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PRE-FEASIBILITY REPORT OF

2 x 60 KLPD GRAIN BASED DISTILLERY PLANT &

2 x 2.5 MW CO-GENERATION OF POWER AT

Village-Titerikata, Post – Ramvikata, Tehsil- Harabhanga,

District: Boudh, Odisha

By

Boudh Distillery Private Limited

Prefeasibility Report

2 x 60 KLPD Grain based Distillery plant along with 2 x 2.5 MW Cogen. Power Plant

TABLE OF CONTENTS Chapter – 1: EXECUTIVE SUMMARY .................................................................................................................1

1.0 ABOUT THE PROPOSED PROJECT ......................................................................................................1

Chapter – 2 : INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION ..............................................3

2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT ................................................................3

2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT ............................................................................5

2.3 NEED FOR THE PROJECT AND IS IMPORTANCE TO THE COUNTRY OR REGION ..................................5

2.3 DEMAND – SUPPLY GAP ................................................................................................................ 10

2.4 EMPLOYMENT GENERATION DUE TO THE PROJECT ....................................................................... 10

Chapter – 3 : PROJECT DESCRIPTION .............................................................................................................. 12

3.1 TYPE OF PROJECT INCLUDING INTERLINKED & INTERDEPENDENT PROJECT, IF ANY ........................ 12

3.2 LOCATION OF PROJECT .................................................................................................................. 12

3.3 DETAILS OF ALTERNATE SITE CONSIDERED ..................................................................................... 16

3.4 SIZE AND MAGNITUDE OF OPERATION .......................................................................................... 16

3.5 MANUFACTURING PROCESS .......................................................................................................... 17

3.5.1 GRAIN BASED DISTILLERY PLANT ............................................................................................. 17

3.5.2 CO-GENERATION POWER PLANT ............................................................................................. 23

3.6 RAW MATERIAL REQUIREMENT FOR PROPOSED DISTILLERY .......................................................... 28

3.7 WATER REQUIREMENT AND ITS SOURCE ........................................................................................ 29

3.8 WASTE WATER GENERATED AND IT’S MANAGEMENT .................................................................... 29

3.9 SOLID WASTE GENERATED AND IT’S MANAGEMENT....................................................................... 29

Chapter – 4 : SITE ANALYSIS ........................................................................................................................... 30

4.1 CONNECTIVITY ............................................................................................................................... 30

4.2 LAND USE AND LAND OWENERSHIP ............................................................................................... 30

4.3 TOPOGRAPHY ................................................................................................................................ 30

4.4 EXISTING LAND USE PATTERN ........................................................................................................ 30

4.5 EXISTING INFRASTRUCTURE ........................................................................................................... 30

4.6 SOIL CLASSIFICATION ..................................................................................................................... 31

4.7 CLIMATIC DATA FROM SECONDARY SOURCES ............................................................................... 31

Chapter – 5 : PLANNING BRIEF ....................................................................................................................... 32

5.1 PLANNING CONCEPT ..................................................................................................................... 32

5.2 POPULATION PROJECTION ............................................................................................................. 32

5.3 LAND USE PLANNING ..................................................................................................................... 32

5.3 ASSESSMENT OF INFRASTRUCTURE DEMANT (PHYSICAL & SOCIAL) ............................................... 33

5.4 AMENTIES / FACILITIES .................................................................................................................. 33



Chapter – 6 : PROPOSED INFRASTRUCTURE ................................................................................................... 34

6.1 INDUSTRIAL AREA (PROCESSING AREA).......................................................................................... 34

6.2 RESIDENTIAL AREA (NON PROCESSING AREA) ................................................................................ 35

6.3 GREENBELT .................................................................................................................................... 35

6.4 SOCIAL INFRASTRUCTURE .............................................................................................................. 35

6.5 CONNECTIVITY ............................................................................................................................... 36

6.6 DRINKING WATER MANAGEMENT ................................................................................................. 36

6.7 ENVIRONMENT MANAGEMENT PLAN ............................................................................................ 36

6.7.1 AIR EMISSION AND ITS MANAGEMENT ................................................................................... 37

6.7.2 SOLID WASTES GENERATION & ITS MANAGEMENT ................................................................. 37

6.7.3 WASTEWATER GENERATION AND ITS MANAGEMENT ............................................................. 38

6.10 POWER REQUIREMENT AND SUPPLY ............................................................................................. 38

Chapter – 7 : REHABILITATION & RESETTLEMENT (R & R) PLAN ...................................................................... 39

Chapter – 8 : PROJECT SCHEDULE & COST ESTIMATES .................................................................................... 40

8.1 PROJECT SCHEDULE ....................................................................................................................... 40

8.2 PROJECT COST ................................................................................................................................ 40

Chapter – 9 : ANALYSIS OF PROPOSAL ............................................................................................................ 41

9.1 TECHNO COMMERCIAL VIABILITY .................................................................................................. 41

9.2 FINANCIAL AND SOCIAL BENEFITS .................................................................................................. 41

9.3 SOCIO-ECONOMIC DEVELOPMENTAL ACTIVITIES ........................................................................... 42



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Chapter – 1: EXECUTIVE SUMMARY

1.0 ABOUT THE PROPOSED PROJECT

Boudh Distillery Private Ltd. is a company registered under Indian Companies Act, 1956

having its registered office at 11, 1stFloor, Flat 1c, Gunjan Apartment, Palm Avenue,

Ballygunge Kolkata West Bengal – 700 019.

The company is planning to setup a Grain based Distillery Plant of 2 x 60 KLPD and

Cogeneration Power Plant of 2 x 2.5 MW in a phased manner at Village-Titerikata, Post –

Ramvikata, Tehsil- Harabhanga, Post / District: Boudh, Odisha.

Project Details

Name of the company M/s Boudh Distillery Private Limited

Registered address 11, 1st Floor, Flat 1c, Gunjan Apartment, Palm Avenue,

Ballygunge, Kolkata, WestBengal – 700 019

Corporate office C-84, Palasapalli, Bhubaneswar -751020

Factory Village-Titerikata, Post – Ramvikata, Tehsil- Harabhanga,

Post / District: Boudh, Odisha - 769024

Date of incorporation 10th April, 2015

Constitution Pvt. Limited Company

Promoters of the project 1. Shri. RiteshSahu – Managing Director

2. Shri. AmitSahu – BoD

3. Shri. Uday Shankar Sahu – BoD

Other group of Companies 1. M/s. BaldevSahu& Sons

2. M/s. Sahu Alcohol Pvt. Ltd

3. M/s. Santevita Hospital

Line of Activity Manufacture of RS/ENA/Pharma Alcohol/ Industrial

Alcohols

Source of Plant &Machinery

Supplies

Indigenous and Imported Based Technology.

Installed Capacity Phase # 1

60 KLPD RS/ENA/ Pharma Alcohol/ Industrial Alcohols

from GRAINS



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Phase # 2

60 KLPDRS/ENA/Pharma Alcohol/ Industrial Alcohols from

GRAINS

Capacity Utilization 1st Year - 90%

2nd Year-95%

3rd Year-100%

4th Year-100%

Product& By Products

Production PHASE # 1 PHASE# 2

RS /ENA / Pharma Alcohol / Industrial Alcohols 60KLPD 60KLPD

By Products

CO2 40/MT 40/MT

Fuse Oil 0.60/MT 0.60/MT

DDGS 50/MT 50/MT



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Chapter – 2 : INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION

2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT

The company Boudh Distillery Private Limited was registered as a Private Limited Company

namely “M/s PADMINI TRADE Link Private Limited” under the Indian Companies Act 1956.

