prefeasibility report john...

John Distilleries Pvt.Ltd., A/P :-Chitali, Tal:- Rahata, Dist:- Ahmadnagar, (M.S.)

Prefeasibility Report

2014

CONSULTANT: sd engineering services private limited, Aurangabad (MS) Pg. 1

INDEX

1. EXECUTIVE SUMMERY

2. INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

2.1 Identification of the project and Project Proponent

2.2 Nature of the Project

2.3 Need of project with description for region and country

2.4 Demand and Supply gap

2.5 Imports vs. Indigenous production

2.6 Export Possibility

2.7 Domestic/ Export Markets

2.8 Employment Generation due to Project

3. PROJECT DESCRIPTION

3.1 Type of Project

3.2 Location of Project

3.3 Details of Alternate sites

3.4 Size of magnitude of Operation

3.5 Project Description

3.6 Raw material and Finished Products

3.7 Resources optimization

3.8 Availability of Resource (Water, Energy/ Power Requirement)

3.9 Quantity of Waste to be Generated

4. SITE ANALYSIS

4.1 Connectivity

4.2 Land form, Land use, Land ownership

4.3 Topography

4.4 Existing land use pattern

4.5 Existing Infrastructure

4.6 Soil classification

4.7 Climatic data for secondary sources



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4.8 Social Infrastructure available

5. PLANNING BRIEF

5.1 Planning concept

5.2 Population Projection

5.3 Land use planning

5.4 Assessment of Infrastructure Demand

5.5 Amenities/ Facilities

6. PROPOSED INFRASTRUCTURE

6.1 Industrial area

6.2 Residential area

6.3 Green Belt

6.4 Social Infrastructure

6.5 Connectivity

6.6 Drinking Water Management

6.7 Sewerage System

6.8 Industrial Waste management

6.9 Air Pollution

6.10 Solid waste Management

6.11 Power Requirement & Supply/ Source

7. REHABILATION AND RESETTLEMENT (R & R PLAN)

7.1 Policy to be adopted

8. PROJECT SHEDULE & COST ESTIMATES

8.1 Time schedule for the Project

8.2 Estimated project cost (Economic viability of the project)

9. ANALYSIS OF PROPOSAL

9.1 Financial and Social benefits



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CHAPTER 01

EXECUTIVE SUMMARY

M/S John Distilleries Pvt.Ltd. is proposing a expansion of existing distillery complex based

on molasses. It is desirous to produce alcohol in this Large Size Industrial (LSI) sector at

At-Po – Chitali Tal. Rahata Dist. Ahamadnagar Maharashtra. The existing capacity to

manufacture Alcohol (ENA/ RS) is 50 KLPD and it is proposed to add additional 100

KLPD totally 150 KLPD.

The Notification no. S. O. 1533 promulgated on 14th September 2006 have covered these

types of industries under its entry 5(g) stated distillery.

The proposed land is at Chitali Gut no.398, 399, 420, 423, and 424 admeasuring area of

226.34 acres. Proposed Layout Plan is attached. This is an expansion of existing project.

The Land converted to Industrial purpose since 1960. Thus there is no change in the status.

The main river, city, Railway line, National Highway is sufficiently at a safe distance.

Local Authority has provided all infrastructures like assured Electrical Power, Continuous

water supply from the Godavari Right bank canal, the internal road network, external

approach road and networking. There is no sensitive establishment in the vicinity (study

zone) such as health resort, hospital, archaeological monuments, sanctuaries etc. All

villages are provided with drinking water from wells or Government Water Supply

Schemes RWS. Hence we do not encroach upon their resource.

There will be no nuisance from noise. Machinery and Equipments will be provided with

Acoustic Enclosure. There will not be crushing, pulverizing operations. Labour strength is

also limited in this LSI unit. In this case input is odorless. No nuisance generation.

List of Products:

Sr. No. Product name Quantity Unit 1 Alcohol (ENA/ RS) 100 KLPD



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Whereas, during production water input requires 807 M3/Day. Fuel used for boiler will be,

Coal 14 tons/day, biogas 14 tons/day and Bagasse 200 MT/day requirement shall be, and

there will be chimney with adequate height.

In John Distilleries Pvt.Ltd. Safety and occupationally Health will be dealt carefully. A

disciplined approach is natural to this industry. Safety policy will be in place. This unit will

be registered under Factories Act and is bounded by State Factory Rules. Thus, first aid

trained and Fire – fighting trained person will be available in every shift. Safety Officer

will be appointed. Wherever necessary, provisions of other Acts, like petroleum Act,

Explosive Act etc.will are obeyed. Firefighting system is kept as per norms of Insurance

Company and CIF.

DMP (Disaster Management Plan) and off-site emergency plan will be in place.

Accordingly, Personal protection equipment will be given and use will be insisted.

Consulting physician will be retained to attain the factory.

This proposed project is located at near Srirampur MIDC at-village-Chitalli, Tal.Rahata

Dist. Ahmadnagr, Maharashtra. The Site is km from 16 km away from State highway

Ahmadnagar - Kopargaon, and 10 k.m. away from Godavari River. The electricity and

other is made available by local authority and the raw material is easily available. The

Srirampur city has Railway station. State Highway is passing adjacent to the project site.

The industry is proposing to manufacture Alcohol for growing needs of India. This will not

disturb the present land use because our area occupied will be only small % of influence

zone of 10 km.Trees are present at the proposed site , rehabilitation is not required. There

will be no problematic waste materials as all will be disposed as per CPCB norms.



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CHAPTER 02

INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

2.1 Identification of the project and Project Proponent

John Distilleries Pvt.Ltd., private limited company is floated and promoted by reputed

well-known Industrial families in Ahmadnagar in Maharashtra state.

Mr. Paul P John, by Qualification and first generation entrepreneur started John

Distilleries in 1996, a company manufacturing Indian Made Foreign Liquor and within a

span of 16 years, our reach spread from Bangalore to establish footprint in 11 States

across India. We are the Sixth Largest Liquor Company in the country in terms of

volume. Currently, we are present in 11 States & CSD business through multiple models

like own, lease & tie- up facilities. We also export our premium products to developed

countries and regular brands to Middle East & African Nations.

