all Electrical drives With Necessary interlocks,

Mimic, and control push button

station.

1

MCC Panel

2. Electrical

Power cabling from MCC to field

drive.

Local push button station for all

the drives.

3. Ducting Chutes &

Supports

All the equipments supports,

ducting / piping connection between the equipments

LOT

IV Section Mill Feed, Milling, Flour Sieving Qty.

55

1. Silo Discharge Conveyor

Duty – For Discharging the grains

from silos 1

Capacity – 22 TPH

2 Bucket Elevator #3

Duty – For Feeding Grains to Milling Section 1

Capacity – 22 TPH

3 Classifier

Capacity – 22 TPH

1+1

With Aspiration System- Cyclone,

Blower-4 Nos.

Rotary Airlock Valve at Bottom

4 Magnetic Separator

Duty – For screening the ferrous

material 1+1

Capacity – 22 TPH

5 Destoner

Duty – To remove the stones from grain 2+1

Capacity – 11 TPH

6 Hammer Mill Feed Hopper

Duty – for Feeding Hammer Mill

2+1

Accessories – High Level Switch

Vibratory Feeders fitted at the

bottom of hoppers for controlled

feeding to the mills, Capacity 30 tph.

7 Hammer Mill Capacity – 20 TPH 2+1

8 Screw Conveyor #1 Duty - To feed flour from hammer mill discharge to Bucket Elevator

1

9 Bucket Elevator # 4

Duty – For Elevating flour to feed

Flour Sifter. 1

Capacity – 75 TPH

10 Sieving Machine Duty – To remove oversize material

from floor 1

56

(Oversize flour of 1.0 mm and

above shall be diverted to buffer hopper of hammer mill.)

11 Screw Conveyor #2 Duty – To feed flour from Sifter

discharge to Flour Storage Silos. 1

V Section Flour Storage, Flour Weighing Qty.

1. Flour Storage Silo

Duty – for Storing Grain Flour for 8

hours.

1

Capacity – 100 Tons of Flour,

MOC– Mild steel

with high & Low level switch

Bin activator fitted at bottom for

smooth discharge.

2. Screw Conveyor # 3

Duty - To feed flour to bucket

elevator 1

Capacity – 45 TPH

3. Bucket Elevator # 5 Duty – For Elevating Stored flour to Weighing system. Capacity – 45

TPH

1

4. Buffer Hopper Duty – To Feed flour to Weigh

Hopper. 1

5. Weigh Hopper

Capacity –25 TPH

1

Duty: To weigh Material

Duty – Weighing, MOC – SS 304

Accessories – Load cells with

Microprocessor based

programmable batch controller with built in batch counter and

totaliser.

Electro Pneumatic slide gate at

discharge.

6. Discharge Hopper with Duty – To feed Premasher Hopper

1

Screw Feeder Screw Feeder Capacity – 30 TPH

57

VI Section Common Systems For Section I

& II

1. Flour Dust Extraction

System

Duty – To avoid dusting at various

points in flour handling section

and to recycle the flour to buffer

hopper of flour weighing system.

1

2. MCC Panel for Milling Starter Panel for all Electrical

drives. 1

3

PLC Control Panel

To operate the grain milling system

in desired sequence in Auto Mode.

1

PC and PLC based Control System

SCADA is considered for Display of

Graphics

Electrical

Power Cabling from MCC to field

drive.

LOT

4


the drives

Cable trays as per layout.

5

Ducting Chutes &

Supports


ducting / piping connection

between the equipments

LOT

Decantation Section :

Sr. Description Tech. Data M.O.C. Qty

No.

1. Thin Slop Holding Tank

after decanter Capacity : 60 M3 AISI 304 1

2. Decanter Centrifuge

AISI 304 Internals 4+1

Capacity : 15 M3

3. Thin Slops Transfer

Pump Centrifugal Type Wetted parts CF8 1+1

4. Ribbon Mixer Ribbon type AISI 304 1+1

58

5. Pipes and Fittings &

Valves

As per mentioned in respective

Annexure Lot

6. Electrical As per mentioned in respective

Annexure Lot

7. Instrumentation As per mentioned in respective

Annexure Lot

Multi-Effect Integrated Evaporator :

Integrated Evaporation Plant :

Sr. No. Equipment Description Material of

Construction Qty

1.

