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Madhucon Sugar & Power Industries Limited ENVIRONMENT MANAGEMENT PLAN 65 KLPD ENA/ETHANOL DISTILLERY

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PROJECT AT A GLANCE

Name of the Industry Madhucon Sugar & Power Industries Ltd. Project Name Environmental Clearance by adopting Waste Minimization

Technology and Generation of 2.5 MW power from 25 TPH Spent wash incineration Boiler.

Existing EC details File No: J-11011/359/2006-IA-II(I) Existing Products as per EC order

1) 65 KLPD Molasses/ Grain based Distillery (not installed till now)

2) Operating days of distillery: 270 days 3) Sugar Unit 3500 TCD (operating) 4) Power Plant (operating) : 24.2 MW (After amendment via CFE

(expansion order no: 48/PCB/CFE/RO-KGM/HO/2009-1611 dated 05/10/2009)

Proposed 1) Operating days of Distillery: 330 days (200 days on molasses and 130 days on grain)

2) Waste Minimization technology: Addition of Incineration boiler for spent wash generating from Molasses based distillery along with existing Biocomposting and Biomethanation technology as per EC order.

3) Production of 2.5 MW additional Power from Spent Wash Incineration Boiler.

Achievement of Zero Effluent Discharge. Area availability 134 acres Area acquired by the Project

20 acres

Latitude 17 07’ 53.19” N Longitude 80 00’ 26.93” E Nearest Village Ammagudem Village, 0.5 Km (NE) Raw material requirement Molasses: 52000 MT for 200 working days.

Rice grain: 2020 Mt for 130 working days. Fuel Requirement for 25 TPH Incineration Boiler

Coal: 25600 MTPA Spent wash: 31200 MTPA

Spent Wash generation From Molasses mode: 8 KL/KL of alcohol produced: 520 KLPD From Grain mode: 6 KL/KL of alcohol produced: 390 KLPD

Water requirement 1017 KLD for Molasses mode Distillery 854 KLD for Grain mode Distillery 50 % of total water requirement will be met from recycle of effluents.

Employment 55 Total cost of project 11453.54 lakhs EMP Cost 1145 lakhs


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ENVIRONMENTAL MANAGEMENT PLAN

1.0 INTRODUCTION

Madhucon Sugar and Power Industries Limited, incorporated on 05.11.2002 as Madhucon

Sugars Limited, with an object to acquire, takeover all the assets and properties including the

licenses of The Palair Co-Operative Sugars Limited, Rajeshwarapuram, Khammam District.


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(established in co-operative sector in the year 1982)? In accordance with the policy decision

by the then Government to privatize sugar industry by open auction, Madhucon Sugar &

Power Industries Ltd. bought the unit through public auction in the year Nov 2002. The

company has already taken up these programmes on free seed supply, Cash loans, Seed loans,

Development loans, Fertilizers, Pesticides, Weedicides etc., in a big way in general and

propagating new varieties in particular in the region and the response of the growers was very

positive and it is expected the existing variety will be replaced to an extent of 50% in next 2 to

3 years time very comfortably as planned. This in turn will achieve higher yield and higher

recovery and contribute to improved physical performance of the plant.

In view of the above encouragements given by the company, the cane cultivation for the

factory command area has risen to 20,000 acres. On account of these developments the

Company has expanded the crushing capacity of the mill from 1250 TCD to 3500 TCD

besides establishing 24.2 MW Co-Gen plant in the year 2008.

After successful expansion of the sugar factory and establishment of cogeneration power

plant, the company has been recording good operational and financial performances. However

to consolidate its position by improving the dependability and eliminating the uncertainty in

the long run now the company has mooted the proposal of establishing a distillery unit of 65

KLPD capacity for producing ENA/ETHANOL in the current year as demand for ethanol is

likely to increase many folds as Government of India has made blending mandatory and

further Government also have increased the procurement price for ethanol from present

Rs.27/- to Rs. 42/- per litre to encourage sugar manufacturers to take up ethanol production in

large scale.

Keeping in view of the above the company has proposed 65 KLPD capacity of alcohol/

ethanol production unit considering own source molasses as input for 100 days and out

sourced molasses for remaining 100 days in total of 200 days operation with molasses and 130

days with grain (broken rice) as raw material to improve economic viability further.

2.0 DESCRIPTION OF PROJECT & PROJECT SITE

2.1 PROJECT PROPOSAL

The industry has proposed for the establishment of 65 KLPD molasses/grain based distillery

for producing ENA/Ethanol and is also having valid EC for the same vide File No: J-

11011/359/2006-IA-II(I) dated 27th august 2007 but as the distillery plant has not been

constructed till now and EC validity is up to 27.08.2012. Following changes will be made like


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addition of Raw Spent Wash Incineration system in addition to the existing Biometahanaion

and Biocomposting plant. Further addition of 2.5 MW power plant captive power generation is

also proposed from 25 TPH Spent wash Incineration boiler. It is also proposed to increase the

no. of operating days from 270 to 330 days (200 working days on molasses and 130 working

days on grains) as the industry has proposed for Zero water discharge.

2.2 LOCATION OF THE PROJECT SITE

The proposed project is to be located at Nelakondapally, Rajeshwarapuram, and Khammam

District, Telangana. The promoters are already running a sugar factory with an annual

crushing of 6 Lakh tons cane and also a co-generation plant of 24.2 MW for the last 5 years.

The sugar factory is proposing to crush 8 lakh tons in the coming year there by producing

36000-37000 metric tons of molasses. In view of the existing sugar factory skilled man power

availability is not a problem.

Water is sourced from Pal air Canal and the sugar factory is having enough cushions in the

water treatment plant capacity to cater to the needs of the proposed distillery unit. Molasses

produced in the sugar factory will meet the requirements of the distillery for 100 days.

Molasses requirement for another 100 days will be procured from other sugar factories.

Broken rice will be used as raw material for the 130 days and will be procured from the nearby

grain markets.

The Details of the Project site is given in the next page followed by a preliminary site.

2.3 SITE PARTICULARS

Table 1. The Salient Features of the proposed project

Nature of the project 65 KLPD ENA/Ethanol Distillery & 2.5 MW

electricity from Spent Wash Incineration Boiler

Size of the Project 65 KLPD Ethanol


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2.5 MW Electricity

LOCATION OF PROJECT

District & State Khammam District, Telangana

Village & Mandal Rajeshwarapuram Village & Nelakondapally

Mandal

Total land area 134 acres

Area required for the proposed project 20 acres.

Topography Krishna Godavari Zone

Altitude 107 meters

Llatitude/Longitude 17 07’ 53.19” N &

Rainfall 80 00’ 26.93” E

Ambient temperature 25 C- 38 C

Relative Humidity 70%

Rainy Season June to September

Climate Condition Tropical Wet and Dry

Wind velocity 158.4 KPH

Nearest Railway station Khammam- 27 km

Nearest Highway NH-9 Kodad-20 km

Nearest airport Vijaywada-135 km

River Palair Reservoir

Soil bearing capacity 22-40 T/sqmt.