Mr. Paul P John has also got his presence in Hospitality Industry and currently owns

“Kumarakom Lake Resort” in Kerala and “The Paul” in Bangalore. Apart from

Beverages & Hospitality segment, he has business interests in US, with a furnishing

fabric trading house, real estate & construction business based in Tampa, Florida, that has

a distribution network across the US and Canada.

Promoted John Distilleries and has grown Original Choice into a 12 million case brand

with distribution in 11 states & CSD Business. A visionary entrepreneur having interests

in beverages and hospitality with the award winning Kumarakom Lake Resort Expanded

into premium wines with Big Banyan Holds degrees in Commerce and Law At John

Distilleries Pvt. Ltd.

Going to carry a Business of Distillery Plant for the manufacture of Country Liquor and

Foreign Liquor. The proposed expansion will have the flexibility to produce Rectified

Spirit, Extra neutral alcohol and Anhydrous Alcohol based on the market requirement.

The plant will incorporate multi-pressure distillation over conventional steam distillation

for better energy efficiency and consistent good quality of the product.

John Distilleries Pvt. Ltd. factory is situated at Chitali Gut no. 398, 399, 420, 423, 424 of



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Village- Chitalli, in Rahata tahesil of (MS) Ahmadnagar District. Application has been

made to MPCB for the Consent to establish. The manufacturing site is located at Chitali

Gut no.398, 399, 420, 423, 424 of Village-Chitalli, in Rahata tahesil of (MS)

Ahmadnagar District (Maharashtra).

The plot admeasures about 226.34 acres. The company shall be engaged in manufacture

of molasses based alcohol. Form I, as is prescribed by the EIA Notification, 2006

amendment 2009 is duly filled up and submitted. This Pre-feasibility Report is an

accompaniment to the same.

The Form I & Prefeasibility report generally covering Justification, Nearby Land Use,

Resources, Process, Pollution Control, Aesthetics, Risk Involved, Consequent

Developments and Environmental Sensitive Issues.

2.2 Nature of the Project

John Distilleries Pvt.Ltd. is proposing 100 KLPD of expansion with existing capacity as

50 KLPD Alcohol. This level of production will not be commenced from day one, but

will be commissioned smoothly. This is an optimum site for us because it is manageable

from production, pollution control and quality assurance point of view.

2.3 Need of project with description for region and country

1. The molasses has very high level BODs & CODs. If the same is not in use properly

shall cause more damage to environment.

2. The molasses can be converted in valuable products like alcohol and the risk of

more pollution can be diluted.

3. The latest technology is adopted with a better productivity and Quality of alcohol.

4. The molasses based distilleries are linked with sugar factory and sugar producing

farmers will be benefit by it.

5. These also involved in several developmental activities to help farmers.



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Justification: -

1) ENA will be available for the IMFL unit

2) Revenue will be generated for state government.

3) Ethanol will be used for mixing in fuel like petrol. It will reduce the valve of

petrol in the country.

4) Foreign Currency will be saved

5) Import of Foreign Liquor will reduce

6) Employment will be provided to the nearby region which will reduce poverty

7) Development of Local region

8) Increase in Local Business

9) Standard of Living of people will increase. Worker will be skilled

• How this project is economically strong

• How the wastage and scrap arising out of one development activity can serve as

raw material for us, in turn again to be useful to serve further national

development in building, bridges, factories etc and

• How the pollution generated from this unit can be successfully managed through

EMP implementation.

• How the residual pollution can be successfully managed through common

facilities like, though it is hardly needed in this instant case.

2.4 Demand and Supply gap

As per the increase in population demand in the Market for alcohol always prevail.

As far as the products like the molasses is by product of sugar mill. It is concerned to

alcohol are there is a huge gap in our country in demand and supply.

There are three main uses of ethanol in India. Of the total available ethanol, the

maximum – about 45 per cent – is used to produce potable liquor, about 40 per cent is

used in the alcohol-based chemical industry (as a solvent in synthesis of other organic

chemicals) and the rest is used for blending with petrol and other purposes. The demand

for ethanol has been continually increasing on account of the growth of user industries



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and use of ethanol as a fuel in the country. However, the production and availability of

ethanol has largely lagged behind. India is the fourth largest producer of ethanol.

In the world after Brazil, the United States of America (USA) and China, producing

approximately 2000 million litres of ethanol, mainly by fermentation of sugarcane

molasses. Ethanol is made by fermentation of sugars: enzymes from yeast change simple

sugars into ethanol and carbon dioxide. Potable ethanol and more than half of industrial

ethanol is made by this process.

Table 1: Ethanol production and consumption in India (million liters) Ethanol Production 2004 2005 2006 2007 2008 2009 ISMA (in sugar year) 1240 1925 2950 2715 1560 –

ICC (in alcohol year) 980 1590 2100 2200 1300 1680

USDA FAS 1199 1300 1,898 2,398 2,150 1073

Ethanol Consumption ISMA (in sugar year) 1410 1550 1700 1840 2010 –

ICC (in alcohol year) 1470 1740 2120 2280 1650 2870

USDA FAS 1430 1479 1639 1750 1940 1780

Surplus Ethanol ISMA (in sugar year) (–170) (375) (1250) (875) (–450) –

ICC (in alcohol year) (–490) (–150) (–20) (–80) (–350) (–1190)

USDA FAS –231 –179 259 648 210 (–707)

Imports ICC (in alcohol year) 490 150 20 80 350 –

USDA FAS – – 29 15 70 280

2.5 Domestic / Export Markets

Marketing will be done at the local level as well as finished goods will be exported to the

Regulated and non- regulated International Market.



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2.6 Employment Generation due to Project

Employments generated for administration and production purposes will be recruited

locally without any difficulty.

Indirect employment is done through road-side business & allied activities. Manpower

required as follows.