Subsequently, the name of M/s PADMINI TRADE Link Private Limited” has been changed to

“Boudh Distillery Private Limited” in the year 2015 dated 10th April.

The promoters are the descendants of Late RaiSahebBaldeoSahu, one of the leading and

eminent businessmen of the erstwhile Chotanagpur division of State of Bihar, now

Jharkhand. The promoter group consists of families of six sons of Late RaiSahebBaldeoSahu

referred to as the “SAHU FAMILY”.

The family has been in business for last more than 75 years. Their main business has been of

liquor. They have retail country liquor and IMFL shops in Jharkhand, Odisha& West Bengal. In

Odisha they have more than 50 mini distilleries where liquor is manufactured from Mahua

flower and sold in the retail out still Shop. They also have bottling plants for IMFL in the State

of Odisha and Jharkhand and for Country liquor in the State of West Bengal and Jharkhand.

With the experience which the family has in the liquor trade, the family is confident of being

able to successfully implement and manage a distillery vender which it prepares to set up in

the State of Odisha.

i) ShriRiteshSahu is the Managing Director of Boudh Distillery Private Limited. He

has been in the liquor business for over 15 years, and has been managing over 50

micro-distilleries. Mr.RiteshSahu completed his MBA from Sydenham Institute of

Management (Mumbai). He has been a pioneer in the development of liquor

business in the state of Odisha. Prior to the current assignment, he was the Chief

Operating Officer of Kishore Prasad Bijay Prasad Beverages Private Ltd.

ii) Mr.AmitSahu, Director of the Company is B.Com (Hons) from Delhi University,

and as well MBA from Clark University, USA. Mr.AmitSahu is having more than

two decades of business experience. He is also Director / Partner of the following

Companies:

Director - Santevita Hospital (an unit of Sahu Estate Pvt. Ltd.) a modern multi-

speciality hospital in Ranchi

Director - Sahu Alcohols Pvt. Ltd., engaged in the liquor trade in Jharkhand



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Partner - Silica Bottling & Blending Enterprises, bottling plant for Seagrams

iii) Mr.Uday Shankar Prasad has had more than fifty years of experience in the liquor

trade (country spirit & IMFL) in the states of Orissa, Jharkhand/Bihar & West

Bengal. He has had an impeccable track record with the Excise Departments of

the three states especially in Orissa. His decades of experience and knowledge in

the liquor trade as well as the goodwill with the Excise Department in the state of

Orissa will stand in good stead in the implementation and running of the

proposed distillery. Apart from the liquor trade he is a partner in Arya Hotel in

Ranchi.

iv) Mr.Pankaj Kumar, Executive Director of the Company, is a Chartered Accountant,

and MBA. Pankaj Kumar has an impressive 30+ year professional background

marked by notable achievements as the Group Managing Director, Managing

director, and as CFO of large corporations like Tower Group, Dangote Industries

Ltd, PT Indo Foods, and of Philips India.

Based on the past experience of the Directors of the company, the company is now planning

to set up distillery unit of 2 x 60 KPLD in a phased manner at Village– Titerikata, District:

Boudh, Odisha. The industry would also generate the power of 2 x 2.5 MW.

The proposed project shall be catering to the demand of Odisha State and neighbouring

States where-in almost all liquor companies like PernodRicard (Seagram), Jagatjit, ABD,

Radico, USL and many others are selling their reputed IMFL brands. Also, the demand of

Ethanol is growing and the government has made it mandatory for blending of minimum

10% Ethanol in Petrol. The implementation of the project shall be within 1 year from the

date of receipt of Environmental Clearance from MoEF, New Delhi and Consent for

Establishment from the State PCB.



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2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT

The Bio-energy industry across the world has the potential to make significant contributions

to meet the world’s energy needs. In India, Bio-energy can contribute towards achieving the

country’s energy security and help reduce the dependence on fossil fuels. Large possibilities

exist for biomass resources, in particular energy crops to penetrate into Power Generation,

Transport Markets, Pharmaceutical Markets and Potable alcohol markets.

This proposed project of M/s. Boudh Distillery Private Limited. aims to be part of the Agro-

Based Industry revolution for manufacturing Rectified Spirit / ENA/ Pharma Alcohol by using

agricultural not for human consumption crops such as Maize, Sorghum grain, broken rice and

starch based cereals and power generation.

2.3 NEED FOR THE PROJECT AND IS IMPORTANCE TO THE COUNTRY OR REGION

Expert Committee on Ethanol Blending

Indian Government had set up an Expert Group headed by the Executive Director of the

Centre for High Technology for examining various options of blending ethanol with petrol at

terminals/depots. Considering the logistical and financial advantages, this Group had

recommended blending of ethanol with petrol at supply locations (terminals / depots) of oil

companies. In view of the above, Government vide the Gazette notification of 3rdSeptember,

2002 No. P-45018/28/2000-C.C had mandated that with effect from 1-1-2003, 5% ethanol-

doped petrol will be supplied in following nine States and four contiguous Union Territories

of Andhra Pradesh, Gujarat, Haryana, Karnataka, Maharashtra, Punjab, Tamil Nadu, Uttar

Pradesh, Pondicherry, Daman & Diu, Goa, Dadra and Nagar Haveli & Chandigarh. This was

the beginning of ethanol implementation in 1st phase.

Government of India further announced to implement the Ethanol programme in 2nd phase.

This was intended to supply ethanol blended Gasoline across the country effective the year

2006 and in 3rd phase switching over from the existing 5% to 10% blending of ethanol in

selected states.

With implementation of the 5% Ethanol-Blended Petrol (EBP) programme throughout the

country still a distant dream due to various complications like ethanol shortages, the variable

taxation structure of state governments and regulatory restrictions, the petroleum ministry



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has decided to defer the proposed rollout of mandatory 10% blending of ethanol, which was

expected to take place from October, 2008 onwards.

Potable Alcohol Market

Indian alcoholic beverages market is the third largest alcoholic market across the globe. As

per ASSOCHAM, Alcohol consumption in India is to cross 19,000 million litres. Currently,

there are about 425 distilleries operating in the country with the total production capacity of

4,800 million litres.

The Alcoholic Beverage Industry in India can be broadly classified into 4 types:

Production Trend of alcoholic beverages in India *

The production of alcohol beverages in India grew from 913 MN litres in FY 05 to 1,594 MN

litres in FY 09, translating into a CAGR of 14.94%. During FY 09, Indian alcoholic beverages

industry was valued at Rs 2100 bn. The changing perception of the people towards alcohol,

rising youth population in the country coupled with rising acceptability of the alcohol



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consumption among the female population is driving the growth story of alcohol in India.

CARE Research expects the Indian alcoholic beverage industry to grow at a CAGR of 8%,

during the period of FY09-13.

IMFL

The IMFL primarily comprises wine, vodka, gin, whisky, rum and brandy with the market

share heavily skewed towards whisky. Whisky accounts for 55% of the total IMFL market and

other spirits accounts for the rest 45%.