Design Wind Pressure 660 N/M2


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Figure 1. Location map of the Proposed Project Site

PROJECT SITE


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Figure 2. Google map of 10 km radius of the Proposed Project Site


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Fig. 3 Site plan of the industry


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3.0 REQUIREMENTS FOR THR PROPOSED PROJECT

330 Working days/annum (i.e. 200 working days on molasses + 130 working days on

grain)

3.1 Steam Consumption for different modes.

Table 2. MOLASSES MODE

Steam Quantity Unit

Distillation 3.50 Kg/ltr

Integral Evaporator 0.00 Kg/ltr

Stand alone evaporation 2.70 Kg/ltr

Total 6.20 Kg/ltr

Tonnage of steam required per hour 16.79 TPH

SCAPH + de-aerator 4.00 TPH

GRAND TOTAL 20.79 TPH

Table 3. BROKEN RICE MODE

Steam Quantity Unit

Liquefaction .080 Kg/ltr

Distillation 3.50 Kg/ltr

Evaporation 0.90 Kg/ltr

Drier 1.90 Kg/ltr

Total 7.10 Kg/ltr

Tonnage of steam required per hour 19.23 TPH

SCAPH + de-aerator 4.00 TPH

GRAND TOTAL 23.23 TPH

3.2 FUEL REQUIREMENT

TABLE 4. FUEL REQUIREMENT FOR DISTILLERY UNIT

Molasses Mode ( 200 WDPA) Broken Rice Mode (130 WDPA)

Concentrated Spent Wash: 31200 MTPA -

Coal: 10000 TPA Coal: 15600 TPA

Total coal requirement for 330 days: 25600 MTPA


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3.3 RAW MATERIAL DETAILS

Total Molasses requirement: 52000 Mts for 200 Working Days / Annum.

(Own Molasses 26000 Mts for 100 working days & Bought out Molasses 26000 Mts for 100

working days)

Grains Requirement (Broken Rice/ Maize): 2020 MT for 130 Working Days/Annum.

Total Number of operable days: 330 days/annum

3.4 MANPOWER REQUIREMENT

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.

Table 5. No. of Employees

Grade Numbers

Unit head 1

Production-in-charge 1

Manager Commercial 1

Filter 4

Electrician 4

Boiler Operator 7

Technical Operator 14

Semi & unskilled labour 14

Supervisors/ Shift-in-charge 4

Stores Assistant 1

Maintenance Engineer 1

Commercial Accountant 1

Office assistant 2

TOTAL 55

3.5 LAND & BUILDING REQUIREMENT

The plant is to be constructed in 20 acres of land at the existing facility of Madhucon Sugar &

power industries Ltd, Rajeshwarapuram Village, Nelakondapally Mandal of Khammam

District, Andhra Pradesh.


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

Table 6. Size & Material for Building Construction

Section Approximate Size Description

Grain Godown 28 mtr x 22 mtr x 12 mtr AC sheet roofing, RCC & Masonry

work to side walls.

Silo & unloading Platform 30 mtr x 30 mtr Open area for silo plus small shed for

unloading platform.

Milling Section 28 mtr x 17 mtr x 20 mtr Ground + four Floors covered on all

sides RCC and masonry work.

Liquefaction & fermentation 39 mtr x 43 mtr x 15 mtr AC sheet roofing sides open.

Distillation Section with ethanol 25 mtr x 15 mtr x 40 mtr AC sheet roofing sides AC sheet

cladding.

Reciever Section 18 mtr x 18 mtr x 12 mtr Roof AC sides roofing all sides

closed with RCC and masonry work.

Storage Section 40 mtr x 24 mtr Open area with boundary and dyke

walls.

Condensate polishing Unit 60 mtr x 30 mtr Open area with RCC constructions.

Evaporation section 20 mtr x 7 mtr x 24 mtr AC sheet roofing with sides open,

Ground + four floors of RCC

construction.

Dryer 15 mtr x 40 mtr x 20 mtr AC sheet roofing all sides open.

Incineration Boiler 50 mtr x 15 mtr Structural sheet constructions, open

on all sides

Turbo-alternator set 15 mtr x 20 mtr x 8 mtr RCC building

Apart from the above buildings, civil foundations (RCC) are required for Machinery and

Tanks & chimney for Boiler. Compound wall with gates, internal roads, drainage are also

required.

4.0 PRODUCTION DETAILS WITH PROCESS DESCRIPTION

4.1 Production Capacity

Table 7: Production Details

Particulars UOM No. of days

of

operation

Per day

production

Annual

production

Operating with molasses


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Ethanol Kilo Ltr 200 60.0 12000.00

Operating with Grain

ENA Kilo Ltr 130 60.45 7858.0

Technical alcohol Kilo Ltr 4.55 455.00

DDGS MT 43.55 4355.00

Assumed that price will be increase every year by 5 %

By the time the conceived distillery unit is ready for operation, it is expected that the

availability of cane for the plant will increase to about 8 lakhs MT. and therefore expected

own molasses availability will increase which can be utilized for 100 days of distillery

operation. As proposed the bought out molasses from nearby mills and open market shall be

used for production of alcohol / ethanol for another 100 days and the remaining days as per the

needs (130 days) the grain will be procured and will be used for manufacture of alcohol. In

this connection it may be mentioned that the grain like broken rice and maize are abundantly

available in the region where plant is located at reasonable prices. In the process the factory

shall be mostly dependent on own molasses and rest of the period the bought out molasses and

grain operation will be used for achieving better economic and viable status to the project and

company. However depending on the ruling prices and availability of the different products

like molasses and grain the production plan will be designed and ensure viability of the plant

from time to time.

As a policy the Pollution Control Boards are stipulating stringent conditions like Zero

Discharge of its effluent for establishment of distilleries for ensuring protection to

environment. Therefore in the proposed project, the company is using updated technology by

putting up incineration boiler to use spent wash as a raw material to generate heat to produce

steam and power for captive use and in the process no pollutant is discharged to the open

streams etc. The effluent discharged from the Distillery Unit is known as spent wash with

molasses as feed stock and has dissolved solids of about 14-18 %. This effluent is

concentrated by evaporation to increase the solid content to 60% and after concentration the

spent wash will have a calorific value of 1700 KCal./Kg which is burnt as fuel in incinerator

boiler to produce high pressure steam. Thus the concentrated spent wash almost meets half of

the energy requirements of the incineration boiler and in the process effluent treatment and

discharge problem are totally solved. Thus zero discharge of effluent is achieved. Balance half

of the energy requirement of the incineration boiler will be met by using coal as supporting

fuel. The use of concentrated spent wash as energy source in the Incineration boiler results in

reduced fuel cost compared to conventional boilers.


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The other raw material resource is grains which include broken Rice. Maize as feed stock, the

effluent is known as thin slops. Thin slops are decanted to remove suspended solids and a part

of decanted thin slop is recycled in the process. The balance thin slops are concentrated in an

evaporator so that solid content reaches 35%. The concentrated slops and the cake from the

decanter are mixed and dried in a steam heated dryer. The dried product having a moisture

content of around 10% is known as DDGS (Distillery Dried Grains & Soluble). The DDGS is

used as cattle feed; poultry feed etc. and is having a very good market.

Molecular Sieve based alcohol Dehydration plant is included in the project. Depending on the

demand of the market the main product can be either ENA/Ethanol. The overall energy

requirements in case of Ethanol will be slightly less than the energy requirements of ENA.

Products & byproducts handling & disposal

• Main products obtained are ENA/Absolute Alcohol and are marketed

• By products namely Technical Alcohol and DDGS are marketed.

• Concentrated spent wash obtained during the process is incinerated in the boiler and

energy recovered.