Sr.no. Particulars No. of

employees

1. Officers & supervisors 25

2. Skilled 40

3. Semiskilled 08

4. Labour 13

Total 86



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CHAPTER 03

PROJECT DESCRIPTION

3.1 Type of Project:

John Distilleries Pvt.Ltd. is proposing an expansion of existing distillery complex

consisting of Distillery. John Distilleries Pvt.Ltd. is desirous to produce alcohol in this

Large Size Industrial (LSI) sector at Chitalli Gut no. 398, 399, 420, 423, 424 Village.

Chitali Tal. Rahata Dist. Ahamadnagar Maharashtra. The proposed Expansion capacity of

the complex shall be Alcohol 100 KLPD.

With Screening it is necessary for John Distilleries Pvt.Ltd. to approach Delegated

Authority from Ministry of Environment and Forest (MoEF), New Delhi for Environment

Clearance guidance for this unit. This Pre-feasibility report however, is prepared for

forming a framework for EIA study, Scoping and finalizing the Terms of Reference, as

may be required.

The Local Authority has a desire to improve status of this District and has encouraged

Industrial establishments at Chitalli. In order to have a sustainable development, the

pollution generation from this industry is finally made insignificant having taken all the

precautions right from raw material selection up to low or no waste generation and

conversion.

3.2 Location of Project:

The proposed expansion of distillery complex at Chitalli Gut no. 398, 399, 420, 423, 424

of Village- Chitalli In taluka - Rahata of Dist.Ahamadnagar in Maharashtra state. Area is

around 226.34 acres. The Geographical Location of this Industry is N 19041’13.0”

Latitude and E 740 37’06.2” Longitude with an elevation of 532 m. (1745.41 ft) above

mean sea level (MSL). Local Authority has assured to provide all infrastructure like

assured Electrical power, continuous water supply from the nira right bank canal, the

internal road network, external approach road are already available.



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Some important air distances from proposed site are as under…..

1. Nearest Airport at Aurangabad 81km towards East direction.

2. Nearest State High way 16 km away from Ahmadnagar - Kopargaon towards East

direction.

3. Nearest Railway station at Chitalli 0.5km towards North Direction.

4. Nearest Habitat is Chitalli village towards South direction.

5. Nearest river is” Godavari River” at 10 km towards North direction.

GPS Location and Google Imagery of the proposed site are attached as (Annexure I).

3.3 Conclusion of the report

Considering merits and demerits of the sites in question, a marking system that is

Followed for ranking the considering following aspects is as under:

a) Source of water and land availability for Industrial (factory) use.

b) Topography, soil condition, land cost.

c) Environmental impact.

With all this consideration, this site was ranked first and adopted.

Lay-Out

Layout is designed properly. It is proposed to make construction to house storage yards

for Raw Material and finished products, ware houses, utility building, Canteen and

administrative offices. In addition to this plant, attendant waste minimization,

sophisticated R & D laboratory is required and shall be provided.

The Layout of facility is prepared based on following:

1. There will be sufficient space for the movement of vehicles especially fire

tender.

2. Shortest route for transfer of Raw material & Products from one department to

other.

3. Consideration of prevalent Wind speed & direction for dispersion of Pollutants.

4. Optimum Utilization of utilities.

5. Use of Natural gradient to transport waste water.



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Proposed Layout Plan is given as (Annexure II).

3.4 Size or Magnitude of Operation

John Distilleries Pvt.Ltd.is proposing Expansion of existing distillery complex with

capacity from 50 to proposed 100 KLPD Alcohols. This level of production will not be

commenced from day one, but will be commissioned smoothly. This will not disturb the

present land use because our area occupied will be only small % of influence zone of 10

km. Landscape and greenery will be developed in 33% area and only native species will

be promoted No Rehabilitation is required.

3.5 Project Description with Processes Details:

Product Details:

Sr. No. Product name Quantity Unit 1. Alcohol(ENA/ RS ) 100 KLPD/Day

Manufacturing Process:

(A) Manufacturing Process of Alcohol:-(Molasses–based)

FERMENTATION

In Hi Ferm Fermentation process for molasses based operation, culture yeast is used. Hi

Ferm Fermentation is Fermentation system which offers running the process in fed batch

mode. Hi Ferm Fermentation Plant has following sections,

Molasses Handling and Distribution

Screened molasses from Day Molasses Tank is fed to molasses receiving tank and

molasses is weighed. Weighed molasses is distributed to cell mass propagation,

Fermentation and yeast.

Yeast Propagation

Culture yeast is grown in laboratory during plant start-up. Yeast propagation section

comprises molasses diluter and hygienically engineered yeast vessels equipped with

heating, cooling and air Sparing facility.



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Pre Fermentation

In Pre-Fermented vessel, molasses, process water, nutrients and additive are added for

activation/growth of cell mass. Filtered air is spared as required for repairing of cell

membranes and other cell components. Activated cell mass is transferred to Fermented to

maintain desired cell mass concentration in Fermented.

• Dilute molasses media is prepared in yeast vessel by re-circulating media through

molasses diluter.

Laboratory propagated cell mass is scaled up in series of yeast vessels. Sterile air is

spared in pasteurized and cooled dilute molasses medium for optimum growth of yeast.

Temperature is maintained at 30-32 degree by recirculation cooling water through jacket

of yeast vessels. Cell mass from Yeast vessel is transferred to Pre fermented to build up

cell mass required for Fermentation by cell mass transfer pump.

Fermentation

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

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

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

oxide. Significant heat release takes place during Fermentation. The fermented

temperature is maintained at around 30 -320C by forced recirculation flow through plate

heat exchangers

Molasses, a by-product of sugar industry is used as raw material by most of the

distilleries for production of alcohol by fermentation and distillation processes. The

molasses contains about 40-50% sugar, which is diluted to bring sugar contents to 10-

15% sugar, 20-250 Brix for further fermentation process. The pH is adjusted by addition

of sulphuric acid, if necessary.