The fermentation route using sugary or sugar-yielding material and yeast has been in

practice in India since long for the production of alcohol or Ethanol. Most of the Ethanol

produced (almost 95%) is through the fermentation route. Grains like rice, corn or maize,

barley-malt, rye, wheat, sorghum etc., starchy bulbs and vegetables like cassava (tapioca)

and potatoes are commonly used for producing ethanol under the fermentation route in

India. In India, ethanol is mostly produced from molasses obtained during the process of

crushing sugarcane.

Maharashtra government approved the usage of grains for producing alcohol during 2000.

However, due to the difference in cost of production between the grain based & molasses

based alcohol, grain based industry could not take off. In order to encourage grain based

neutral alcoholProduction. The Maharashtra government passed a scheme known as

“Financial Assistance to Grain Based Distillery& Integrated Units-2007” in June 2007.



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Demographic profile of India

In terms of the demographic profile, India is one of the youngest nations in the world with

the median age of 25.9 years. More than 40% of the population is in the range of 15-40

years. The growing youth population coupled with increasing per capita income and

increasing exposure to western influences are boosting the alcohol consumption in country.

Further, the growing social acceptability and popularity of the alcoholic beverages among

the female population is also boosting the alcohol demand. This will in turn boost the

demand for grain based alcohol as it is used for producing premier alcohol in India.

Demand drivers for Ethanol or extra neutral alcohol can be summarized as government’s

emphasis on bio-fuel consumption; growing vehicle population; low per capita consumption

of liquor; growing population, Higher youth population; growing economy and urbanization.



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Growth drivers’ of ethanol/extra neutral alcohol

Liquors are manufactured in a synthetic way to imitate foreign liquors viz. Whisky, Brandy,

Rum and Gin. They are called Indian Made Foreign Liquor (I.M.F.L.). (Different varieties are

produced by addition of flavours & are called spiced liquor.) The excise duty on I.M.F.L. is

much higher than that on country liquor. Supply of country liquor at low rates is very much

needed to keep away the illicit liquor manufacturers & traders. The I.M.F.L. requires alcohol

of very high purity and high quality. For this purpose separate distillation plant to redistill

and purify Rectified Spirit is necessary. This alcohol is called Extra Neutral Alcohol. It is also

useful in cosmetics and perfumes manufacturing.

Extra Neutral Alcohol (ENA) is used as the main raw material in the manufacture of

consumption alcohol. There are two varieties of ENA: Molasses based ENA and Grain based

ENA. The molasses based ENA is mainly used to manufacture cheap liquor and Grain based

ENA is used for premium brands. In developed nations it has been declared that

consumption alcohol should not be manufactured from molasses as it is dangerous for

human consumption. But in India there is an acute shortage of Grain ENA and only available

raw material for consumption alcohol is molasses ENA so it is been widely used.



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2.3 DEMAND – SUPPLY GAP

Alcohol has assumed very important place in the Country’s economy. It is a vital raw material

for a number of chemicals. It has been a source of a large amount of revenue by way of

excise duty levied by the Govt. on alcoholic liquors. It has a potential as fuel in the form of

power alcohol for blending with Petrol & Diesel. Also, the fermentation alcohol has great

demand in countries like Japan, U.S.A., Canada, Sri Lanka etc. as the synthetic alcohol

produced by these countries, from naphtha of petroleum crude, is not useful for beverages.

Teething problems in the 5% EBP program are primarily on account of the shortage of

ethanol at various locations across the country. Even in states where blending has taken off

in full swing, it has been seen that ethanol supply has not been adequate to meet demand.

Even supply locations in UP and Uttara hand where supplies have been satisfactory so far are

now facing a severe shortfall of ethanol.

The petroleum industry however looks very committed to the use of ethanol as fuel, as it is

expected to benefit the farmers as well as the oil industry in the long run. Ethanol can be

produced from Sugar cane, wheat, corn, beet, sweet sorghum etc. Ethanol is one of the best

tools to fight vehicular pollution, contains 35% oxygen that helps complete combustion of

fuel and thus reduces harmful tailpipe.

2.4 EMPLOYMENT GENERATION DUE TO THE PROJECT

Boudh Distillery Private Limited are planning to set up grain based distillery project of 2 x 60

KLPD and having 2 x 2.5 MW cogeneration power plant in a phased manner at Village-

Titerikata, Post – Ramvikata, Tehsil- Harabhanga, Post / District: Boudh, Odisha.

The plant will be continuous and automatic in operation, with necessary control

instrumentation. The steam required will be supplied for self-generation. Prior to utilizing

the steam in the process the high pressure steam is used to generate power. All the three

operations namely steam and power generation, production of Ethanol are integrated. The

personnel required for all operations are listed below with their grades.



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No. of Employees Numbers Number

Phase –I Phase-II

1. Unit head 1 -

2. Production-in-charge 1 1

3. Manager Commercial 1 0

4. Maintenance Engineer 1 1

5. Commercial Accountant 1 1

6. Purchase Manager 1 0

7. HR manager 1 0

8. Electrical Manager 1 0

9. Instrument engineer 1 0

10. Excise and warehouse incharge 1 0

11. Grain unloading supervisors 2 0

12. Coal unloading supervisors 2 0

13. Warehouse and DWS sale supervisors 2 0

14. Office assistant 2 2

15. Fitter 4 2

16. Electrician 4 2

17. Boiler Operator 7 5

18. Technical Operator 14 14

19. Semi & unskilled labour 14 14

20. Supervisors/ Shift-in-charge 4 4

21. Stores Assistant 1 1

TOTAL 66 47



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Chapter – 3 : PROJECT DESCRIPTION

3.1 TYPE OF PROJECT INCLUDING INTERLINKED & INTERDEPENDENT PROJECT, IF ANY

Proposed project is a Distillery Project for production of Rectified Spirit / ENA / Pharma

Alcohol / Industrial Alcohols and Cogeneration Power plant at Village-Titerikata, Post –

Ramvikata, Tehsil- Harabhanga, Post / District: Boudh, Odisha. Following is plant

configuration and production capacity:

S.No. Product Phase

Phase # 1 Phase # 2

1. Rectified Spirit / ENA / Pharma Alcohol / Industrial Alcohols

60 KLPD 60 KLPD

2. Cogeneration Power Plant 2.5 MW 2.5 MW

By Products

1. CO2 30 TPD 30 TPD

2. Fuse Oil 0.60 TPD 0.60 TPD

3. DWS 150 TPD 150 TPD

4. DDGS 49.5 TPD 49.5 TPD

3.2 LOCATION OF PROJECT

Boudh Distillery Private Limited is planning to setup a grain based distillery plant of 2 x 60

KLPD and cogeneration power plant of 2 x 2.5 MW in phased manner at Village-Titerikata,

Post – Ramvikata, Tehsil- Harabhanga, Post / District: Boudh, Odisha.

Total land envisaged for the proposed project is 35.58 acres and same in possession of

management.

The Coordinates of the proposed 20°41'51.23"N 84°23'17.38"E.

Boudh District is present at a distance of 18 Kms. (by road) from the proposed project site.

Mahanadi River is flowing at distance of 4.0 Kms. from the proposed project site.

Nearest Grid is at distance of 10 Kms. from the proposed project site.

NH # 224 is passing at distance of 1.0 Kms. from the proposed project site.

Donga RF, Jajpur RF, Bankamundi RF, Aragarh RF, Parapata RF exist within study area.