4.2 Process & Technology

4.2.1 MOLASSES BASED PROCESS

Ethanol production mainly involves three main processes:

1. Fermentation

2. Primary Distillation for production of Rectified Spirit. (R.S.)/E.N.A.

Molasses Storage and Handling:

Molasses is generally stored in Steel tanks. It is proposed to install Molasses storage capacity

(26000 MT) for 100 days of its consumption in the distillery plant. This capacity has been

chosen considering the molasses storage capacity available in the sugar factory premises.

Molasses is thereafter pumped to the Molasses receiving tank in the fermentation section.

Fermentation

Fermentation is a critical step in a distillery plant. It is here that yeast converts sugar present in

molasses into ethanol.

Fermentation practices vary depending upon the raw material, ambient temperatures and end

product requirement.

The Fermentations consists of following steps:

a. Molasses weighing.


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b. Yeast propagation and Pre Fermentation

c. Fermentation

A Load cell based system is to be provided for weighing of molasses with provision for

totalizing molasses consumed in a day. This weighed molasses is distributed to yeast

propagation section, pre-fermentation and fermentation section.

Yeast Propagation:

Yeast propagation section comprises of three culture vessels, Pasteurization and cooling

facility. During fermentation start up, yeast is grown in yeast propagation section. The grown

yeast is transferred to pre-fermentation stage (Yeast activation vessel).

Fermentation of Molasses for Production of Alcohol Cane molasses by itself will not ferment

on its own without dilution, as the sugars and salts exert a very high osmotic pressure. It is

therefore necessary to dilute the molasses to below about 25° Brix. Above this point the yeast

will not start fermenting rapidly, and bacterial contamination may develop before the yeast

had a chance to get established, as molasses is laden with contaminating bacteria.

Typically, molasses is diluted and allowed to ferment using yeast. The yeast converts sugars

into alcohol under anaerobic conditions, while it multiplies itself under aerobic conditions.

Fermentation is carried out under controlled conditions such as temperature, pH, yeast cell

concentration, sugar concentration, and solid’s concentration in the fermenter. These

conditions are maintained in the fermenter so as to maximize efficiencies and obtain higher

yields and productivity. However, there are many factors that affect fermentation. These are:

Molasses composition.

Water Quality.

F/N ratio of molasses.

Bacterial count, Volatile acidity or other key influencers during fermentation

process.

The fermentation efficiency generally is in the range of 88-90% provided all the factors

influencing the fermentation process are under control.

During the last decade, interesting developments have taken place in the field of technology of

fermentation of alcohol, which promise high yield of alcohol, better efficiencies, economy in

steam consumption and better quality of spirit produced.

Process

Raw molasses from the storage tank is pumped to the molasses weighing system where exact

weighing of molasses going into the fermentation system is achieved. Weighed molasses is


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then pumped to a static molasses dilutors attached to each fermenter where it is mixed with

water / fermentation wash so as to achieve proper concentration of fermentable sugars in the

dilute molasses. Typically, this is a four fermenter system. Process water is also added to first

one or two fermenters. The fermenters are agitated using agitators and recirculation pumps.

Process water is used to scrub the total outgoing carbon dioxide so as to recover the alcohol

vapours in CO2. This water is then led to wash holding tank. Nutrients & sulfuric acid etc., are

fed to the first fermenter by metering or dosing pumps. In this manner by controlling

parameters like molasses and water flows, pH, Nutrient and temperature, alcohol

concentration between 5.5 and 8.5% v/v is maintained in first and last fermenter respectively.

Temperature of the individual fermenters is maintained in the desired range of 34 to 36ºC by

re-circulating the fermenting wash through the individual plate heat exchangers. A separate

cooling tower and pump is used for recirculation of cooling water for maintaining fermenter

temperature.

The fermented wash with 9-10 % v/v alcohol is then fed into the degasifying column top for

distillation.

Average fermentation time is about 22-24 hrs. Advantages of this system are that it could take

inferior quality of molasses and yet produces higher efficiencies, good quality of spirit. Power

requirement is lower as compared to the process with yeast recycling.

Distillation

The next stage in the production of alcohol is to separate alcohol from fermented wash and to

concentrate it to 96% alcohol called rectified spirit (RS)/Extra neutral alcohol (ENA).

Rectified spirit is industrial alcohol and ENA is more purified and is used for potable purpose

especially for manufacturing IMFL (Indian made foreign liquor).

Distillation is separation of one liquid from other liquids taking advantage of their difference

in rate of vaporization. This is achieved in alcohol distillation using seven columns. The

columns are same for RS & ENA preparation. RS requires 5 columns whereas ENA uses all

seven columns. These are described below:

(A) Wash to RS Mode: -

Following columns will be under operation

1. Analyzer Column

2. Degasifying Column

3. ED column

4. Rectifier cum Exhaust Column

5. Recovery Column


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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 Thermosyphon re-boiler. Vapors of Degasifying column are condensed and

taken to Recovery Feed Tank. Analyser vapors are condensed in the Falling Film Evaporators

in the Integrated Evaporation Section. The condensed Analyser vapors are fed to ED column.

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, which operates under pressure, concentrates it. Condensing steam provides

energy to Purifier and Rectifier column through a vertical Thermosyphon re-boiler. Fusel Oil

Draws are taken from appropriate trays and fed to Recovery Column.

Recovery Column concentrates the fusel oil streams and Degasifying condensate to 95% v/v

concentration. An impure spirit cut is taken out from the top of the recovery column &

rectifier column. Rectified Spirit draw of 95% to 96.1% v/v is taken out depending upon the

end customer’s requirement from the upper trays of Rectifier Column.

Rectifier cum Exhaust Column meets the energy requirement of Analyser cum Degasifying

Column. Flashing the steam condensate will provide energy to Recovery column or separate

team will be provided to meet energy requirement.

Generally the distillation efficiency is around 98.5%

(B) Wash to ENA Mode: -

Following Columns will be under operation

1. Analyser Column

2. Degasifying Column

3. Pre-Rectifier cum Exhaust 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 Analyzer column. Rectifier vapors provide energy to Analyzer

column through a Thermosyphon re-boiler. Vapors of Degasifying column are condensed and

taken to Recovery Feed Tank. Analyzer vapors are condensed in the Falling Film Evaporators

in the Integrated Evaporation Section. The condensed Analyser vapors are taken to Pre-

Rectifier Feed Tank. Analyzer Condensate is concentrated in Pre-Rectifier column, which

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


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vertical Thermosyphon reboiler. A Technical Alcohol cut of about 1-2% of total spirit is taken

from the Pre- Rectifier column. Concentrated alcohol drawn from Pre-Rectifier column is fed

to Extractive distillation 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 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. 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.

Condensing steam through a vertical Thermosyphon re-boiler provides energy to Rectifier

cum Exhaust Column.

Rectifier cum Exhaust Column meets the energy requirement of Analyzer cum Degasifying

Column.

Supplying steam to Reboiler of the Pre Rectifier column provides energy to Pre-Rectifier

Column.

Vapours of Pre-Rectifier Column meet the energy requirement of Extractive Distillation

Column and Simmering column.

Flashing the steam condensate will provide energy to Recovery column.

Molecular Sieve Dehydration:

As ethyl alcohol and water form an azeotrope (constant boiling mixture) at 97.1% v/v it is not

possible to concentrate the ethanol above azeotropic composition by normal distillation

procedures.