Yeast culture is done in the laboratory and propagated in a series of fermenters, each

about 10 times larger than the previous one. The diluted molasses is inoculated with

about 10% by volume of yeast inoculums. In the fermenters the reducible sugars are

broken down to ethyl alcohol and carbon di oxide (CO2). The reaction is exothermic and



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cooling water is sprayed on fermenter walls to maintain the temperature at 29-300C.

Sludge is produced and discharged from the bottom, while the clear fermented beer from

top is sent to degasifying section of the analyzer which is a bubble- Cap- fractionating

column, the beer is heated by live steam and fractionated to give a 40% alcohol stream

from the top. This stream is further fractionated in the rectifier column to obtain rectified

spirit. Part of the rectified spirit is sent back to the column, and the condensed water from

this stage, known as “spent lees” is usually pumped back to the analyzer column. The

bottom discharge from the analyzer column is known as the spent wash, which is drained

off after heat exchange with the incoming beer from the fermenters.

In general the layout of, most distilleries is similar and can be divided into two broad

sections. The first section houses laboratory; yeast propagation vessels, diluters, pre-

fermenters and fermentation vessels. The second section houses all the distillation

columns condensers and heat exchangers.

The first section generally has two floors with equipment like diluter, pre-fermenters,

etc., and laboratory placed on the first. Fermentation vessels are laid on the ground floor

with their top extending about 1.5 m. into the first floor. The ground floor of the

fermenters is usually wet because of the cooling water sprayed on the outer walls of the

fermenters. This water splashes on the floor and flows out through open channels on the

floor along with fermenter sludge and washes water.

The yeast propagation vessels are generally closed reactors where strict temperature

control is maintained. The diluter in most of the distilleries is of continuous type where

the molasses and water streams are pumped into two coaxial tubes in a closed vessel. The

two streams get thoroughly mixed by the high turbulence before they flow into the

fermenter. Generally, the continuous diluter is cleaned once in a day with water and

steam. There is no process waste stream produced from yeast propagation vessels, diluter

and pre- fermenters except the wash waters used for cleaning after processing cycles.

Most of the distilleries have open top fermenters where CO2 is generally not recovered.



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Manufacturing process for Alcohol:

In India, Alcohol is manufactured by two processes:

• Batch Process

• Continuous Process

a) Batch Process

The molasses obtained from the sugar industry is first diluted to bring down the

concentration of sugar from 40-45% to 10-15%. Using a portion of the diluted

molasses a yeast culture is developed from inoculums. After 4-6 hours, when the

culture has developed fully, the remaining molasses is mixed and allowed to

ferment for 30-40 hours. The pH is maintained around 4-4.5 by addition of

Sulphuric acid. As the reaction is exothermic, the contents of the fermentation

tank are kept at 35-370C by constantly sprinkling cold water on the outer surface

of the fermentation tank. After fermentation is complete the yeast sludge is

removed from the bottom and the fermenter wash is pumped to the analyzer

column for distillation using steam. The free mixture of alcohol vapors and steam

is collected at the top of the column and alcohol free spent wash is discharged

from the bottom,

The alcohol and the steam are fed to rectification column where water and alcohol

vapors condense at different levels and rectified spirit is withdrawn. The

condensed water from this stage is called spent lees and forms another waste

stream.

b) Continuous Process:

In this process yeast is recycled. Fermentation and distillation is coupled to get a

continuous supply of fermented beer for the distillation column. The advantage of

the process is that a highly active yeast cell initiates the fermentation rapidly and

the alcohol yield is also much higher compared to the batch process.



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Bio-still process is one of the continuous processes, which is a trade name in

which molasses is fed to the fermenter at a constant flow rate. The flow rate of

molasses is controlled to maintain the sugar and alcohol concentrations in the

wash at 0.2% or lower and 6-7% respectively.

The waste streams comprise spent wash which is the main source of waste water,

spent lees and yeast sludge. Spent lees are usually mixed with the spent wash. The

yeast sludge is disposed separately after drying. In addition wastewater may be

generated from the bottling, fermentation tank cooling and washing and utility

sections of the plant, which is used as a diluents for the treated spent wash.



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Flow Sheet:

Manufacturing Process Flow Diagram for Distillery unit



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Material Balance Findings: Controlling Equations:

1. C12H22O11 + H2O 2C6H12O6

Sucrose + Water Reducing Sugar

342 + 18 360

1 + 0.05263 1.05263

2. C6H22O6 2C2H5OH + 2CO2

Reducing Sugar Ethyl Alcohol + Carbon Dioxide

180 92 + 88

1 0.5111 + 0.4889

1.05263 0.53978 + 0.51462

DISTILLATION - WASH TO RS MODE

Wash to RS Mode: -

Following Columns will be under operation

1. Analyser Column

2. Degasifying Column

3. Rectifier cum Exhaust Column

4. Recovery Column

5. Purifier Column

Pre-heated Fermented wash will be fed to Degasifying Column. Fermented wash is

stripped off alcohol by ascending vapors in Analyser Column. Vapors of Degasifying

Column are condensed and appropriate TA cut is taken out from this Column. The DG

Condensate is fed to Recovery Column.

Analyser vapors are condensed in Analyser Condensers and taken to Rectifier Feed Tank

(which acts as Pre-Rectifier Column Feed Tank in Wash to ENA mode). Rectifier

Column, which operates under pressure, concentrates the condensate of Analyser Column

to 95% v/v concentration. Fuel Oil Draws are taken from appropriate trays and fed to

Recovery Column. Recovery Column concentrates the fuel oil streams.



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A suitable Impure Spirit cut is taken out from this Column. Rectified Spirit draw of 95%

v/v is taken out from the upper trays of Rectifier Column and taken to storage after

passing it through a cooler.



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DISTILLATION - WASH TO ENA MODE

Following Columns will be under operation

1. Analyser Column

2. Degasifying Column

3. Pre-Rectifier Column

4. Extractive Distillation Column

5. Rectifier cum Exhaust Column

6. Recovery Column

7. Simmering Column

Pre-heated Fermented wash will be fed to Degasifying Column. Fermented wash is

stripped off alcohol by ascending vapors in Analyser Column. Rectifier vapors provide

energy to Analyser Column through a Thermo-siphon re-boiler. Vapors of Degasifying

Column are condensed and taken to Recovery Feed Tank.