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Boudh Distillery Pvt. Ltd, Project Site



14

LAND Titerikata MAP – 2 KM



15

TITERIKATA LAND USE MAP 10KM



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3.3 DETAILS OF ALTERNATE SITE CONSIDERED

S.No. Particulars Site # 1 (Liaga)

Site # 2 (Titrikata)

Site # 3 (Nuapada)

1. Location Village Liaga, Boudh District

Village Titrikata, Boudh District

Village Nuapada, Boudh District

2. Geographical Coordinates 20°40'26.89"N 84°23'6.44"E

20°41'51.23"N 84°23'17.38"E

20°41'59.79"N 84°22'30.63"E

3. Distance of Nearest Habitations

Liaga Village 0.3 Kms.

Titrikata 1 Kms.

Nuapada 0.4 Kms.

4. Water bodies / Streams / Canals

0.1 Kms. 0.5 Kms. 0.3 Kms.

5. National / State Highway NH # 224 0.1Kms.

NH # 224 1.0Kms.

NH # 224 0.25 Kms.

Based on the above, Site # 2, at Titrikata Villages has been considered for the proposed

project.

3.4 SIZE AND MAGNITUDE OF OPERATION

Proposed project is a Distillery Project for production of Rectified Spirit / ENA / Pharma

Alcohol / Industrial Alcohols and Cogeneration Power plant at Village-Titerikata, Post –

Ramvikata, Tehsil- Harabhanga, Post / District: Boudh, Odisha. Following is plant

configuration and production capacity:

S.No. Product Phase

Phase # 1 Phase # 2

3. Rectified Spirit / ENA / Pharma Alcohol / Industrial Alcohols

60 KLPD 60 KLPD

4. Cogeneration Power Plant 2.5 MW 2.5 MW

By Products

5. CO2 30 TPD 30 TPD

6. Fuse Oil 0.60 TPD 0.60 TPD

7. DWS 150 TPD 150 TPD

8. DDGS 49.5 TPD 49.5 TPD

Proposed Distillery plant will be operational for 330 days in a year.



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3.5 MANUFACTURING PROCESS

3.5.1 GRAIN BASED DISTILLERY PLANT

Boudh Distillery Private Limited are planning to set up grain based distillery project of 2 x 60

KLPD and having 2 x 2.5 MW cogeneration power plant in phased manner at Village-

Titerikata, Post – Ramvikata, Tehsil- Harabhanga, Post / District: Boudh, Odisha.

In order to produce ethanol from starchy materials such as cereal grains, the starch must

first be converted into sugars. This has traditionally been accomplished by allowing the grain

to germinate, which produces the enzyme, amylase. When the grain is mashed, the amylase

converts the remaining starches into sugars. For fuel ethanol, the hydrolysis of starch into

glucose can be accomplished more rapidly by treatment with dilute sulphuric acid, fugally

produced amylase, or some combination of the two.

The de-polymerization or hydrolysis of starch involves addition of one water molecule per

glucose unit.

n(-C6H10O5-) + n(H2O) n(C6H12O6)

Starch (162) Water (18) Glucose (180)

Enzymes are used for converting starch into alcohol. In its natural form starch exists in a

semi-crystalline state which is not easily accessible to enzyme action. Hence it is necessary to

gelatinize or cook the starch to open up the crystalline structure. This step is known as

liquefaction. With the appropriate combination of alpha and beta amylases the thick starch

slurry is liquefied and then saccharified. Alpha amylase randomly breaks up long chains of

starch in to shorter chains of glucose units called dextrins which are mostly soluble in water.

Hence this step is known as liquefaction. In the next step amylo-glucosidase enzyme

converts dextrin’s to fermentable sugar glucose and is called saccharification. Usually the

gelatination and liquefaction processes are carried out in close combination and often

referred as cooking.

The fermentation of the glucose obtained by saccharification is carried out by the yeast. The

fermented mash is distilled to obtain alcohol.

In the following paragraphs the process is described briefly.

The grain based distillery process will have following steps/operations as described below;

• Grains receiving and storage



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• Grains handling and milling

• Slurry preparation/liquefaction

• Saccharification and instantaneous fermentation

• Fermentation

• Multi-pressure distillation

• Decantation

• Multi-effect evaporation

• Spirit storage

Figure 1 shows the schematic flow diagram of the process operations.

Grain receiving and storage

Grains such as broken rice, rotten wheat, maize, bajra and other edible grains are procured

from various sources, and are stored in silos.

Grain handling and milling

The grain would be lifted in bucket elevators, screened followed by removal of stones and

iron matter. Cleaned grains would then be milled using dry milling process in hammer mills.

The flour would be fed through the bucket elevators and conveyed to the batch tipping

machine through a screw conveyor. The flour addition would be metered through the batch

tipping machine with load cell arrangement, before transferring the flour to the slurry tank

through another screw conveyor (pre-masher) for slurry preparation process.

Slurry preparation/liquefaction

In liquefaction process, starch is hydrolysed to dextrin. The Liquefaction is carried out in

Single stage Liquefaction Tank. Feedstock Flour is transferred to Pre-masher and mixed with

Recycle Streams and liquefying enzyme. Slurry from Pre-masher is taken to Liquefaction tank

where temperature is maintained by means of steam. Necessary retention time is

maintained in the Liquefaction Tank. Slurry pH is maintained by supplying dilute caustic

solution. Contents in Slurry Tank are kept in suspension by Agitation. The Liquefied Slurry is

then cooled in Slurry Cooler using cooling water supply and transferred to Pre-fermentation

and Fermentation section.



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20

Saccharification and instantaneous fermentation

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

Optimum temperature is maintained by circulating cooling water. The contents of the Pre-

fermenter are then transferred to Fermenter. The purpose of Fermentation is to convert the

fermentable substrate into alcohol. To prepare the mash for Fermentation, it is diluted with

water. Yeast is added in sufficient quantity to complete Fermentation to produce alcohol.

At the start of the cycle, the Fermenter is charged with mash and contents of the Preferment

or. Significant heat release takes place during Fermentation. This is removed by passing the

mash through heat exchangers to maintain an optimum temperature. The recirculating

pumps also serve to empty the Fermenters into Beer Well. CO2 can then be taken to CO2

vent line where it is vented out. After emptying of Fermenter, it is cleaned with CIP using

cleaning nozzles. After CIP, Fermenter is ready for next batch to be filled.

Fermentation

The Fermentation process is engineered to operate in batch mode depending upon the

quality of raw material. The purpose of Fermentation is to convert the fermentable sugars

into alcohol. During Fermentation, sugars are broken down into alcohol and carbon-dioxide.

Significant heat release takes place during Fermentation. The fermenter temperature is

maintained at around 30 – 32oC by forced recirculation flow through plate heat exchangers.

We have given a provision for spent wash recycled to Fermentation depending on solids

concentration in fermented wash.

Multi-Pressure Distillation

Multi-Pressure Distillation system has Seven Distillation columns operating at various

pressure conditions. Heat energy from columns operating under high pressure is utilized for

columns operating under low pressure to optimize the operation for energy consumption.

Wash to ENA Mode:

Following Columns will be under operation:

• Analyser Column

• Degasser Column



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• Pre-Rectifier Column

• ED Column

• Rectifier cum Exhaust Column

• Recovery Column

• Simmering Column

Pre-heated fermented wash will be fed to Degasser column. Fermented wash is stripped off

alcohol by ascending vapours in Analyser column. Rectifier vapours provide energy to

Analyser column through a Thermosyphon re-boiler. Vapours of Degasser column are

condensed and taken to Recovery Feed Tank. The condensed Analyser vapours are taken to

Pre-Rectifier Column. Analyser Condensate is concentrated in Pre-Rectifier column, which

operates under pressure. Condensing steam provides energy to pre-rectifier column through

a vertical Thermosyphon re-boiler. A Technical Alcohol cut of about 1-2% of total spirit is

taken from the Pre-Rectifier column.