To concentrate the ethanol to above azeotropic strength, the operating pressure of the system

has to be changed so that azeotrope is shifted favorably to the desired concentration. But this

procedure is only of theoretical interest and no plants have worked with this system

Another procedure to overcome the azeotrope problem is to introduce a third component such

as benzene or cyclo hexane. Water to be separated forms a ternary azeotrope with benzene and

alcohol and comes out as top product and pure ethanol is obtained as bottom product some


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more columns are used to separate the benzene and to recycle. This process is used till two

decades back in India.

The water removal or dehydrogenation by molecular sieve technology is the latest and almost

all the ethanol plants use this technology. Molecular sieves have a very porous structure and a

component with a particular molecular size can only pass through it. In ethanol purification,

water molecules are adsorbed inside the molecular sieve and pure ethanol comes out. Once the

sieve is saturated with water, it is regenerated by changing the pressure. The regenerated sieve

is again used for separation of water. Generally two sieve beds are used – one will be under

regeneration and the second one will be under absorption.

Rectified Spirit containing at least 94% v/v alcohol is pumped from RS collection tank to

dehydration section. Rectified spirit is preheated in Feed pre-heater with the help of product

vapors and then fed to top tray of Evaporator Column. The objective of the Evaporator

Column is to evaporate rectified spirit. The Evaporator Column operates under pressure.

Energy is supplied to the Evaporator Column through Evaporator Column Re-boiler with

steam condensing on shell side. The steam condensate can be recycled back to the boiler.

Overhead feed alcohol vapors from the Evaporator Column are then passed through Super-

heater where alcohol vapors are superheated. Energy for superheating is supplied by steam

condensation on shell side of the Super-heater. Superheated hydrous alcohol vapors are sent to

twin Adsorbent beds. The twin Adsorbent beds operate in cyclic manner. Twin beds are

provided to allow for bed regeneration in continuous operation. While one bed is in

dehydration mode, the other is in regeneration mode. Depending on feed and product

specifications, dehydration regeneration exchange takes place approximately every few

minutes. The feed alcohol vapors are passed through the bed under dehydration mode. The

Adsorbent bed will absorb moisture present in feed vapors and dehydrated product alcohol

vapors are obtained from bottom of the bed. The product alcohol vapors are then passed

through Regeneration Pre-heater and Feed Pre-heater for heat recovery. The product alcohol

vapors are then passed through Product Condenser where product vapors are condensed with

the help of cooling water. Condensed product alcohol is collected in product receiver. The

product alcohol from Product Receiver is pumped to Product Cooler where it is cooled with

the help of cooling water and then sent for storage.

During regeneration mode, vacuum is applied to the bed under regeneration. A small amount

of product alcohol vapors are purged through the bed in regeneration mode under high

vacuum, to prepare the desiccant for cycle changeover when this bed goes online. The purged

alcohol vapors act as carrier for removal of moisture from the bed. These alcohol vapors along

with moisture are obtained from the top of bed. These alcohol-water vapors (regeneration


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stream) are condensed in Regeneration Condenser, which is attached to Vacuum Eductor.

Vacuum is pulled in the system with the help of Vacuum Eductor. Regeneration stream is used

as motive fluid for Vacuum Eductor. The regeneration stream coming from the Regeneration

Condenser is pumped, preheated in Regeneration Pre-heater and fed to the Evaporator Column

for recovery of alcohol.

Moisture present in feed alcohol is removed from the bottom of the Evaporator Column in the

form of spent lees containing less than 500 ppm of ethanol. After one cycle is over, the beds

are interchanged, that is, the bed on dehydration mode will be switched over to regeneration

mode and the bed on regeneration mode will be switched over to dehydration mode, with the

help of automation system.


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Fig. 4 Process flow diagram for ethanol from Molasses


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4.2.2 GRAIN BASED PROCESS:

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

be converted into sugars. In brewing beer, this has traditionally been accomplished by

allowing the grain to germinate, or malt, which produces the enzyme, amylase. When the

malted 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 sulfuric 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.

Stage I: Preparation of feed for fermentation

Grain handling and milling

Grains are stored in the Silos & from there they are conveyed through Screw Conveyor to

Bucket Elevator. Bucket Elevator lifts the grains to the required height (approximately 15mtr)

and then passes the grains on to the Vibrating Screen, Destoner and Magnetic Separator to

remove dust and stones. The flow through these equipments is under gravity.

The cleaned grains are then again conveyed by bucket elevator to an intermediate hopper,

which is provided with rotary air lock system for controlled flow in Hammer Mill. In Hammer

Mill the particle size is reduced to as required by the process. From hammer mill the flour is

pneumatically conveyed to Flour Bin (Intermediate storage for flour).From the flour bin, the


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flour is carried to Pre masher unit. In Pre masher flour is mixed with addition of required

quantity of water under agitation.

Slurry preparation/partial liquefaction

Slurry from pre-masher is taken to Slurry preparation tank where slurry is further diluted by

addition of f fresh water and recycled streams. Slurry is taken to initial liquefaction tank where

liquefying enzyme is added. This slurry is then “cooked” in the jet cooker. The slurry is

continuously pumped to a steam jet cooker where high-pressure steam rapidly raises the slurry

temperature. The mixture of slurry and steam is then passed through a retention vessel having

sufficient capacity to provide the desired retention time at a given flow rate. The cooked mash

is discharged to a flash tank. The cooking process, accomplished in the above manner,

converts the slurry into a hydrated, sterilized suspension (as starch molecule is solubilized)

and is therefore susceptible to enzyme attack for liquefaction.

Final liquefaction:

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

liquefying enzyme is added. Then the liquefied mash is cooled in slurry cooler and transferred

to fermentation section.

Sacharification and instantaneous fermentation:

The hydrolyzed starch from the liquefaction step is further treated with enzymes to convert the

material into glucose. This is carried out in the fermenter itself. The fermentation is

instantaneous after formation of glucose.

Stage II: Fermentation

The process followed after liquefaction is same as that is followed in the Molasses route.

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

comprises of diluter and hygienically engineered yeast vessels equipped with heating, cooling

and air s purging facility. Cell mass from Yeast vessel is transferred to yeast activation vessel

to build up cell mass required for fermentation. Here yeast cells are multiplied and activated.

The fermentation plant consists of pre-fermenters and fermenters. The fermentation is started

in the pre-fermenters in small lot and transferred to the main fermenters. During fermentation,

sugars are broken down into alcohol land carbon –dioxide. Significant heat release takes

place during fermentation. The fermentation temperature is maintained at around 32°C by

forced recirculation flow through plate heat exchangers.

CO2 evolved during fermentation carries along with it some entrained alcohol. This CO2 is

taken to a CO2 scrubber where it is washed with water to recover the entrained alcohol.


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Stage III: Distillation

Multi-pressure (MPR) distillation schemes with the above systems & applied along with

various heat integration methods is used for the optimal economic operation of the plant.

Multi-Pressure Distillation system chosen 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 proper energy

consumption.

Depending upon the market requirements either ENA is produced or RS which is subsequently

converted to Ethanol. The distillation process is same either with molasses or broken rice. The

detailed description of distillation is provided under the molasses head.

By Product recovery/Zero Discharge

In the grain based distillery, the grain flour feed contains, starch, protein and minerals.

Normally the starch content is about 65%, and moisture of 12%. Remaining 23% (proteins and

minerals) goes through the fermentation process without change. This is recovered as bottoms

(slops) of the analyzer column.