Analyser vapors are condensed in Analyser Condensers and are taken to Pre-Rectifier

Feed Tank. Analyser Condensate is concentrated in Pre-Rectifier Column, which operates

under pressure. Condensing steam provides energy to Pre-Rectifier Column through a

vertical Thermosyphon reboiler.

A Technical Alcohol cut of about 1-2% of Total Spirit is taken from the Pre-Rectifier

column. Concentrated alcohol draw from Pre-Rectifier Column is fed to Extractive

Distillation Column for purification. Dilution water 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 Thermosyphon

Reboiler.

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. Fuel 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



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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.

Technology selection:

1. The process used is based on Raw materials that are available, without any

bottleneck.

2. Thus it is not necessary to store any one of it in excess. Excess storage also means

wastage. Here we can follow easily the principle of JIT (Just in Time)

procurement. Basic raw material i.e. sugar cane is available in the surrounding

area abundantly. Rest of the raw material is the byproduct of the prevailing

process e.g. Bagasse and Molasses.

3. The process used is developed and streamlined by team and hence are aware

about the sensitive points that need careful attention in advance.

4. The process is cost effective, safe and environment friendly.

5. There is no highly elevated pressure condition in processing.

6. Working pressure of furnaces is reasonably low. Such furnaces are available and

are easy to manage.

7. No hazardous material is involved in process.

8. We can recover alcohol and generate power from molasses and Bagasse. After

recovery the remains can be used in brick making and as manure thus following

the principal of “at source reduction of waste”.



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3.6 Raw Material for finished Product: List of Raw Materials:

List of Raw Materials and their Requirements on monthly basis

Name of Raw Material

Required Quantity

Description Mode of Transport

Source Storage at site

Molasses 28000 M.T Minimum 50% T.RS and 88° Brix

By Road with tanker

Nearer sugar factories

12000 M.T

List of Products and production on monthly basis:

Name of the Product

Description (Physical and Chemical Nature)

Storage at site Mode of Transport

Extra Neutral Alcohol

Clear Appearance Soluble in water

12 Laks B. L. By Road

Rectified Sprit Clear Appearance Soluble in water

19 Laks B.L. By Road

3.7 Source for Raw Material Procurement:

Raw Material is easily available in the local. Market and in the surrounding

Mode of Transport of Raw Materials: The raw materials will be transported locally by

way of road.

Storage at the site: Raw materials will be stored in Storage Yard at the project site as per

the norms. Location of Storage Yard is demarcated in Layout Plan.

3.8 Availability of Resources (Water, Energy/Power Requirement):



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Power: The total power generation here will be 1000 kw/hr. The power required for the

factory will be consumed from the in-house production and excess will be sold to MSEB.

Water: The water requirement is about 807 M3/Day for domestic, greenery, process, and

part cooling purposes. The source of water is already available from existing dam and the

same is adequate and satisfactory. The source is dependable and reliable.

Manpower: The manpower required for administration and production purposes will be

recruited locally without any difficulty. The requirement will be variable as per phase of

working but shall be about workforces including staff members shall work in shifts. The

list of workers & staff as shown in table below

List of staff & workers

Fuel for Furnace: Fuel used will be as below.

a) Coal – 14 Tons/day.

b) Biogas- 14 Tons/day.

c) Bagasse – 200 MT/day

DG Set: proposed DG set capacity shall be of 1010 KVA.

Sr.

No.

Particulars No. of

employees

1. Officers & supervisors 25

2. Skilled 40

3. Semiskilled 08

4. Labour 13

Total 86



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Land: Approximately 226.34 acres of land is already in the possession of proponent.

Project Cost: 40 Cr. (Fourty Core) for this unit.

EMP Cost: 6.35 Cr.

3.9 Quantity of waste to be generated:

Water & wastewater: The water supply will be through the Nira river right bank canal

located near village. This source is from Nira River and hence extremely dependable

source. Local Authority has provided full water works including filtration. The water &

wastewater generated in the factory will be as follows:

A) Water requirement for various purpose:

Sr. No.

Purpose Fresh Water Recycled Water

1. Boiler 70 cum/day 353 cum/day

2. Process (Fermentation) 425 cum/day 495 cum/day

3. Floor Washing ------ 20 cum/day

4. Cooling Tower make up ------ 400 cum/day

5. Domestic 12 cum/day

6. Green Belt ------ 80 cum/day

7. Distillation 300 cum/day 400 cum/day

Total 807 cum/day 1748 cum/day



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B) Effluent Generation

Blow Down (Boiler/CT/WTP) 95 cum/day

Process Effluent (Lean stream) 267 cum/day (spent lees)

Process Effluent (Spent Wash) 800 cum/day

Floor Washings 15 cum/day

Domestic 9 cum/day

Waste water generation and Characteristics.

Table lists the major wastewater streams generated at different stages in the alcohol

manufacturing process summarizes the typical characteristics of spent wash generated in

Indian distilleries using sugarcane molasses. Values for beet molasses-based effluent are

given for comparison. The main source of wastewater generation is the distillation step

wherein large volumes of dark brown effluent (termed as spent wash, stillage, slop or

vinasse) is generated in the temperature range of 71–81 1C The characteristics of the

spent wash depend on the raw material used also, it is estimated that 88% of the molasses

constituents end up as waste.

Sample quantities and characteristics of wastewater streams generated in an Indian distillery Characteristics of spent wash generated from various feedstock.

Parameter

Mg / lit.