Concentrated alcohol draw from Pre-Rectifier column is fed to ED column for purification.

Dilution water in the ratio of 1:9 is added in this column for concentrating higher alcohol at

the top. Top of this column is condensed in its condensers and fed to recovery feed tank

while bottoms are fed to Rectifier cum Exhaust Column for concentration. Rectifier Column

operates under pressure and condensing steam provides energy to this column through a

vertical Thermosyphonreboiler. Technical Alcohol cut is taken out from the top of this

column while ENA draw is taken out from appropriate upper trays and fed to Simmering

Column after cooling. Fusel Oil build up is avoided by taking fusel oil draws from appropriate

trays.

These fusel oils along with the condensate of Degasifying & Extractive Distillation columns

are fed to recovery column for concentration. A technical alcohol cut is taken out from the

top of this column. Simmering Column is operated under high reflux for better separation of

methanol and di-acetyls. Final ENA product draw is taken from the bottom of this column.

Decantation & Thin Slops Recycle Section

Decantation section comprises of a Centrifuge Decanter for separation of suspended solids

from Spent Wash coming out of Grain Distillation Plant. Wet cake has 30-32% w/w solids as



22

removed from bottom of Decanter which can be sold directly in wet form as cattle feed

(DWG).

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

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

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

the entire mixture can be dried in a DDGS Dryer and then sold in dry form as Cattle feed

(DDGS).

Evaporation System - Integrated Evaporation Scheme

The suggested treatment scheme Effect working on the principle of falling film & Force

Circulation Analyser vapours is fed to the first effect evaporator shell side and steam is fed to

shell side finisher at the given pressure and temperature as the heating medium.

Vapours from last effect are condensed in Surface Condenser. A Shell & tube type Multi-pass

Surface condenser is employed for condensing the shell side vapours.

The product at the desired concentration 35-40% is obtained at the outlet of Finisher. Each

effect is provided with recirculation cum transfer pump.

The condensate from surface condensers is collected in a common condensate pot. The

condensate is transferred for further treatment / Recycle by using centrifugal pump.

• The Pure steam condensate are collected in receiving vessels and can be pumped to

partially process and ETP.

• Highly efficient operating pumps have been provided for pumping the required fluid.

• The plant is having high level of automation to get consistent output at required

concentration.

• The system operates under vacuum. Water-ring vacuum pumps are used to maintain

a desired vacuum.

• Cooling water from cooling tower is used in the surface condensers for condensing

vapours



23

DWGS Dryer with Cooling and Conveying System

System Description for Dryer

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

feeding system. The Fluidised Bed Dryer is enclosed in an insulated dryer housing and its

outer flights are fixed. Dry saturated steam is to be supplied to the dryer through rotary joint

at one end & the condensate is discharged through joint mounted on another end.

During the course of fluidization, these flights pick up the material and shower them on to

the tube bundles. The heat transfer is primarily by conduction. The water vapours are

exhausted through an Exhaust Blower & passed through a cyclone separator for separating

fines.

Dry product partially recycled back to Feed conditioner for feed conditioning through

Product Screw & Recycle Conveyor.

Entire operation of the Dryer is controlled through Control panel.

Spirit storage

Spirit storage would be divided into two sections. One would be daily spirit receiver section

and the other would be bulk storage section. The spirit coming out of distillation would be

transferred to daily spirit receivers (separated for Ethanol/RS/ENA). Subsequently, after

gauging, the spirit would be transferred to respective bulk storage tanks.

3.5.2 CO-GENERATION POWER PLANT

Boudh Distillery Ltd will install a capacity of (2 x 2.5 MW) of cogeneration of power based on

biomass & coal (Indian / Imported).

The cogeneration power plant is divided in three parts, namely;

Boiler & Auxiliaries

Turbine & Auxiliaries

Generator & Auxiliaries

Boiler & Auxiliaries



24

Boiler: The industry plans to install additional 2 x 25 TPH capacity fluidized bed boiler (FBC)

for steam and 2 x 2.5 MW of cogeneration of power. FBC boiler is most suitable technology

for the biomass and coal as fuel to be used. When air passes upward at low velocities

through a mass of finely divided solid particles (such as ash & crushed refractory) the

particles are not disturbed. As air flow is gradually increased, the particles become

suspended. Further increase in the air flow gives rise to bubble formation and vigorous

turbulence. The bed of solid particles has the same characteristics of the liquid and thus the

bed is termed as Fluidised Bed. Combustion of fuel in this bed is termed as Fluidised Bed

Combustion (FBC). The boiler would be having other auxiliaries as described below;

Drum: The feed input, separation of steam and water & blow down are all carried through

the drum.

Furnace: It is the primary part of boiler where the chemical energy available in the fuel is

converted to thermal energy by combustion. It is the designed for efficient & complete

combustion.

Super Heater: These are meant for raising the steam temperature above the saturation

temperature to a maximum of around 5500C (due to the metallurgical problem, the

percentage of heat to super heater is approx... 30%).

De-Super Heater: To control the super heater temperature & always try to maintain the

steam temperature constant during variation of load, de-super heater is used.

Draft System: The combustion process in a furnace can take place only when it receives a

steady flow of air & has the combustion gases are continuously removed.

Economizer: The economizer absorbs heat from the flue gas mainly as sensible heat to the

feed water. By this, the efficiency of boiler is improved.

Water Wall/Evaporator: Where water converted into steam by latent heat addition.

Support: All modern boilers are top support units. The hanger rods are designed for the

direct tensile stress resulting from the weight of units & the bending stress from the pressure

part expansion.

Soot Blower: Deposits result from combustion of husk & relatively smaller extent from oil.

Means have to be provided to prevent an accumulation of deposit from chocking the boiler

gas passes & to maintain boiler heating surface in a suitably clean condition for effective

heat transfer whilst on load. Steam is used for soot blowing.



25

Air Heater: It is now an essential boiler auxiliary because hot air necessary for rapid &

efficient combustion in the furnace & also for the husk & to recover waste heat from the flue

gas to increase boiler efficiency.

Primary Fluidising Air Fan: It is used for fluidising the bed of fuel and giving the upward

movement.

Forced Draft Fan: To take air from atmosphere at ambient temperature to supply essentially

the combustion air required, in addition to fluidising air.

Induced Draft Fan: To evacuate the gases out of the furnace & exhaust through the stack.

The ID Fan maintains the negative draft inside the furnace.

Ash Collection: The method used for removal of ash from the flue gas consists of mechanical

dust collector & electrostatic precipitator. The mechanical dust collector removes the

coarser particles through cyclones. The ESP consists of two sets of electrodes. Wires which

are charged at HVDC are called emitting electrodes. The collecting electrodes are in the form

of plates, which are at earth potential. The dust particles in the flue gas get charged while

coming in contact with the emitting electrodes. The charged particles are attracted to the

earthed collecting particles and get discharged and fall down the hopper. Very high

efficiency of ash collection up to 99.90% can be achieved in the ESP

Boiler Feed Pump: It is multistage pump provided for pumping feed water from the de-

aerator storage tank to economizer of the boiler. Generally two pumps each of 100%

capacity are provided.