Falling Film Designed based on FF principle Shell: SS 304

4

Evaporator Construction: Shell & Tube Type. Tubes : SS 304 Tube

sheet: SS 304

2.

Falling Film Designed based on Forced

Circulation principle Shell: SS 304

1

Evaporator as Finisher Construction: Shell & Tube Type. Tubes : SS 304

Tube sheet: SS 304

Vapor Liquid Separators

Construction: Vertical, with

tangential entry for effective vapor

separation.

Shell : SS 304 5

Surface Condenser Shell and Tube heat exchanger Shell : SS 304 1

Thin Slop feed tank

Cylindrical / Vertical Shell with

Dished Ends SS 304 1

(Feed Tank) Cap: 50 M3

S/B/T 3/3/3

Process condensate pot



Cap: 20 M3

S/B/T 3/3/3

Steam Condensate Pot

Horizontal MS 1

S/B/T 6/6/6

59

Feed Pump Type - Centrifugal Pump Wetted Parts : CF8 1+1

Recycle cum Transfer

pump Type - Centrifugal Pump Wetted Parts : CF8 4+ 4

Process condensate pump

Type - Centrifugal Pump Wetted Parts : CF8 1+1

Steam condensate

pump Type - Centrifugal Pump Wetted Parts : CF8 1+1

Vacuum Pump with

Motor Water Ring Type CI 1+1

CIP Tank



Cap: 2 M3

S/B/T, 3/3/3

CIP pump Type - Centrifugal Pump Wetted Parts : CF8 1

Piping + Valves

As described in respective

annexure 1 Lot

Instrumentation


annexure 1 Lot

Electrical (MCC and onwards)

As described in respective annexure

1 Lot

Molasses Bulk Storage Section :

Sr.No. Description Equipment Capacity Qty. M.O.C.

1

For 120 KLD

Molasses Storage Tank 16000 MT storage capacity.

2 Mild steel, painted

Nos.

2 Raw molasses Transfer pumps. Gear type positive

displacement pumps

2+2 C.S.

Nos.

3 Interconnecting piping. Carbon steel pipes. LOT MS

4 For 200 KLD Molasses Storage Tank 16000 MT storage 2 Mild steel,

60

capacity. Nos. painted

5 Raw molasses Transfer pumps. Gear type positive displacement pumps

2+2 C.S.

Nos.


Outline Technical Specifications for Molasses/Grain based 300 KLPD Ethanol plant

Storage & Handling:

Sr.No. Equipment Technical Specifications Qty. MOC

1 Raw Molasses transfer

pump


90 MT/hr 2+1 CI

2 Day Molasses Tank Capacity- 1400 MT 1 MS

3 Molasses Transfer

Pump


90 MT/hr 2+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-

7.5 MT

1 MS

6 Molasses Weighing

System

Type- Load Cell Capacity 15 MT

Per Trip 1 MS

7 Weighed Molasses Tank


Top & Sloping Bottom, Capacity- 300 MT

1 MS

8

Weighed Molasses

Transfer Pump with

Motor


68 MT/hr 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: 900 mm 1 AISI 304

61

2 Culture Vessel-I with

Air Sparger



3 Culture Vessel-II with

Air Sparger



4 Culture Vessel-III with

Air Sparger


with Dished Ends. Capacity- 9 m3 1 AISI 304

5 Cell Mass Transfer

Pump with Motor

Type- Centrifugal with Trolley

Capacity- 30 m3 1

6 Fermenter with

Agitator, SG, LG



2400 m3

4 AISI 304

7 Molasses Broth Mixer

for Fermenter Type- Static Mixer 3 SS 304

8 Fermenter Recirculation

Pump with Motor


m3/hr 4+1 CF8

9 Fermenter Wash Cooler Type- PHE 4 AISI 316

10

Pre-fermenter/Yeast

Activation Vessel with

SG,LG



300 m3

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 AISI 316

14 Wash Holding Tank

Type – Cyl/Vert. Shell with Conical

Top & Sloping Bottom, Capacity –

2400 m3

1 MS Epoxy

15 Wash Transfer Pump Type- Centrifugal Capacity- 50 m3/hr

1+1 CF8

16 Air Filter Type- HEPA 1+1 MS

62

17 Air Blower with Motor Type- Watering Capacity- 630 A

m3/hr 1+1 CI

18 Nutrient Dosing Tank

with Agitator Capacity- 7.5 m3 1 AISI 304

19 Nutrient Dosing Pump Type- Centrifugal Capacity- 7.5

m3/hr 1+1 CI

20 Acid Dosing Tank Type- Cylindrical, Vertical

Capacity- 3 m3 1 MS

21 Acid Dosing Pump Type- Centrifugal Capacity- 3

m3/hr 1+1 Alloy 20

22 Antifoam Dosing Tank Type- Cylindrical, Vertical

Capacity- 3 m3 1 MS

23 Antifoam Dosing Pump Type: Gear Capacity- 3 m3/hr 1+1 CI

24 CIP tank Type- Cylindrical, Vertical Capacity-38 m3

1+1 AISI304

25 CIP Pump Type- Centrifugal Capacity- 30

m3/hr 1+1 Alloy 20

26 Piping, Valves

Instrumentation As Per Standards Lot

Re boilers

1 Analyzer Column

Reboiler Shell & Tube Type AISI 304 2+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

Condensers & Coolers

5 DG Condenser I Shell & Tube Type AISI 304 1

6 DG Condenser II Shell & Tube Type AISI 304 1

7 Analyser Condenser I &

II Shell & Tube Type AISI 304 2

63

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

PHE's, Pumps

18 DM Water Preheater PHE, SS 316 Plates /MS Frame SS 1

19 Rectifier Feed Preheater PHE, SS 316 Plates /MS Frame SS 1

20 PR Feed Preheater PHE, SS 316 Plates /MS Frame SS 1

21 Analyser Bottom Transfer Pump

Centrifugal Type, CF8 (Wetted Parts Only)