COD (mg/l) 65,000–130, 000

BOD (mg/l) 30,000–70,000

COD/BOD ratio 2.49



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Total solids (mg/l) 30,000–100,000

Total suspended solids (mg/l) 350

Total dissolved solids (mg/l) 80,000

Total nitrogen (mg/l) 1000–2000

Total phosphorus (mg/l) 800–1200

Potassium (mg/l) 8000–12,000

Sulfur as SO4 (mg/l) 2000–6000

pH 3–5.4

Molasses spent wash has very high levels of BOD, COD, COD/BOD ratio as well as high

potassium, phosphorus and sulfate content (Table 3). In addition, cane molasses spent

wash contains low molecular weight compounds such as lactic acid, glycerol, ethanol and

acetic acid (Wilkie et al., 2000). Cane molasses also contains around 2% of a dark brown

pigment called melanoidins that impart color to the spent wash (Kalavathi et al., 2001).

Melanoidins are low and high molecular weight polymers formed as one of the final

products of Maillard reaction, which is a no enzymatic browning reaction resulting from

the reaction of reducing sugars and amino compounds (Martins and van Boekel, 2004).

This reaction proceeds effectively at temperatures above 50 1C and pH 4–7. The structure

of melanoidins is still not well known (Rivero-Pe´ rez et al., 2002). Only 6–7%

degradation of the melanoidins is achieved in the conventional anaerobic–aerobic effluent

treatment process (Gonzalez et al., 2000). Due to their antioxidant properties,

melanoidins are toxic to many microorganisms involved in wastewater treatment



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(Sirianuntapiboon et al., 2004a). Apart from melanoidins, spent wash contains other

colorants such as phenolics, caramel and melanin. Phenolics are more pronounced in cane

molasses wastewater whereas melanin is significant in beet molasses.

Effluent Treatment:

The molasses based distillery shall generate two types of waste water.

a) Concentrated stream – call as spent wash

b) Learn stream – consisting of spent leese, boiler and cooling tower blow down,

DM water, softener regeneration and process condensate.

The treatment shall be as under:

1) Spent Wash- the spent wash generated from factory shall be collected in a 30 days

storage lagoon and shall be forward to bio-digester. The bio-gas from biodigester

shall be used as fuel in boiler. The treated effluent from biodigester shall be

forward to MEE. The concentrated spent wash shall be further incinerated in

boiler. The press mud from sister concern unit and boiler ash shall be used as

filler material. The bio compost shall be sold as fertilizer.

2) Lean Steam – all lean stream from various sources like boiler blow down,

cooling tower blow down, spent leese, MEE condensate, process condensate,

floor washing shall be collected together and subjected to primary and two stage

biological treatment followed by UF and RO to recycle the treated effluent.

i) Solid Waste

The main solid waste from this factory will be of non-hazardous from office, garden and

Effluent Treatment Plant. Non hazardous waste will be segregated as compostable and

saleable. This will be so done.

M/S John Distilleries Pvt. Ltd. has in place the following mitigation policy future:

• Waste minimization at all levels of operations.



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• The plant will produce very less amount of scrap material. All these will however

be stored carefully on raised platform, with dwarf toe-walls all around and an

overhead roof.

• The main solid waste from sugar unit will be in form of bagasse which is utilized

completely for power generation.

• The hazardous waste will be disposed scientifically as per the norms.

(a) Non Hazardous Solid Waste:

Based on above working, the summery is:

Sr. No. Waste Quantity kg/day Treatment Disposal Remark 1. Canteen 20 Compost Own garden Organic 2. Garden Trash 114 Compost Land filling -- 3. Office waste

paper 70 Collection Sales For

recycle

(b) Generation of hazardous solid waste:

Sr. No.

List of Processes Generating Hazardous Waste

Waste stream Quantity

5 Every action relating to and every use of lubricating and system oil

5.1 Spent oil

230 lit /year 5.2 Wastes/residues containing oil

Aesthetics: Boiler Turbine, Centrifuges etc. shall be source of noise and vibrations.

Sturdy foundations and anti vibration arrangements shall be provided to reduce the effect.

Acoustic enclosures and enclosures shall be done to reduce noise level. Tree plantation

will be carried out. PPF’s will be provided to the workers in this area.

There will be no nuisance from noise as the machinery and equipments are acoustically

enclosed. DG sets will run occasionally. No nuisance will go to surrounding area.



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CHAPTER 04

SITE ANALYSIS

4.1 Connectivity:

The proposed production shall be at Gut no. 398, 399, 420, 423, 424 Village- Chitalli, in

Taluka – Rahata of Dist. Ahmadnagar in Maharashtra state. Total area is around 226.34

acres.

The Geographical Location of this Industry is N 18001’54.5”latitude and E 740

20’33.2”Longitude with an elevation of 539 m. (1768.37 ft) mean sea level (MSL). Local

Authority has assured to provide all infrastructures like assured Electrical power,

continuous water supply, the internal road network, external approach road etc.

Some important air distances from proposed site are as under…..

1. Nearest Airport at Aurangabad 81km towards East direction.

2. Nearest State High way 16 km away from Ahmadnagar - Kopargaon towards East

direction.

3. Nearest Railway station at Chitalli 0.5km towards North Direction.

4. Nearest Habitat is Chitalli village towards South direction.

5. Nearest river is” Godavari River” at 10 km towards North direction.

GPS Location and Google Imagery of the proposed site are attached.

4.2 Land form, Land use and Land ownership:

Land Form: Although land is on the upper elevation compared to the surrounding area,

the said Land has a large portion with plain contour. Slope is gentle to moderate type.

Land Ownership: Land ownership is with project proponents. Total area is about 226.34

acres 91.596 (ha) only.

Existing Land use Pattern: This agricultural land already converted to industrial land.

Now it is used for the industrial purpose. Hence there is no change in land use pattern.



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Existing Infrastructure:

Presently this area is existing with capacity 50 KLPD. This Project will participate in

improvement of the physical infrastructure of this area by incorporating Roof rain water

harvesting, Storm water management and green belt development.

4.3 Topography:

Proposed expansion site is located on the topographically flat terrain with very less

undulations. There is no river or stream or natural drainage line is passing through the

area.

Site

1. Open land, with no encroachment involved.

2. Climatic condition suitable for finer adjustment of control, making it fit for

process condition.