Turbine & Auxiliaries

Turbine: The turbine shall be horizontal, single cylinder, extraction cum condensing

design coupled to a generator to generate the rated output of 2 x 2.5 MW of

electricity with the steam inlet parameters as specified in this specifications. The

steam turbine, gear box, main oil pump with its interconnecting piping and its

supports shall be assembled and aligned on a single skid and shall be delivered. All

the cabling within the skid shall be laid in the metal conduits and shall be fixed to the

base frame with respective junction boxes mounted on the skid. Main component &

associated system of the Turbine are described below;

Casing: It is essentially a pressure vessel, which must be capable of withstanding the

working pressure & temperature of the steam. The casing is supported on each end,



26

with provision to permit expansion at one end. The fixed blades (Orifice) are

supported in the casing.

Rotor: It supports the moving blade.

Blades: These are the most important component of turbine as these are responsible

for the converting heat energy to mechanical.

Sealing System: Glands are used on turbine to prevent or reduce the leakage of

steam air between rotating & stationary components which have a pressure

difference with the atmosphere. If the cylinder pressure is higher than the

atmospheric pressure then there will be a leakage of steam outward (HP sides). If the

cylinder is below atmospheric pressure, then there will be leakage of air (LP side).

Steam is generally used for sealing of labyrinth glands.

LP Heater: The condensate pumped by the condensate pump is heated in the LP

heater by steam extracted from the turbine after it has performed some useful work.

This improves the cycle efficiency.

De-aerator: The presence of certain gases like oxygen, carbon dioxide, & ammonia

dissolved in water is harmful because of their corrosive action on boiler metal parts

particularly at elevated temperatures. The condensate is sprayed inside the de-

aerator and it is heated by the extraction steam from the turbine. The airs etc. are

thus liberated from the condensate. The deaerated condensate thus comes to the

storage tanks, from which the boiler feed pump pumps the condensate to the boiler.

Turbine Oil System: The high pressure hydraulic oil for turbine control, oil for bearing

lubrication of turbine generator are received from the turbine shaft mounted main oil

pump. Start-up AC and emergency DC pumps are provided for start-up and maintain

bearing oil flow during turbine trip. Turbine Oil Coolers are provided to cool the

bearing oil.

Turbine Governing System: The main purpose of governor is to maintain speed of

turbine during fluctuation of load on the generator by varying steam input to the

turbine. The governing system consists of hydraulically operated Control Valves. It

helps to start the turbine from rest to rated speed and synchronizing with the grid.

The load on the generator can be controlled in a pre-determined manner by the

control valves. Emergency stop valve is provided to shut off the steam supply to the

turbine completely in abnormal & emergency situation.



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Generator & its Auxiliaries

Generator: The generator shall be of CACW, brush less design with horizontal shaft

mounted AC exciter driven by a steam turbine through reduction gearing and fitted

with one PMG on the extended shaft of alternator. Supplier shall clearly specify the

excitation arrangement in case PMG is not applicable. The Generator shall be capable

of delivering the maximum output obtainable from the steam turbine under any

operating conditions at 0.8 power factor lag, 11 KV output with a frequency of 50 Hz.

Main component & associated system of the generator are described below;

Stator: The stator houses the armature winding also supports the rotor bearings. The

insulation of the windings is Class “F”, but designed for temp rise for Class “B”

insulation.

Rotor: The generator rotor is cylindrical in construction and carries the DC field

windings. The field is normally of 2 or 4 pole design.

Generator Bearing: These are the pedestal type of spherical sealing to show self-

alignment & are support on s separate pedestal on suffering sides & turbine side.

Generator Cooling System: The heat loss in the generator windings are dissipated by

air circulated by the rotor mounted fans. This heat should be taken off for safe

operation of the generator. The air is in turn could be generator air coolers, located

at four corners. Water is the cooling medium.

Generator Excitation System: The DC Power supply to the field winding will be given

either through a static excitation system or through shaft mounted brush-less

excitation system. The control system varies the DC Current to change the terminal

voltage or reactive power.

Generator Protection: Generator has to protect from faults occurring within

generator stator or rotor & also from external faults/ abnormal operating condition in

the grid which affected the generator. Various devise are used to detect which can

give warning alarm or trip the unit automatically as required.



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3.6 RAW MATERIAL REQUIREMENT FOR PROPOSED DISTILLERY

The distillery will use grains such as broken rice, maize, bajra, jowar and other starch

containing grains etc. as basic raw material. Besides this, processing chemicals would be

used for the production of RS / ENA / Pharma alcohol / ethyl alcohol. Phase wise daily

consumption of raw materials for the distillery plant is given below:

S.No. Raw Materials PHASE-I PHASE-II

1. Broken rice, maize, bajra, jowar and other

starch containing grains etc.

150 MT 150 MT

2. Enzymes 120 Kgs. 120 Kgs.

3. Sodium Hydroxide 60 Kgs. 60 Kgs.

4. Urea 150 Kgs. 150 Kgs.

5. Anti-foam agent 30 Kgs. 30 Kgs.

6. Yeast 20 Kgs. 20 Kgs.

Fuel Requirements for Boiler

Boudh Distillery Private Limited plans to install an boilers of 2 x 25 TPH capacity to meet the

steam requirements in the proposed project. The industry would use biomass as well as coal

(Indian / Imported) as fuel for the boilers.

Following is the fuel requirement for the boiler:

S.No. Fuel PHASE-I PHASE-II

1. Indian Coal 115 TPD 115 TPD

or

2. Imported Coal 70 TPD 70 TPD

or

3. Biomass 135 TPD 135 TPD



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3.7 WATER REQUIREMENT AND ITS SOURCE

Water required for the proposed project will be sourced from Ground Water sources and

Mahanadi River.

Water required for the proposed Distillery plant & Cogen. Power Plant will be 1264 cum/day.

3.8 WASTE WATER GENERATED AND IT’S MANAGEMENT

Thin slop generated will be concentrated in the Evaporation system up to 40% solids (w/w).

This concentrated spent wash (40 % Solids) will be sent to the drier along with wet cake

generated from Decanter for making DDGS with 90 % solids and the DDGS obtained will be

sold as cattle feed / prawn feed / fish feed. This technology is based on zero discharge which

is approved by CPCB.

The non process effluent will be treated in ETP and will be utilized for Ash conditioning, Dust

suppression and greenbelt development after ensuring compliance with SPCB norms.

3.9 SOLID WASTE GENERATED AND IT’S MANAGEMENT

Following is solid waste generated and its management from the proposed project:

Ash from the boiler will be used as manure/ given to brick manufactures/cement

plant.

Sludge generated from ETP will be used as manure

DDGS will be sold as cattle feed / fish / prawn feed.



30

Chapter – 4 : SITE ANALYSIS

4.1 CONNECTIVITY

Boudh is well connected with road and rail with other district headquarters and the state

capital Bhubaneswar. The distance of Boudh from Bhubaneswar is 240 km. One can come to

Boudh via State Highway No. 1 & 14 (via Nayagarh–Charichhak) or can come by National

Highway No. 42. (Via- Angul). Regular train services are available from Bhubaneswar viz.

Bhubaneswar –Sambalpur Intercity Express, HirakudExpress,Puri-Sambalpur passenger train.