CF8 1+1

22 Rectifier Lees Pump Centrifugal Type, CF8 (Wetted

Parts Only) CF8 1+1

23 PR Lees Pump Centrifugal Type, CF8 (Wetted

Parts Only) CF8 1+1

24 Pre Rectifier Feed Pump Centrifugal Type, CF8 (Wetted

Parts Only) CF8 1+1

25 PR Refux Pump Centrifugal Type, CF8 (Wetted

Parts Only) CF8 1+1

26 Rectifier Reflux Pump Centrifugal Type, CF8 (Wetted

Parts Only) CF8 1+1

27 FO Washing Pump Centrifugal Type, CF8 (Wetted Parts Only)

CF8 1+1

64

28 ED Bottom Transfer

Pump


Parts Only) CF8 1+1

29 Alcohol Transfer Pump Centrifugal Type, CF8 (Wetted

Parts Only) CF8 1+1

30 Recovery Feed Pump Centrifugal Type, CF8 (Wetted Parts Only)

CF8 1+1

31 Steam Condensate Pump

Centrifugal Type CI 1+1

32 Vacuum Pump Water Ring Type CI 1+1

33 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 Pump capacity 6 cu.m

For Recovery Column As Per Standard 1+1

7 TA Mixing Bottle As Per Standard 1

8 Pipes & Fittings, Valves

and Instrument As Per Standard Lot

SN Description Technical Specifications Qty. MOC

1 Absorber Bed AS per standard (Suitable) 2 AISI 304

2 Evaporator Column AS per standard (Suitable) 1 AISI 304

3 Evaporator Column Re

boiler AS per standard (Suitable) 1 AISI 304

4 Feed Preheater AS per standard (Suitable) 1 AISI 304

5 Regeneration Preheater AS per standard (Suitable) 1 AISI 304

65

6 Product Condenser AS per standard (Suitable) 1 AISI 304

7 Product Cooler AS per standard (Suitable) 1 AISI 304

8 Regeneration

Condenser AS per standard (Suitable) 1 AISI 304

9 Regeneration Cooler AS per standard (Suitable) 1 AISI 304

10 Super heater AS per standard (Suitable) 1 AISI 304

11 Regeneration Receiver AS per standard (Suitable) 1 AISI 304

12 Product Receiver AS per standard (Suitable) 1 AISI 304

13 Vacuum Educator AS per standard (Suitable) 1 AISI 304

14 Feed Pump with Motor AS per standard (Suitable) 1+1 AISI 304

15 Regeneration Pump

with Motor AS per standard (Suitable) 1+1 AISI 304

16 Product Pump with

Motor AS per standard (Suitable) 1+1 AISI 304

17 Filters 3 CS

18 RS Feed Tank Capacity : 300 m3 1 MS

19 Instrumentation Standard Lot

20 Piping and Valves Standard Lot

21 Electricals Standard Lot

Reveiver and Storage (W.H.):

Sr.No. Equipment Technical Specification MOC Qty.

1 RS Receivers Capacity: 315 m3 MS 3

2 IS Receivers Capacity: 38 m3 MS 1

3 Ethanol Receiver Capacity: 315 m3 MS 3

4

RS Storage Tank with

Vent Condenser &

Flame Arrestors


5

Ethanol Storage Tank

with Vent Condenser &

Flame Arrestors


66

6

IS Bulk Storage Tank

with Vent Condenser & Flame Arrestors

Capacity: 600m3 MS 1

7 FO Storage Capacity: 60 m3 MS 1

8 Alcohol Pumps with Flameproof Motor

Centrifugal,Wetted Parts CF 8 CF8 1+1

9 Issue Measures PD Flow

meters Standard 3

10 Piping & Fittings Standard Standard 1 Lot

11 FO Purification Tank Capacity 38 KL CF8 2

Integrated

Evaporator:

Sr.No. Description Technical data Qty. M.O.C.

1 Multiple effect

evaporator Shell & Tube type, Falling Film 1 SS304

2 Vapor Separator Cylindrical 1 SS304

3 Surface condenser Sheet & Tube type 1 SS304

4 Circulation pump Double Mech Shaft 1 SS 304

5 Process Condensate

pump 1+1 SS 304

6 Concentrate Spent

wash transfer pump 1+1 SS 304

7 Condensate Pump 1+1 SS 304

8 Vacuum pump 1+1 SS 304

9 Piping & Valves Lot

10 Electrical &

Instrumentation Lot

Independent

Evaporator:

r. No Description Technical data Qty. M.O.C.

1 Feed and Product Tank Type:- Rectangular 2 SS304

67

2 Feed Pump & Spent

wash pump Type - Centrifugal type 1+1 SS 316

3 Evaporators Type : Forced circulation SS304

4 Vapor Liquid Separators Type : Gas liquid separator type SS304

5 Evaporation Pump Recirculation pump SS 316

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

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

10 Condensate Tank Capacity – Suitable 1 SS 304

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

12 Piping and Valve, Electrical and Instruments

Utilities: Cooling

Tower:

Sr.No. Equipment

Description Specifications Qty.

1 Cooling tower for Fermentation plant

as per standard 1

2 Cooling tower for

Distillation as per standard 1

3 Cooling tower for

Ethanol as per standard 1

4 Cooling tower for

evaporation as per standard 1


for Fermentation Suitable. Centrifugal, 1+1


for Distillation Suitable. Centrifugal, 1+1


for evaporation Suitable. Centrifugal, 1+1


for Ethanol Suitable. Centrifugal, 1+1

9 PRDS Suitable. 2

68

10 Instrument Air

compressor & dryer Suitable capacity 1+1

11 Piping, Valves standard Lot

12 Instrumentation standard Lot

13 Liqufication Cooling Tower

standard Lot

Slop Fired Incinerator Boiler & Turbine:

Sr. No. Particulars Specification Qty.