3. Well connected road network with ease of transportation.

4. Almost leveled ground and load bearing soil.

4.6 Soil Classification:

Ahmednagar is the biggest district of Maharashtra in terms of area and population. The

total geographical area of the district is 17.41 lakh ha. The net cropped area is 12, 56, 500

ha, out of which an area of 3,30,000 ha. (26.27 %) is under canal (84,000 ha) and well

irrigation. About 9, 26, 500 ha. (73.73 %) area is rain fed. The area under Kharif crops is

4, 60,000 ha. (36.6 per cent) while 7, 58,000 ha (60.32 per cent) area is under Rabi crops.

A multiple cropping system is followed on 1, 10, 500 ha. area.

A total of 8.73 per cent area of the district is under forest. The soil types of the district are

broadly divided into four categories namely coarse shallow soil; medium black soil; deep

black soil and reddish soil occupying about 38, 41,13 and 8 percent of the cultivated area

respectively. In the first two categories, soil moisture is the predominant limiting factor

affecting productivity of crops particularly under rainfed condition.



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4.7 Climate data from secondary sources:

Climate Classification:

Project site features a semiarid climate under the Koppen climate Classification.

Temperature:

Annual temperature has a relatively high range between the weather and climate

influence on our day to day life. Analysis of any weather data is most important. They are

gives and identified appropriate condition of the given station. To using the various data

man has aclimization to particular climatic position. Many methods are helps to

declaration of the weather conditions. With the help of the climatic data we are able to

find out climatic classification.

With the help of koppen's classification we are able to understand that the climate of

Ahmednagar city is semi arid, hot and dry climate is found. The concentration of ppt. in

Summer / warmer six month is more than70% Precipitation that is 88.23% in summer /

warmer six month at the Ahmednagar city therefore the dry climate is present.

Rainfall is less than upper limit for B but more than half that amount that's why semi arid

climate is present. And Average annual Temperature is over 180c therefore hot climate is

present. In an all criteria fulfilled therefore in Ahmednagar city having dry arid hot type

climate according to koppen classification.

Rainfall: The climate of the district is hot and dry, on whole extremely genial and is

characterized by a hot summer and general dryness during major part of the year except

during south-west monsoon season. Ahmednagar district receives average 566 mm.

rainfall. The major rainfall received during month of June to September.

4.8 Social Infrastructure available:

Infrastructures like Airport is at the distance of 81 Km East and Railway Station is at 0.5

km in North direction and nearest habitat is at the distance of 2 Km in East direction; in

north direction Godavari right bank canal are located in the study area.



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CHAPTER 05

PLANNING BRIEF

5.1 Planning Concept:

The area covered under study zone comprises of medium to heavy soil quality. Profuse

availability of stored water has encouraged villagers to grow cash crops.

Facilities:

This site appeared to be environmentally best as also from the business angle and therefore this

option was finally adopted. This site is inside the campus of the Village-Chitalli Shivar and

means safe transportation, less need of Utilities, less constructing buildings and roads, less fuel,

less water with optimization of infrastructure.

Local Authority has provided all infrastructures like assured Electrical power, continuous water

supply. The internal road network, external approach road.

All surrounding villages are provided with drinking water from wells or Government Water

Supply Schemes RWS. Hence we do not encroach upon their supply.

5.2 Population Projection:

Total population of the district is 40.88 lakhs of which 32.84 lakhs is living in the rural area

whereas 8.04 lakhs lives in urban area. The literacy of the district is 75.82 percent. The female

to male ratio of the district is 941.

In the district, there are 6.8 lakh farming families, out of these 32.45 per cent farmers are having

less than 2 ha land holding, 57.89 per cent farmers are having land holding between 2-10 ha. and

9.66 per cent farmers have a land holding with more than 10 ha. Total 3.8 lakhs are agriculture

laborer, 7.88 lakhs are SC/ST population, 2.11 lakh are dairy and sheep owners and total

working population is 14.32 lakh.



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5.3 Land use planning:

The proposed expansion is a prime industrial land. Thus there is no change in the status. This is

flat land whereby Cutting-filling balances and there will be No/Low Borrowing from nature.

Topography Map of the proposed site is attached.

Proposed expansion will house the facilities, some part will remain untouched for the Future

Expansion and 33% area will be demarcated for Green belt development.

5.4 Assessment of Infrastructure Demand (Physical and Social):

In Project proponent expansion will be having which does not require any addition in existing

Physical Infrastructure; so there will not be any demand of expansion of physical infrastructure

and social infrastructure. As manpower requirement is very less for the proposed expansion

which will not lead to any additional load on the existing social infrastructure.

5.5 Amenities/ Facilities:

Project proponent is proposing Manufacturing of Rectified spirit ENA & Ethanol from

Sugarcane molasses, compost & CO2 gas are byproducts in existing Industrial area. Local body

provides many basic facilities like uninterrupted water supply, power and Road Network &

solids disposal facility. This site is near the campus of the industrial area and means safe

transportation, less need of Utilities, less constructing buildings and roads, less fuel, less water

with optimization of infrastructure.



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CHAPTER 06

PROPOSED INFRASTRUCTURE

6.1 Industrial area:

This is new facility to manufacture Alcohol from molasses. Project proponent will develop

infrastructure as per requirement for proposed project of production.

6.2 Residential Area:

Residential already exist.

6.3 Green Belt:

About 33% of the total Plot area i.e. 226.34 acre is demarcated and additional along the

boundaries shall be proposed for tree plantation. The selection of trees is based upon the

Climatological conditions of the Study area.

In and around the project plantation is carried out to develop green belt. The treated sewage

water is used for green belt development within the factory premises. Following are the status of

green belt development.