Still age or Slops which has some nutritional value are recovered as co-product. The Still age

or slops obtained from the bottom of the still are centrifuged to increase the concentration by

separating the coarse grain from the 22oluble. Thin Still age or soluble obtained from the

centrifuge is concentrated by evaporation to 30% solids and the resulting syrupy material

obtained is known as Condensed distillers soluble (CDS) or “syrup”. The coarse grain and the

syrup are then dried together in a drier with steam or hot flue gas obtained from the boiler to

obtain dried distillers grains with soluble (DDGS), a high quality, nutritious live-stock feed.

The major problem in disposing the wet soluble is that its deterioration rate is fast i.e. less than

24 hours. This can be sold off immediately as wet cake to cattle feed, but the best method is to

dry the wet cake and concentrated slops to obtain DDGS for easy handling and increase of

shelf life, which can be stored or sold off.

The process block flow diagram starting from grain is shown below in Figure 5


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Fig. 5 Process flow diagram for ethanol from Grain


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4.2.3 POWER PRODUCTION.

The industry has proposed for the production of 2.5 MW of electricity from the Spent Wash

Incineration Boiler to be installed for spent wash generated from Molasses based distillery.

As a policy the Pollution Control Boards are stipulating stringent conditions like Zero

Discharge of its effluent for establishment of distilleries for ensuring protection to

environment. Therefore in the proposed project, the company is using updated technology

by putting up incineration boiler to use spent wash as a raw material to generate heat to

produce steam and power for captive use and in the process no pollutant is discharged to

the open streams etc.

The effluent discharged from the Distillery Unit is known as spent wash with molasses

as feed stock and has dissolved solids of about 14-18 %. This effluent is concentrated by

evaporation to increase the solid content to 55-60% and after concentration the spent

wash will have a calorific value of 1700 K.Cal./Kg which is burnt as fuel in incinerator

boiler to produce high pressure steam. Thus the concentrated spent wash almost meets half

of the energy requirements of the incineration boiler and in the process effluent treatment

and discharge problem are totally solved. Thus zero discharge of effluent is achieved.

Balance half of the energy requirement of the incineration boiler will be met by using

coal as supporting fuel. The use of concentrated spent wash as energy source in the

incineration boiler results in reduced fuel cost compared to conventional boilers.


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Fig 6. Flow Chart for Power production from Spent Wash Incineration Boiler


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5.0 WATER BALANCE

5.1 Water Requirement

Table 8. Fresh Water Requirement for Distillery

5.2 Waste Water Generation

Table 9. Waste water generation form Distillery Unit

S.No. Description Generation of Waste

Water in KL/day

Disposal

1 Spent Wash (for

molasses based)

520 Biocomposting and remaining to

Incineration Boiler after concentration

Spent Wash (from grain

based)

390 Decanter and evaporation to produce

DDGS

2 Domestic Activities 5.0 Septic tank followed by soak pit

3. Cooling Towers 5.0 Recycled and reused

4 Boiler Blow Down 20.0 Recycled and reused

TOTAL 550 in case of Molasses based and 420 KLD with grain based

distillery.

Molasses Mode (With approx. 50 % from recycle of effluents after treatment)

Description Process Water DM Water Soft Water

KLD KLD KLD

Fermentation 454.00 - -

Distillation - 288.00 -

Boiler make up water - 150.00 -

Cooling water make

up

- - 125.00

TOTAL 454.00 438.00 125.00

GRAND TOTAL 1017 KLD

Broken Rice Mode (With approx. 50 % from recycle of effluents after treatment)

Fermentation 216.00 - -

Distillation - 288.0 -

Boiler make up water - 150.00 -

Cooling water make up - - 200.00

TOTAL 216.00 438.00 200.00

GRAND TOTAL 854 KLD


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NOTE: In molasses mode distillery:

Spent Wash Generation: 8 KL/KL of alcohol produced.

In grain based distillery:

Spent Wash Generation: 6 KL/KL of alcohol produced.

5.3 Disposal:

ZERO DISCHARGE TECHNOLOGY

5.3.1 For Grain Mode

Generation of Effluent:

The major effluents generated in a distillery are:

1. Spent wash: The alcohol present in the fermented wash is separated as equilibrium vapor

from the top of the analyser and the balance of fermented wash comes out of the analyser as

bottom product called spent wash. The quantity of spent wash depends upon the fermented

wash strength. It can be taken on an average to 8 liters per liter of spirit produced. For a 65

KLPD distillery the spent wash quantity will be 590 KL per day.

Distillery effluent-spent wash carries one of the highest pollution loads and is highly acidic in

nature.

Earlier the spent wash is mixed with press mud from the sugar factory and is allowed to

compost. The compost product is used as fertilizer. This process requires lot of land and There

is a possibility of odour and fly nuisance. Further the operation days are limited to 270 as the

composting cannot be worked in monsoon. The pollution control boards are not giving

permission for this process to new units.

At present zero discharge is the norm prescribed by pollution control authorities. The spent

wash with an initial solid content of 12-18% is concentrated in an evaporator to bring the solid

content to 60%. This concentrated spent wash which is having a calorific value of 1700

KCals/Kg is incinerated in a specially designed boiler. The boiler requires another fuel,

generally coal, as supporting fuel. The spent wash incineration gives energy output and at the

same time avoids the discharge on to land or water bodies.

The spent wash from grain distillery is known as thin slop. In this case also zero discharge is

achieved by decantation and evaporation to a solid content of about 35%. The concentrated

thin slop ad the cake from the decanter are mixed and dried in a specially designed drier. The

dried product is known as DDGS (Distiller’s Dried Grains and Solubles). The DDGS contains

proteins and other valuables originally present in the grains and hence is a very popular cattle

and poultry feed.


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2. Spent lees: The water carried along with the alcohol vapours from the analyser top will be

discharged from the bottom of the rectifying column after separation of alcohol and is called

spent lees. The quantity varies from 1-3 liters per liter of spirit produced. The pollution load of

spent lees is very much less as compared to spent wash. The BOD load may vary between

1500-3000. The spent lees together with the condensate from the evaporator section is treated

in condensate and spent lees treatment plant and the output from the treatment plant is

reused/recycled in fermentation section as process water and cooling towers as makeup water.

The details of the treatment are discussed below.

A distillery generates large quantity of waste water. The waste water from distilleries is also

termed as vinasse or spent wash. Spent wash contains high level of BOD/COD and is viscous

in nature. This makes spent wash treatment doubly challenging. Apart from this, distilleries

are also keen to recover some value from the spent wash.

Table 10. Typical Composition of spent wash:

Parameters Description

Colour Dark brown

Odour Smell of burnt sugar

Temperature 50 C

Ph 4.5-5.4

BOD, mg/l 50,000-55,000

COD, mg/l 1,00,000-1,20,000

Total Solids, mg/l 65,000-85,000

Volatile solids , mg/l 15,000-35,000

Total Nitrogen, mg/l 1000-2500

Total Sulphide, mg/l 300-1000

Chloride, mg/l 3000-6000

Potassium as K, mg/l, 6000-10,000

Sodium, mg/l 150-2000

Sulphate, mg/l 2000-12,000

Calcium, mg/l 400-1500

Magnesium as Mg, mg/l 800-2700

Silica as SO2, mg/l 300-1300

Iron, mg/l 50-187


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After effects of unprocessed effluent:

The disposal of the spent wash on the land creates the following problems namely: -

Pollution of ground water.

Charring of crops.

Accumulation of salts.

Increase in the cropping period.

Increase in the electrical conductivity of the soil.

Bad smell.