To reach Boudh one has to get down at Rairakhole station. From here one has to travel

around 27 km. either by Bus or taxi to reach Boudh. The nearest Airport is at Bhubaneswar.

4.2 LAND USE AND LAND OWENERSHIP

Total envisaged for the proposed project is 35.58 acres and same is in possession of

management. The land will be converted for Industrial use.

4.3 TOPOGRAPHY

The topography of the land is flat without undulations.

4.4 EXISTING LAND USE PATTERN

35.58 acres of land is envisaged for the proposed project. The land will be converted to

Industrial use.

There are no ecologically sensitive places like national park, sanctuary, biosphere

reserve, etc. around 10 Kms. radius of the site. Few Reserve forest exists within the study

area. There is no route of migratory animals within the project site.

4.5 EXISTING INFRASTRUCTURE

Water supply in most of the villages is available. Inter-village transport facility is available

only for the selected villages. While educational facilities & health facilities are not

encouraging in most of the villages. There is well established road connection.



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4.6 SOIL CLASSIFICATION

The area is a flat featureless plain having alluvial soils. Prominent types of soil in the district

are loam, clay loam, sandy and sand dunes. Clay loam soil is suitable for cotton, wheat,

sugarcane, mustard, etc. while the sandy soils are suitable for cultivation of gram under

rainfed conditions. The agro climatic conditions are suitable for raising horticulture crops

particularly Kinnow, Grapes, Guava, Ber, Aonla, etc.

4.7 CLIMATIC DATA FROM SECONDARY SOURCES

The climate of the district is of extreme type. It is dry except during monsoon. There are

large varieties of day and night temperature. The average annual rainfall of the district is 400

mm. The variation in the rainfall from year to year is not large. The monsoon starts late in

June and generally lasts up to September. 90% of the rainfall is received from June to

September. August is the month with more number of rainy days. About 28% of rainfall is

received during this month.



32

Chapter – 5 : PLANNING BRIEF

5.1 PLANNING CONCEPT

Boudh Distillery Private Limited is planning to setup a grain based distillery plant of 2 x 60

KLPD and cogeneration power plant of 2 x 2.5 MW in phased manner at Village-Titerikata,

Post – Ramvikata, Tehsil- Harabhanga, Post / District: Boudh, Odisha.


management.

5.2 POPULATION PROJECTION

The project will be providing employment to nearly 100 workers. The local persons will be

given preference in employment as per the qualification and technical competencies.

Necessary training will be given to train the unemployed youths of the nearby villages as per

the qualification and technical competencies. Indirect employment opportunities will be

created in the periphery of the project automatically as the project started operation in

the region. In order to operate and maintain the plant facilities, including its technical

general administration needs, the manpower for the proposed project will be 50. The

above manpower covers the top management, middle and junior level executives and

other supporting staff including workforce.

5.3 LAND USE PLANNING


management. Following is breakup of land use:

S.No. Particular Extent of Land (In Acres)

1. Built up area including storage 12.00

2. Internal roads 1.50

3. ETP 3.00

4. Greenbelt 12.00

5. Parking area 1.50

6. Vacant area & others 5.58

Total 35.58



33

5.3 ASSESSMENT OF INFRASTRUCTURE DEMANT (PHYSICAL & SOCIAL)

The road facility is already available which shall be used and maintained. Infrastructure

facilities like road transport, Post & Telegraph, Telephone, Banks etc. are basics for each and

every area. The company management will take various steps for upliftment of the basic

amenities of the area by providing drinking water, pucca road, communication facilities etc.

The area is not very well developed as far as job opportunities and living standard of the

population is concerned. With the start of the proposed Plant, various employment

opportunities will be generated. Several persons will be benefited with contract works,

employment through contractor, running of jeep and buses, canteens, different kind of

shops and transport related business avenues. This will improve the economic condition of

the persons.

5.4 AMENTIES / FACILITIES

A well planned office will be provided having sufficient space to accommodate executives

and staff. It will be equipped with telephones and Internet facilities.

Facilities like canteen, rest room and indoor games facilities will be provided in the proposed

plant as basic facilities to workers.



34

Chapter – 6 : PROPOSED INFRASTRUCTURE

6.1 INDUSTRIAL AREA (PROCESSING AREA)

The plant is to be constructed in 35.58 acres of land at Village-Titerikata, Post – Ramvikata,

Tehsil- Harabhanga, Post / District: Boudh, Odisha.

The approximate size of the buildings required for PHASE -I various sections are as under:

Grain Warehouse

o 28 meter x 22 meter x 12 meter AC sheet roofing, RCC & Masonry work to

side walls.

Silo & unloading Platform

o 30 meter x 30 meter. Open area for silo plus small shed for unloading

platform.

Milling Section

o 28 meter x 17 meter x 20 meter. Ground + four Floors covered on all sides

RCC and masonry work.

Liquefaction & fermentation

o 39 meterx 43 meterx 15 meter AC sheet roofing side open.

Distillation Section with ethanol

o 25 meter x 15 meter x 40 meter AC sheet roofing sides AC sheet cladding.

Receiver Section

o 18 meter x 18 meter x 12 meter Roof AC sides roofing all sides closed with

RCC and masonry work.

Storage Section

o 40 meter x 24 meter Open area with boundary and dyke walls.

Condensate polishing Unit

o 60 meterx 30 meterOpen area with RCC constructions.

Evaporation section

o 20 meterx 7 meterx 24 meterAC sheet roofing with sides open

Ground + four floors of RCC construction.

Dryer

o 15 meterx 40 meterx 20 meterAC sheet roofing all sides open.



35

Incineration Boiler

o 50 meter x 15 meterStructural sheet constructions, open on all sides

Turbo-alternator set

o 15 meterx 20 meterx 8 meterRCC building

6.2 RESIDENTIAL AREA (NON PROCESSING AREA)

No colonization is proposed in the proposed project. However Facilities like canteen, rest

room and indoor games facilities will be provided in the proposed plant as basic facilities to

workers.

6.3 GREENBELT

More than 1/3rd of total land availability is reserved for plantation i.e. greenery.

Greenbelt development plan

Local DFO will be consulted in developing the green belt.

Greenbelt of 33% of the area will be developed in the plant premises as per CPCB

guidelines.

10 m wide greenbelt is being maintained all around the plant.

The tree species to be selected for the plantation are pollutant tolerant, fast growing,

wind firm, deep rooted. A three tier plantation is proposed comprising of an outer

most belt of taller trees which will act as barrier, middle core acting as air cleaner and

the innermost core which may be termed as absorptive layer consisting of trees

which are known to be particularly tolerant to pollutants.

6.4 SOCIAL INFRASTRUCTURE

With the start of Construction phase, various employment opportunities will be generated.

Several persons will be benefited with contract works, employment through contractor,

running of jeep and buses, canteens, different kind of shops and transport related business

avenues. Peoples will be provided with either direct employment or indirect employment

such as contract work, development work like road etc.



36

6.5 CONNECTIVITY

Boudh is well connected with road and rail with other district headquarters and the state

capital Bhubaneswar. The distance of Boudh from Bhubaneswar is 240 km. One can come to

Boudh via State Highway No. 1 & 14 (via Nayagarh–Charichhak) or can come by National

Highway No. 42. (Via- Angul). Regular train services are available from Bhubaneswar viz.

Bhubaneswar –Sambalpur Intercity Express, HirakudExpress,Puri-Sambalpur passenger train.