List of Species for landscape development:

Sr. No. Name of Plant Common Name For Dry Region

1 Ailanthus excelsa Maharuhk 2 Albizia lebbeck Siris 3 Azadiracta indica Neem 4 Casuarina equisetifolia Beef- wood/ Saru 5 Dalbergia sissoo Sisham 6 Eugenia jambolana Jamun 7 Grevillea robusta Silver oak 8 Peltophorum ferrugineum Copper pod 9 Tamarindus indica Imli 10 Pongamia glabra Indian beech 11 Tamarix articulate Tamarisk 12 Mangifera indica Mango



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13 Ficus glomerata Umbar 14 Ficus bengalensis Vad 15 Dandrocalamus strictus Cane Bamboo 16 Cassia tora Tarwat 17 Bauhinia varigeta Kanchan 18 Psydium guava Peru 19 Plumbago zeylania Plumbago 20 Santalum album Chandan 21 Acalypha spp. Acalypha 22 Alastonia scolarasis Saptaparni 23 Embelica officinalis Amla 24 Hibiscus spp. Jaswand 25 Jatropha curcus Mogli errand/ Ratanjyot 26 Symbopogon martini Lamon grass 27 Lantana camara Lantana 28 Vinca rosea Sadafuli 29 Jasmine grandiflorum Jasmine 30 Calotropis procera Aak 31 Ipomea purpurea Beshram 32 Dhatura mental Dhatura 33 Vitex nurgundo Nirgudi 34 Ixora parviflora Ixora

6.4 Social Infrastructure:

There is no need of providing any Social infrastructure as the proposed expansion project is

involving only very small number of man power. Existing infrastructure will be sufficient to

accommodate the increasing load from the proposed project.

6.5 Connectivity:

This proposed Alcohol manufacturing facility is located at Village - Chitalli Shivar in

Ahamadnagr district, Maharashtra. The Site is 16 km from Srirampur town and 0.5 km from

Chitalli railway Station and 81 km from Aurangabad Air port. The land and infrastructure is

made available by Local Authority and the raw material is easily available through the easy



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transport via road connectivity and via Sea route and Air route. The Kopargaon Road State

Highway is passing adjacent to the project boundary.

6.6 Water Management:

The water requirement is about 807 M3/Day for Domestic, Greenery and Processes. The source

of water is already availability from existing water works of local authority and the same is

adequate and satisfactory. We are not encroaching on anybody’s water source.

6.7 Sewage System:

The Domestic Effluent will be treated in Septic tank and will be used for green belt after

treatment.

6.8 Air Pollution:

Process Emissions:

The air pollution caused by this industry is mainly from boiler. The boiler shall be provided with

bag filter followed by stack of 40 m height.

Fugitive Emissions:

A number of mitigation measures are taken to control fugitive emissions, the presence of which will

be noticeable by plain vision if not controlled. The measures are thus taken seriously and

continuously such as:

• Rubber wheel carts / trucks to bring in Raw Materials, not filled high, sides cladded,

slow speed travel, avoiding vibrations en-route.

• Collection of fugitive emissions by suitable suction system at the time of casting etc.

• Engineering the plant layout in such a way so as to virtually

Eliminate need of using heavy equipment for material handling in the main plant

• Internal roads paved, scrap area paved, leveled, no undulations, no sharp curves, slow

speed. No open storage of materials on barren unlined land to the maximum extent

possible.



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6.9 Solid Waste Management:

The main solid waste from this factory will be (a) non-hazardous from office, garden and sewage

ETP. Non hazardous will be segregated as recyclable/ saleable and Compostable. This will be so

done.

JDPL has in place the following mitigation policy future:

• Waste minimization at all levels for discarded products, packing surplus, unloading

spillages and fugitives.

• The plant will produce very less amount of scrap material. All these will however be stored

carefully on raised platform, with dwarf toe-walls all around and an overhead roof. The

contents will not be stored in the factory for more than a fortnight.

• The non-hazardous waste will be disposed by scientifically designed composting plant.

(a) Non Hazardous Solid Waste:

Based on above working, the expansion uses existing canteen facilities and STP. The canteen

waste goes as manure in landscaping after treatment.

Consented quantities of Solid waste generation are:

i) From Process Manufacture:

The quantity of generation of non-hazardous solid waste from the process of manufacture is

Nil.

ii) From the waste treatment:

Domestic Bio waste (dry leaves, roots & hey) & composting will be carried out for producing

bio-compost & will be used for Green Belt Development.

6.10 Power Requirement & Supply/ Source

John Distilleries Pvt.Ltd.Power requirement 1000 kw/hr for unit connected load available

through Govt. Electricity i.e. MSEDCL. Source of Power-from own Turbine & State Grid DG

set only in emergency backup of capacity 1010 KVA for proposed product. Quantity of fuel shall

be 283 Liters /hr of HSD.



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CHAPTER 07

REHABILITATION AND RESETTLEMENT (R & R PLAN)

7.1 Policy to be adopted

This project does not require acquisition of Land and the Infrastructure so there is no any kind of

activity of Rehabilitation and Resettlement to be carried out over here.



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CHAPTER 08

PROJECT SCHEDULE & COST ESTIMATES

8.1 Time schedule of the Project

John Distilleries Pvt.Ltd. has ability to complete their construction within 12 to 15 Months after

getting all relevant permissions and clearances.

8.2 Estimated project cost (Economic Viability of the Project)

1) Estimated project cost is 40 Cr. (Fourty core) for the proposed project.

2) Estimated Environmental Management Plan cost is 6.35 Cr.



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CHAPTER 09

ANALYSIS OF PROPOSAL

9.1 Financial and Social Benefits

John Distilleries Pvt. Ltd. has proposed to develop Alcohol manufacturing products which will

be used for Machinery manufactured by local manufacturer in the market.

This will be financial benefit to the industry as well as nation for a generation of foreign revenue.

By doing so, John Distilleries Pvt. Ltd. can participate towards the development of nation by

generating the foreign exchange, and also serve the social community.



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Annexure I

GPS Location and Google Imagery of Proposed Site.



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Annexure II

Toposheet.



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Annexure III

Project Location in Maharashtra:



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Annexure IV

Lay-Out Plan with Proposed expansion:

prefeasibility report john...

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