1

Slop fired incinerator

boiler with coal as supporting fuel

Capacity 75 TPH, working pressure 45 Kg/Cm2 (g)

1

2 Turbine

Capacity of 6 MW back pressure

with exhaust pressure of 4.5

Kg/Cm2(g)

1

Water Treatment Area Filtration Plant:

Sr. No. Particulars MOC Qty.

1 Multi grade Sand

Filter 1 No.

Pressure vessel


black bituminous and

externally with red oxide primer


Piping work with valves 1 No.

Graded filtering sand

specifically selected and

graded

1 No.

2 Activated Carbon Filter

1 No.

69

Pressure vessel


black bituminous and externally with red

oxide primer


Piping works with

valves 1 No.

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 No.

1 Strong acid cation 1 No.

2 Degasser tower & pump 1 No.

3 Strong acid anion 1 No.

4 Mixed bed exchanger 1 No.

grain receipt & cleaning, milling & flour handling section:

I Section Grain Receipt / Cleaning Section Qty.

1. Receiving Hopper

Duty – To feed Grains to Chain Conveyor

1

Bags to be dumped manually in the hopper.

Safety Grill on the top

70

Manual Slide Gate at Bottom.

Provided with hood on top for

dedusting.


Duty – For feeding grains to Pre-

Cleaner 1

Capacity – 68 TPH

3. Bag Dump Station

Fitted on the receiving hopper to

avoid dusting in receiving area.

Filter bags and pulse valve for cleaning

1

M.O.C. – M. S.

4. Chain Conveyer

Duty – For feeding grains to Pre-Cleaner 1

Capacity – 68 TPH

5. Drum Cleaner

Duty – For screening the impurities. 1

Capacity – 68 TPH


Duty – For Feeding Grains to

Storage Silos 1

Capacity – 68 TPH MOC-Mild

steel,

II Section Grain Storage Section Qty.

1. Bulk Storage GIC Silos

Galvanised Flat Bottom Silos

2+1

Capacity – 7500 MT with Level Sensors, Aeration System, Sweep

Auger. Discharge Gates

III Section Common Systems For Section I

& III

1.

Electrical Starter Panel for all Electrical

drives With Necessary interlocks, Mimic, and control push button

station.

1

MCC Panel

2. Electrical Power cabling from MCC to field

drive.

71


the drives.

3. Ducting Chutes &

Supports




LOT

IV Section Mill Feed, Milling, Flour Sieving Qty.

1. Silo Discharge Conveyor

Duty – For Discharging the grains

from silos 1

Capacity – 33 TPH

2 Bucket Elevator #3

Duty – For Feeding Grains to

Milling Section 1

Capacity – 33 TPH

3 Classifier

Capacity – 33 TPH

1+1

With Aspiration System- Cyclone, Blower-4 Nos.

Rotary Airlock Valve at Bottom

4 Magnetic Separator

Duty – For screening the ferrous

material 1+1

Capacity – 33 TPH

5 Destoner

Duty – To remove the stones from

grain 2+1

Capacity – 17 TPH

6 Hammer Mill Feed

Hopper

Duty – for Feeding Hammer Mill

2+1

Accessories – High Level Switch

Vibratory Feeders fitted at the

bottom of hoppers for controlled

feeding to the mills, Capacity 45

tph.

7 Hammer Mill Capacity – 30 TPH 2+1

8 Screw Conveyor #1 Duty - To feed flour from hammer

mill discharge to Bucket Elevator 1

72

9 Bucket Elevator # 4

Duty – For Elevating flour to feed

Flour Sifter. 1

Capacity – 113 TPH

10 Sieving Machine

Duty – To remove oversize material from floor

1

(Oversize flour of 1.0 mm and

above shall be diverted to buffer

hopper of hammer mill.)

11 Screw Conveyor #2 Duty – To feed flour from Sifter

discharge to Flour Storage Silos. 1

V Section Flour Storage, Flour Weighing Qty.