To reach Boudh one has to get down at Rairakhole station. From here one has to travel

around 27 km. either by Bus or taxi to reach Boudh. The nearest Airport is at Bhubaneswar.

6.6 DRINKING WATER MANAGEMENT

Drinking water for the proposed project will be sourced ground water sources. It is estimated

about 10 KLD will be required for domestic and drinking purpose during operation of the

proposed plant.

6.7 ENVIRONMENT MANAGEMENT PLAN

The major objective and benefit of utilizing Environmental Management Plan in project

planning stage itself, is to prevent avoidable losses of environmental resources and values as

a result of Environmental Management Plan. Environmental Management Plan includes

protection/mitigation/enhancement measures as well as suggesting post project monitoring

programme. It may often suggest additional project operations that have to be incorporated

in the conventional operation.

The industrial development in the study area needs to be with judicious utilization of non-

renewable resources of the study area and within the limits of permissible assimilative

capacity. The assimilative capacity of the study area is the maximum amount of pollution

load that can be discharged in the environment without affecting the designated use and is

governed by dilution, dispersion, and removal due to Physic-chemical and biological

processes. The EMP is required to ensure sustainable development in the study area of the

proposed plant site, hence it needs to be all encompasses plan for which the proposed

industry. Government, regulating agencies like pollution control board working in the region

and more importantly the affected population of the study area need to extend their

cooperation and contribution.



37

It has been evaluated that the study area has not been affected adversely as there are no

major polluting industries in the study area and likely to get economical fillip. The affected

environmental attributes in the region are air quality, water quality, soil, land use, ecology

and public health. The management action plan aims at controlling pollution at the source

level to the possible extent with the available and affordable technology followed by

treatment measures before they are discharged. Environmental management plan aims at

the preservation of ecosystem by considering the pollution abatement facilities at the plant

inception.

6.7.1 AIR EMISSION AND ITS MANAGEMENT

The air pollution will be due to combustion emissions released by the boilers attached to the

proposed 2 x 25 TPH boilers. The boiler, FBC type, will use chiefly rice husk and coal (Indian /

Imported) as fuel.

As per the statutory norms (as applicable to the industry), the flue gas emission shall not

have SPM levels (in the stack) exceeding 50 mg/Nm3 in each PHASE. Additionally, the stack

height requirements for discharge of emissions will need to be complied with.

DG sets: The industrial unit is planning to have one DG set of 500 kVA as backup to state

power supply. As per the applicable norms, the DG sets will be housed in an acoustic

chamber. The combustion emission outlet, of the DG set, will be provided with a muffler

along with a minimum stack height of 6.5 m above the height of nearest building.

6.7.2 SOLID WASTES GENERATION & ITS MANAGEMENT

Following is solid waste generated and its management from the proposed project:

Ash from the boiler will be used as manure/ given to brick manufactures/cement

plant.

Sludge generated from ETP will be used as manure

DDGS will be sold as cattle feed / fish / prawn feed.

Hazardous Waste Generation

The plant facility will result in generation of spent oils (lubricants and transformer oil), which

will be stored on site and sold to SPCB authorised recyclers.



38

6.7.3 WASTEWATER GENERATION AND ITS MANAGEMENT

PROCESS & NON PROCESS WASTEWATER MANGEMENT

Thin slop generated will be concentrated in the Evaporation system up to 40% solids (w/w).

This concentrated spent wash (40 % Solids) will be sent to the drier along with wet cake

generated from Decanter for making DDGS with 90 % solids and the DDGS obtained will be

sold as cattle feed / prawn feed / fish feed. This technology is based on zero discharge which

is approved by CPCB.

The non process effluent will be treated in ETP and will be utilized for Ash conditioning, Dust

suppression and greenbelt development after ensuring compliance with SPCB norms.

SEWARAGE SYSTEM

Domestic effluent collected through toilet blocks and other areas will be collected through

well designed sewer network and send to Septic tanks followed by sub-surface dispersion

trench. No effluent will be left-out after Soak pits.

6.10 POWER REQUIREMENT AND SUPPLY

Power required for the proposed plant will be taken from cogeneration power plant.



39

Chapter – 7 : REHABILITATION & RESETTLEMENT (R & R) PLAN

No rehabilitation and resettlement is required as there are no habitations in the in the

Project site.



40

Chapter – 8 : PROJECT SCHEDULE & COST ESTIMATES

8.1 PROJECT SCHEDULE

The plant will be implemented in 18 months from the date of receipt of Environmental

Clearance from the Hon’ble MoEF & NOC from SPCB.

8.2 PROJECT COST

S.No. Particulars Cost (Rs. In lakhs)

1. Milling, Liquefaction and Sacherification 200

2. Fermentation with Chiller 350

3. Plate Heat Exchangers 100

4. Distillation and MEE 2000

5. Cooling Towers 200

6. Drier 400

7. Boiler and Turbine 2000

8. Pipelines 200

9. Civil works 750

10. Storage tanks 300

11. CPU 200

12. Electrical work 300

13. MS Structure 300

14. DM plant, Softener, RO 250

Total 7550

15. Pre operative expenses 300

16. Contingencies 375

Total Project cost 8225



41

Chapter – 9 : ANALYSIS OF PROPOSAL

9.1 TECHNO COMMERCIAL VIABILITY

The techno – commercial viability of the proposed distillery is proved as the following factors

significantly favour setting up the unit.

Assured supply of grains in abundance around the factory.

Establishment of Plant & Machinery to handle broken rice to manufacture all or any

of the two finished products RS/ENA

Viability of the project is established beyond doubt with broken rice as input raw

materials.

Capital cost considered is low compared to the general trend in the market.

The proposed process and plant and machinery makes the project environmental

friendly.

The proposed manufacture of fuel ethanol makes the country that much less

dependent on imports of petroleum product (fuel).

To the extent of its installed capacity, production of fuel ethanol improves energy

security & self-sufficiency and saving of foreign exchange for the country.

9.2 FINANCIAL AND SOCIAL BENEFITS

The Proposed project will also improve Socio economic status/standard of living of the

people in the region. In the interest of development and improve the social conditions of the

local habitants, this project should be allowed after considering all the environment aspects.

With the implementation of the proposed project, the socio-economic status of the local

people will improve substantially. The land rates in the area will improve in the nearby areas

due to the proposed activity. This will help in upliftment of the social status of the people in

the area. Educational institutions will also come-up and will lead to improvement of

educational status of the people in the area. Primary health centre will also be developed by

us and the medical facilities will certainly improve due to the proposed project.



42

9.3 SOCIO-ECONOMIC DEVELOPMENTAL ACTIVITIES

The management is committed to uplift the standards of living of the villagers by

undertaking following activities / responsibilities as the part of Corporate Social

Responsibility.

Health & hygiene

Drinking water

Education for poor

Village roads

Lighting

HEALTH & HYGINE

Personal and domestic hygiene,

Maintaining clean neighborhood,

Weekly health camps offering free-check up & medicines

Ambulance services

Education & drug de-addiction, aids.

DRINKING WATER

Making drinking water available at centralized locations in the village,

SUPPORTING EDUCATION

Providing books to all poor children,

Conducting annual sports festival in the village schools,

Providing amenities like fans, lavatories,

Maintain play ground etc.

pre-feasibility reportenvironmentclearance.nic.in/writereaddata/online/tor/0_0_09_jun_2… ·...

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