On the other hand, if the effluent is let out in a river or canal, the oxygen content of the water

is depleted because of high organic content of the effluent.

The high BOD of the effluent consumes lots of oxygen present in the water. On account of

this, as mentioned earlier, the water living organisms are deprived of the oxygen, leading to

their death, in many cases, it is reported that the fish in the river die and float.

It is for these reasons the distillery effluent will be treated before it is disposed off. The

properties of the effluent that can be let out have been specified. The same as per the Indian

Standards Specifications I.S. 3307-1965 and 5061-1968 are given below:

Table 11. Tolerance Limits for the Effluent to be Disposed on the Land

S.No. Item Quantity

1 pH 5.5 to 9.0

2 TDS (mg/l) 2100 max.

3 Suphates as SO4, (mg/l) 1000 max.

4 Chloride (mg/l) 600 max.

5 BOD 30 max.

6 Oil & Grease (mg/l) 10 max.

7 Boron as B (mg/l) 2 max.

8 Sodium as Na (mg/l) 60 max.

The general characteristic of spent wash indicates that it is highly colored with low pH and

high BOD and COD, total solids, volatile solids etc.

The wastes from distillery industry are highly polluting. It is highly acidic and normal micro

fauna and flora cannot survive in it except a few fungi, which also can grow slowly. The spent

wash is having temperature in the range 95-105ºC. When it is discharged it can affect D.O.

concentration in the stream and other temperature dependent reactions-physical, chemical and


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biological. Since it contains high BOD, it putrefies rapidly giving rise to offensive odour. The

brown colour is esthetically objectionable and affects photosynthesis. Prolonged land

irrigation using spent wash if not sufficiently diluted may cause soil sickness.

5.3.2 For Molasses Mode:

The Central Pollution Control Board (CPCB) has recently issued guidelines for treatment and

disposal of effluent by molasses based distilleries. The guidelines have a theme of ZERO

discharge of liquid effluent. They have also recommended effluent treatment schemes and

technologies to be adopted by molasses based distillery effluent to achieve Zero discharge.

They are:

1. Bio-methanation followed by composting.

2. Concentration of Spent Wash and Incineration.

3. Direct Composting.

4. Bio-methanation followed by ferti-irrigation.

Bio-Methanation Followed By Composting: Existing Proposal

Waste water plant comprises of the primary treatment section followed by the secondary

treatment section.

Primary treatment is an anaerobic treatment, which leads to biogas formation to be fired in a

boiler for raising steam.

The secondary treatment of Bio Composting is an aerobic treatment. The spent wash of

distillery poses a very serious problem by way of threat to the environment. The volume

generated from a distillery is around 10 to 12 ltrs. per ltrs. of spirit produced. Reviewing the

work on treatment of distillery effluent and its disposal already done in India, it may be

mentioned that most of the distilleries in India have adopted open anaerobic lagooning for the

last 20 years. This of course reduces the organic pollution load up to 70% but has created its

own problems due to process limitation as briefly described below.

Percolation through sub-soil If soil is sub-standard or porous strata, pollutes drinking

water. However, lining lagoons with polythene sheet can take care of this, though the

investment is high.

Surrounding atmosphere prevails with foul smell

Sludge formation is very high, and reduces the capacity of lagoons.

De-sludging process is laborious and involves heavy expenses.

Area requirement for treatment of effluent is very high.


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It will be pertinent at this stage to discuss related legislative aspects on environmental

pollution control measures formulated by the government. The Government of India by an Act

in 1974 & 1981 respectively, and by amendments made from time to time brought in force

several legislations to keep the environment clean. The delineation of objectives, functions,

duties, responsibilities and institutional forms constitute the first part of legislation. Till

recently, Government had made limited intervention for environmental management. Prior to

1980, the two main Central Government Acts – relating to environmental protection were not

vigorously applied. However, these acts have been recently subjected to detailed review by the

committees appointed by the Government. The same committee is also asked to recommend

the measures for environmental protection. It is only after 1980 that the Government has come

out with well-defined environmental policies as given below in brief.

1. Conservation and development of safe, healthy, productive and aesthetically satisfying

environment.

2. Planning of development on sound ecological principals with environmental input,

analysis and incorporation of appropriate environmental safeguards.

3. Promotion of environmental safety, technology for recycling of resources and utilization

of wastes.

4. Evaluation of environmental norms and establishment of effective mechanisms for

monitoring surveillance and dissemination of information.

Concentration of Spent Wash and Incineration: Current Proposal

Concentrated Spent Wash contains approximately 60 % solids. Distilleries across the world

are increasingly coming under pressure from governments and society for the polluting

effluents (spent wash) from their core process. ‘Zero effluent discharge’ (ZED) norm for

distilleries is already in place in number of countries including India. Since existing disposal

methods – bio-methanation and bio-composting are unable to meet the ZED norms, distilleries

are increasingly looking to an alternate solution of concentrating the spent wash and then

firing it in a specially designed boiler.

Concentration and using as fuel is successfully proven on a commercial scale in terms of

technical scheme, costs, suitability of material of construction of equipment. Hence the same

has been considered as the effluent treatment method for the plant

The process of using concentrated spent wash as a fuel for incinerator boiler along with coal is

now well established and hence the industry has also proposed to use a commercial-scale

incinerator boiler technology for firing spent wash. The twin benefits of the incinerator boiler

include:


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1. Ability to dispose effluent discharge of distilleries in a safe and environmentally sound

way

2. Steam generation for meeting the process steam and electricity requirements of distillery.

Benefits:

1. By generating steam from spent wash, industry can significantly reduce the energy costs.

2. Every kilogram of concentrated spent wash replaces nearly 0.33 kg of Indian Coal.

3. Community life around the distillery site shall not be plagued by pollution, as the discharge

of spent wash is almost entirely eliminated.

4. Distillery meets zero liquid effluent discharge norms.

5. Effective solution for power and process steam requirements of distillery.

6. Ash generated from the boiler has high potash content used in bio-composting and, surplus

ash shall be sold to the brick manufacturers.

5.4 CONDENSATE AND SPENT LEES TREATMENT PLANT

The condensate from the evaporation and drier plants and the spent lees should be treated such

that they are suitable for recycling.

The plant consists of an equalization tank, an anaerobic digester, degassifier, filters, R.O plant,

necessary transfer pumps, instrumentation etc.

The capacity of the plant considered is 25% more than the requirement at full capacity

utilization.

BOD, COD, SS, TDS, pH, Volatile acidity and SDI at each stage is to be monitored.

Description

The proposed wastewater treatment plant shall consist of following units.

PRIMARY & SECONDARY TREATMENT

Equalization / Buffer Tank

Nutrient Dosing Assembly

Anaerobic Reactor

Aeration Tank

Secondary Clarifier

Sludge Drying Beds

TERTIARY TREATMENT

Flash Mixer

Flocculator

Lamella Clarifier - II


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Chlorine contact Chamber

Pressure Sand Filter

Activated Carbon Filter

Softener

Process Description:

Equalization Tank

Equalization tank constructed in RCC is provided for mixing the two streams and dampening

the fluctuations in wastewater quality and quantity. The Equalization tank also helps in

reducing the temperature of wastewater. Equalization tank is provided with mixer for mixing

the effluent. Effluent from Equalization tank will then be pumped to anaerobic Reactor.