1. Flour Storage Silo

Duty – for Storing Grain Flour for 8

hours.

1

Capacity – 150 Tons of Flour,

MOC– Mild steel

with high & Low level switch

Bin activator fitted at bottom for

smooth discharge.

2. Screw Conveyor # 3

Duty - To feed flour to bucket

elevator 1

Capacity – 45 TPH

3. Bucket Elevator # 5

Duty – For Elevating Stored flour to

Weighing system. Capacity – 45 TPH

1

4. Buffer Hopper Duty – To Feed flour to Weigh

Hopper. 1

5. Weigh Hopper

Capacity –38 TPH

1

Duty: To weigh Material

Duty – Weighing, MOC – SS 304

73

Accessories – Load cells with Microprocessor based

programmable batch controller

with built in batch counter and

totaliser.

Electro Pneumatic slide gate at

discharge.

6. Discharge Hopper with Duty – To feed Premasher Hopper

1

Screw Feeder Screw Feeder Capacity – 45 TPH

VI Section Common Systems For Section I

& II

1. Flour Dust Extraction

System

Duty – To avoid dusting at various

points in flour handling section

and to recycle the flour to buffer hopper of flour weighing system.

1

2. MCC Panel for Milling Starter Panel for all Electrical

drives. 1

3

PLC Control Panel

To operate the grain milling system

in desired sequence in Auto Mode.

1

PC and PLC based Control System

SCADA is considered for Display of

Graphics

Electrical

Power Cabling from MCC to field

drive.

LOT

4


the drives

Cable trays as per layout.

5

Ducting Chutes &

Supports




LOT

Decantation Section :

Sr. Description Tech. Data M.O.C. Qty

No.

74

1. Thin Slop Holding Tank

after decanter Capacity : 90 M3 AISI 304 1

2. Decanter Centrifuge

AISI 304 Internals 4+1

Capacity : 22.5 M3

3. Thin Slops Transfer

Pump Centrifugal Type Wetted parts CF8 1+1

4. Ribbon Mixer Ribbon type AISI 304 1+1

5. Pipes and Fittings & Valves

As per mentioned in respective Annexure

Lot

6. Electrical As per mentioned in respective Annexure

Lot

7. Instrumentation As per mentioned in respective

Annexure Lot

Multi-Effect Integrated Evaporator :

Integrated Evaporation Plant :

Sr. No. Equipment Description Material of

Construction Qty

1.

Falling Film Designed based on FF principle Shell: SS 304

4

Evaporator Construction: Shell & Tube Type. Tubes : SS 304 Tube

sheet: SS 304

2.

Falling Film Designed based on Forced

Circulation principle Shell: SS 304

1

Evaporator as Finisher Construction: Shell & Tube Type. Tubes : SS 304

Tube sheet: SS 304

Vapor Liquid Separators Construction: Vertical, with tangential entry for effective vapor

separation.

Shell : SS 304 5

Surface Condenser Shell and Tube heat exchanger Shell : SS 304 1

Thin Slop feed tank

Cylindrical / Vertical Shell with Dished Ends

SS 304 1

75

(Feed Tank) Cap: 75 M3

S/B/T 3/3/3

Process condensate pot



Cap: 30 M3

S/B/T 3/3/3

Steam Condensate Pot

Horizontal MS 1

S/B/T 6/6/6

Feed Pump Type - Centrifugal Pump Wetted Parts : CF8 1+1

Recycle cum Transfer

pump Type - Centrifugal Pump Wetted Parts : CF8 4+ 4

Process condensate

pump Type - Centrifugal Pump Wetted Parts : CF8 1+1

Steam condensate pump

Type - Centrifugal Pump Wetted Parts : CF8 1+1

Vacuum Pump with Motor

Water Ring Type CI 1+1

CIP Tank

Cylindrical / Vertical Shell with Dished Ends

SS 304 1

Cap: 3 M3

S/B/T, 3/3/3

CIP pump Type - Centrifugal Pump Wetted Parts : CF8 1

Piping + Valves


annexure 1 Lot

Instrumentation

As described in respective annexure

1 Lot

Electrical (MCC and

onwards)


annexure 1 Lot

Molasses Bulk Storage Section :

Sr.No. Description Equipment Capacity Qty. M.O.C.

1 For 300 KLD Molasses Storage Tank 36000 MT storage

capacity.

3 Mild steel,

painted Nos.

76

2 Raw molasses Transfer pumps. Gear type positive

displacement pumps

2+2 C.S.

Nos.


Details of Boiler

Sr. No.

Description Existing

1 For 120 KLD Capacity 25 & 40 TPH Pressure - 45 Kg/Cm2(g) Super heated Steam Fuel - Coal cum Bio-gas , Coal cum Slop Fired

2 For 200 KLD (120+80 KLD)

Capacity - -25 & 40 TPH Pressure - 45 Kg/Cm2(g) Super heated Steam Fuel - Coal cum Bio-gas , Coal cum Slop Fired

3 For 300 KLD Capacity - 75 TPH Pressure - 45 Kg/Cm2(g) Saturated Steam Fuel - Coal cum Slop Fired

77

Details Of Existing And Proposed Stack

Capacity

of Boiler

Stack

Height

Flue gas

temp. 0C

Pollution

Control

Equipment

TPM

(mg/Nm3)

SOx

(mg/Nm3)

NOx

(mg/Nm3)

For 120 KLD Plant

40 TPH

25 TPH

82 MTR 160 ° C Air

Preheater,

Dust Collector,

Electrostatic

Precipitator,

50 (max) 80 μg/m3 80 μg/m3

For 200 ( 120 +80 ) KLD Plant

65 TPH 82 MTR 160–

170°C

Air

Preheater,

Dust

Collector,

Electrostatic Precipitator,

Bag Filters

50 (max) 80 μg/m3 80 μg/m3

For 300 KLD Plant

75 TPH 82 MTR 160–

180°C

Air

Preheater,

Dust Collector,

Electrostatic

Precipitator,

Bag Filters

50 (max) 80 μg/m3 80 μg/m3

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 30 acres area ( inside and out side of the site ) has been covered with

the good green belt in with 40000 number of tress. Further it is proposed to

cover 45 acres in next 05 years of time.

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 Bhopal- Raisen- Sanchi Vidisha

road .

78

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


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 2019 (subject to clearances)

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

of the project

Estimated Investment for Design, Engineering, Manufacture, Supply, Erection

and Supervision of commissioning for proposed Plant as per the sections

mentioned below are as follows:

Project Cost of Proposed Unit

Description Particulars Distillery Plant (Rs. Lakh)

For Existing 120 KLD Plant Land and Site Development 4.52 Cr

Buildings 27.39 Cr

Indigenous Plant and Machinery

200 Cr

Miscellaneous Fixed Assets 7.42 Cr

Prelim. & Preoperative Expenses

Contingencies

Working capital margin

Total 239.88 Cr

Out of Above, The capital cost for Slope Fired boiler, MEE, CPU, Rain water harvesting is around - 4000Lacs.

For Existing 120+80 KLD Plant Land and Site Development -

Buildings -


3.15 Cr

79

Miscellaneous Fixed Assets -


-

Contingencies -

Working capital margin -

Total 239.88 + 3.15 Cr

Out of Above, The capital cost for Slope Fired boiler, MEE, CPU, Rain water harvesting is around - 4500Lacs.

For 300 KLD Plant

Land and Site Development 20 Cr

Buildings 35 Cr


500 Cr

Miscellaneous Fixed Assets 100 Cr


-

Contingencies 100

Working capital margin 100

Total 855 Cr

Out of Above, The capital cost for Slope Fired boiler, MEE, CPU, Rain water harvesting is around 6000 Lacs.

Total Project cost of 500 KLD plant will be 1098 Crore and out of that Rs 60 Crore will be incurred on Pollution control aspect as capital cost.

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 in

Documents