Nutrient Preparation Tank:

Nutrient preparation tank is constructed in RCC. This tank is used for Nutrient solution

preparation and continuous mixing of nutrient. Nutrient is fed to equalization tank for pH

correction in required proportion. An agitator is provided for mixing of contents in the tank.

Dosing Pumps are provided for transferring the nutrient solution.

Anaerobic Reactor:

Up-flow Anaerobic Sludge Blanket reactor is provided for anaerobic treatment of effluent.

The anaerobic reactor is constructed in MS. The reactor consists of three zones viz. Influent

distribution zone, Reaction zone, Gas, Solid, & Liquid separation zone.

Influent Distribution Zone:

The raw waste water enters the bottom through influent distribution zone. A sophistically

designed piping network is provided for uniform distribution of effluent in the tank. Effluent

then travels upward in the reactor.

Reaction Zone:

In reaction zone, anaerobic bacteria are maintained in the form of sludge blanket. Organic

matter in waste water comes in contact with bacterial population and is degraded anaerobically

to methane rich biogas, which is the end product. Anaerobic digestion is to be provided with

central driven clarifier mechanism and sludge recirculation pumps. Part of the settled sludge at

the bottom of the settling tank will be pumped to the aeration tank and part of it will be

discharged on sludge drying beds as per operational requirement. This sludge being fully

mineralized is suitable for sun drying on sand drying beds.

Drying Beds:

In aeration system the sludge is sufficiently mineralized and does not need any further

treatment before dewatering and disposal. Sand filtration drying beds will be provided, where


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sludge will be dewatered by filtration through sand bed and sun drying of the dewatered

sludge is scraped & used as manure after composting.

Tertiary Treatment:

Flash Mixer:

The effluent coming from clarifier has certain amount of suspended materials. If not removed

this suspended material damage the equipment provided down the line & further process. This

material is made settle-able with the help of alum dosed in flash mixer. Static Baffled wall

type flash mixer is provided for this purpose.

Flocculator:

The water from flash mixer is then taken to flocculator where the suspended material will be

converted in flocs using flocculator mechanism and transferred to the lamella clarifier - II.

Clarifier-II:

A Lamella Clarifier in the form of rectangular or square tank will be provided for settlement

of flocculated Effluent from the flocculator. The tank will be provided with lamella PVC

plates. The settled sludge at the bottom of the settling tank will be discharged on sludge drying

beds as per operational requirement. This sludge being fully mineralized is suitable for sun

drying on sand drying beds.

Chlorine Contact Chamber:

The treated Effluent will further be subjected to chlorination for denitrification of the treated

effluent. Chlorine solution will be added to the treated Effluent. A baffled wall channel

constructed in RCC M-20 will be provided. Chlorine dose will be adjusted to maintain the

residual chlorine concentration of 0.5-1.0 ppm.

Pressure Sand Filter:

Chlorinated effluent will then be pumped to pressure sand filter for removal of suspended

solids. Pressure sand filter will consist of a cylindrical mild steel vessel with dished ends.

Filter media in the form of sand and gravel will be provided.

Softener:

A softener fabricated in MSRL is provided for removal of the Hardness of the treated effluent.

The softener will be provided with exchange resin for the removal of cations. Regeneration

system consists of brine tank, brine ejector and dosing arrangement. The treated water from

the above plant is reused and recycled as process water and cooling tower makeup water.


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6.0 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 Physio-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 encompassive 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.

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.


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Table 12. Pollution Prevention and Abatement Plan

S.NO. AREA OF CONCERN SOURCE POLLUTION CONTROL MEASURES

1. AIR POLLUTION Particulate Matter, SO2,

NO2 & Hydrocarbons

Proposed Boiler: 25 TPH

Bag Filter will be provided Stack height will be kept at 45 m.

Fugitive Emissions Vehicular emission Grain receipt and

Storage

Roads are paved/asphalted Water Sprinklers (2 Nos.) Cyclones and aspiration systems

are to be provided of capacity 25.0 MT/hr at grain receipt and storage section.

Online Ambient Air Quality Monitoring stations will be installed.

2. NOISE POLLUTION Due to plant facilities Pumps /

compressors /Plant Machinery

Provision of silencers Sound-proofing the pump and compressor

Green belt development Usage of modern technologies & machineries

Due to Power Back up Facility

DG Sets Acoustic enclosures

Due to Transportation of materials & Construction Activities

Vehicles & Machinery

Provision of PPE to workers, Maintenance of machinery & vehicles

3. WATER Plant Facilities Floor Washing,

Fermenter wash, Boiler blow down, cooling water

ETP Green Belt Development Ferti-Irrigation

Domestic Canteen, toilets etc Septic Tank followed by soak pit. 4. SOIL

Plant Facilities Yeast Sludge DDGS

Dried & Disposed off as per norms Sold as Cattle Feed

6.1 AIR POLLUTION CONTROL

Bag filters will be provided to spent wash incineration boiler for pollution control to

control particulate matter concentration within the CPCB prescribed limits. Stack

height of 45 m will be provided.


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Ambient air quality and stack emission is regularly monitored to keep check on

emissions. Same will be continued in future.

Green belt has already developed and the industry is continuing developing green belt

which will help in attenuating the pollutants emitted by the plant.

Action plan to control fugitive emissions

The roads within the premises are concreted / paved to avoid vehicular emissions.

Roads & ash storing yards are sprinkled with water to reduce fugitive emissions

All transportation vehicles carry a valid PUC (Pollution under Control) Certificate

Proper servicing & maintenance of vehicles is carried out

Regular sweeping of all the roads & floors is being done.

Adequate green belt has already been developed. Green belt act as surface for settling

of dust particle and thus will reduce the particulate matter in air.

Ambient air quality is regularly monitored and effective control exercised, so as to

keep emission within the limits.

6.2 WATER POLLUTION CONTROL

No water is withdrawn from nearby surface water body/river.

Proposed unit is based on Zero Liquid Discharge so will not pose any threat to ground

or surface water.

ETP is present in plant and will be used to treat the waste water generated from floor

washing, boiler blow down etc.

Water is conserved at every stage of process. Large quantity of water is reused &

recycled.

Domestic waste is treated in septic tank followed by soak pit.

Rainwater harvesting system is installed at plant. These helps in augmentation of

ground water level of the area.

Water Conservation Measures

The following measures shall be adopted to conserve water-

Recycle of Water

Reuse of wastewater after treatment for green belt development

Periodic preventive maintenance of water distribution systems

Training and awareness on water conservation measures


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6.3 SOLID WASTE

Solid waste generated from the industry is as follows:

Table 13. Solid Waste generated

Type

Quantity Storage Utilization/disposal

Grain based distillery

DDGS 4355 MTPA Covered shed Sold as cattle feed directly

Fly ash

15 TPD

Covered shed Brick manufacturing units

Molasses based distillery

Fly ash

15 TPD

Covered shed Brick manufacturing units

6.4 NOISE ENVIRONMENT

Various components of industrial operations will cause some amount of noise, which will be

controlled by proper maintenance and compact technology.

Time to time oiling and servicing of machineries will be done

Acoustic enclosure for Turbine & D.G. sets would be used

Green belt development (plantation of dense trees across the boundary) will help in

reducing noise levels in the plant as a result of attenuation of noise generated due to

plant operations, and transportation.

High standard of maintenance is practiced for plant machinery and equipments which

helps to avert potential noise problems.

Future expansion and installation of the plant machinery will be done after due

consideration to design noise levels and noise mitigation measures.

Workers are provided with personal protective equipments

Periodical monitoring is being carried out on regular basis

6.5 ODOUR MANAGEMENT PLAN Odour Management Plan outlines the methods by which odorous emissions will systematically

assess, reduce and prevent potentially from the distillery unit.

Better housekeeping by regular steaming of all fermentation equipments.

Regular steaming of all fermentation equipment.

Use of efficient bio-cides to control bacterial contamination.


Page | 39

Control of temperature during fermentation to avoid in-activation / killing of yeast.

Regular use of bleaching powder in the drains to avoid generation of putrefying micro-

organisms.

Any processes or chambers where an unacceptable level of odour could be generated

or released to atmosphere will be covered or enclosed.

To minimize odour risk the site shall be kept tidy at all times and any spillages cleaned

up promptly.

6.6 OCCUPATIONAL HEALTH AND SAFETY

Production of ethanol involves storage handling and use of several chemicals. Some of these

chemicals are toxic and hazardous in nature. Information about these chemicals is therefore

important for the safety of the employees and the plant. Besides, the health status of the

employees is also important which may be affected due to exposure to these chemicals. The

exposures may be sudden and accidental or for a long period. In both of the cases there will be

different health effects. Therefore safety measures dealing with these chemicals are of vital

importance and will be followed judiciously.

In order to ensure good health of workers, regular health check-up of the plant workers

will be carried out.

Occupational health surveillance programme will be taken as a regular exercise for all

the employees and their records maintained.

Proper storage and handling precautions will be taken. The storage area will be cool,

dry and well ventilated away from any source of heat, flame or oxidizers.

Use of Personal Protective Equipment (PPEs) will be encouraged. Proper training on

use of PPEs, characteristics of the material handled and safety precautions to be

adopted will be given to the workers.

Fire safety measures will be incorporated within the factory premises. All the fire

extinguishing media such as water, dry chemicals, CO2, sand, dolomite, etc. will be

kept in vital locations.

Fire Fighting and Safety Instruments

A hydrant line ring surrounding the entire distillery complex is to be provided with

following equipment.

Electric water pump, Diesel Engine driven pump and jack pump (1+1).

Hydrant outlet valves at 20/25 meter distance.

Swiveling type water monitor with nozzles.

Hose reels with hose boxes and G.M nozzles.


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Portable DCP extinguishers and/or CO2 extinguishers-- one /25 M2 plant area.

Fire buckets with stands.

The system should generally comply with F.I /TAC recommendations

Safety precautions will be displayed in the premises on the banners, boards etc

6.7 SOCIO-ECONOMIC ENVIRONMENT

The plant has provided direct and indirect employment and improved infrastructure

facilities and will provide the same in coming future as per the requirements.

Company has been provided assistance to the nearby villagers for their development

related to education, hospital, postal, transportation, medical services etc.

The industry would help in promoting the activities related to environmental awareness

in the nearby villages.

Activities related to awareness for sanitation in schools & nearby villages, Distribution

of essentials in the schools and environment awareness camps will also be organized.

6.8 POST PROJECT ENVIRONMENTAL QUALITY MONITORING SYSTEM

The quality of air, water and noise levels will be monitored at site as per APPCB requirements

and the reports will be submitted to the board on regular basis.

TABLE 14. IMPLEMENTATION SCHEDULE

S.NO Recommendations Time requirement 1 Air pollution control measures Before commissioning of respective unit 2 Water pollution control measures One month before commissioning of plant 3 Noise pollution control measures Along with construction 4 Solid waste management Stage wise implementation before

commissioning

Table 15. Monitoring Schedule for Environmental Parameters

S.NO

PARTICULARS MONITORING FREQUENCY

PARAMETERS

1 Stack gases monitoring- Furnace chimney

Every fortnight SPM, SO2 and NOX

2 Ambient air quality monitoring- Four stations as per prevailing wind directions

Weekly - 24 hours monitoring

SPM, SO2 and NOX

3 Noise monitoring Every fort night - 4 Waste water and effluents Every fort night PH,TDS,SS,COD,BOD,CHLORIDE,

SULPHATES, OIL & GREASE


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6.9 GREEN BELT

The industry has developed green belt of 40 acres around the premises and is constantly

making efforts for further development. The philosophy behind the green belt development is

to improve the ecology and environment of the surrounding of the plant by extensive

afforestation.

PLANT DETAILS

Trees particularly having compact branching closely arranged leaves of simple elliptical and

hairy structure, shiny or waxy leaves and hairy twigs are efficient filters of dust. The following

species have been planted to arrest the dust

Alstonias scholaris

Leucaena luecocephala

Delonia regia

Aeschenomene indica

Ficus benjamina

Coccus nucifera

Lagerstreemia indica

Tabubia rosea

Bauhinia purpurea

Cassia siamea

Peltophorum pterocarpum

Butea monosperma

Tamarindus indica

Azadirachta indica

Greenbelt is a set of rows of trees planted in such a fashion, to create effective barrier between

the plant and surroundings. The greenbelt helps to capture the fugitive emissions, attenuate the

noise levels in the plant and simultaneously improving aesthetics of the plant site. The

greenbelt around the factory compound wall and in the reserve site will be developed in

keeping view of the following objectives.

1. Planting of trees in each row will be in staggered pattern.

2. The short trees will be planted in the first two rows and the tall trees in the outer rows

around the purview of the project site.

3. Since the trunks of the trees are generally devoid of foliage, it will be useful to have

shrubs in front of the tress so as to give coverage to this portion.

4. Sufficient spacing will be maintained between the trees to facilitate effective height of

the greenbelt.

5. Plants of native origin, fast growing type with canopy and large leaf index shall be

preferred.


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Fig. 7. Green Belt Photographs


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6.10 COST OF THE PROJECT

Table 16. Cost of the Project

S.No. Particulars Molasses

mode alone

Grain

mode

alone

Total

cost in

lakhs

1. SITE DEVELOPMENT COSTS 200.00 50.00 250.00

2. CIVIL AND STRUCTURAL BUILDINGS

INCLUDING EQUIPMENT FOUNDATIONS

1500.00 300.00 1800.00

3. PLANT & MACHINERY INCLUDING

ELECTRIFICATION, ERECTION &

COMMISSIONING OF WHOLE PLANT

6158.75 1332.50 7491.25

4. MACHINERY CONTINGENCIES 296.44 66.53 363.06

5. CONTINGENCY ON BUILDINGS 85.00 15.00 100.00

6. TECHNICAL KNOW-HOW FEE 59.29 13.33 72.61

7. VEHICLES 50.00 25.00 75.00

8. OFFICE FURNITURE & EQUIPMENT 50.00 25.00 75.00

9. DEPOSITS 35.00 15.00 50.00

10. PRE-OPERATIVE EXPENSES 651.31 67.56 718.87

11. MARGIN FOR WORKING CAPITAL 274.65 183.10 457.75

12. Total 9360.43 2093.11 11453.54

Total cost allocated towards EMP and Pollution Control Measures is 1145 lakhs.


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7.0 CONCLUSION

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

significantly favour setting up the unit.

Assured supply of Molasses from the Group Company and availability of grain in

abundance around the factory.

Establishment of Plant & Machinery to handle either molasses or broken rice to

manufacture all or any of the three finished products RS/ENA/Ethanol

Viability of the project is established beyond doubt with Molasses or 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.

project at a glanceenvironmentclearance.nic.in/writereaddata/online/tor/0_0... · 2014-11-27 ·...

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