PFR Report Ashoka - environmentclearance.nic.inenvironmentclearance.nic.in/writereaddata/Online/...Pre - feasibility Report Ashoka Distillers & Chemicals Private Limited 3 process

Proposed Expansion of Grain Based Distillery (80 to 160 KLPD) & Co-generation Power Plant (2 MW to 5 MW) within existing plant premises At Village & Tehsil Hathin, District Palwal (Haryana)

Pre - feasibility Report

Ashoka Distillers & Chemicals Private Limited 1

PRE - FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY

(I) INTRODUCTION

Ashoka Distillers & chemicals Private Limited is proposing expansion in existing Grain based

Distillery (80 KLPD to 160 KLPD Grain Based Distillery) & Co-generation Power Plant (2 MW to

5 MW) within existing plant premises at Village & Tehsil Hathin, District Palwal, Haryana.

As per EIA Notification dated 14th September, 2006 and as amended from time to time, the

project falls under Category “A”, Project or Activity 5(g).

TABLE – 1

SALIENT FEATURES OF THE PROJECT

S. NO.

PARTICULARS DETAILS

A) Nature & Size of the Project

Units Existing Capacity Total Capacity after Expansion

Grain Based Distillery (KLPD)

80 KLPD 160 KLPD

Co-generation Power Plant (MW)

2 MW 5 MW

B) Category of the Project As per EIA Notification dated 14th September, 2006 and as amended from time to time; the project falls in Category ‘A’, S. No. - 5(g).

C) Location Details

Village Hathin

Tehsil Hathin

District Palwal

State Haryana

Latitude 28001’57.05’’ N to 28002’07.59’’ N

Longitude 77015’06.35’’ E to 77015’26.97’’ E

D) Area Details

Total Plant Area Existing plant area: 11.82 ha (29.20 acres)

No additional land is required for the proposed expansion, as the same will be done within the existing plant premises.

Greenbelt / Plantation Area (ha)

3.90 ha (9.63 acres) i.e. 33 % of the total plant area has already been developed under greenbelt / plantation and same will be maintained.

E) Environmental Setting Details (with approximate aerial distance & direction from plant site)

1. Nearest Village Hathin (1.5 km in NW direction)

2. Nearest City/Town Palwal (14.5 km in NNE direction)

3. Nearest National Highway / State Highway

NH-2 (7.5 km in East direction)

4. Nearest Railway station Palwal (14.5 km in NNE direction)

5. Nearest Airport Indira Gandhi International Airport, New Delhi (60 km in NNW direction)

6. National Parks, Reserved Forests (RF) / Protected Forests (PF), Wildlife

No National Parks, Reserved Forests (RF) / Protected Forests (PF) Wildlife Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors etc. lies within 10 km radius of the




Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors etc. within 10 km radius

plant site.

7. River / Water Body (within 10 km radius)

Gaunchhi Drain (Adjacent to the plant site in East direction)

F) Cost Details

Total Cost of the Expansion Project

Rs.30.0 Crores

Cost for Environment Management Plan

• Capital Cost - Rs. 10.0 Crores.

• Recurring Cost - Rs. 1.0 Crores / annum.

G) Basic Requirements for the project

Existing

(KLPD)

Additional

(KLPD)

Total after proposed Expansion

(KLPD)

Water Requirement (KLPD) 674 676 1350

Source: Ground Water

Power Requirement (MW) 2.0 MW 1.6 3.6

Source: Co-generation Thermal Power Plant, State Electricity Board& D.G Set (for emergency).

Man Power Requirement 116 34 150

Source: Unskilled / Semi-Skilled - Local Area; Skilled – Outside Haryana.

H) Product Rectified Spirit, Extra Neutral Alcohol, Country Liquor & IMFL, Ethanol

I) Working Days 350 days per annum

1.1 ENVIRONMENT MANAGEMENT PLAN

Particulars Details

Air Management

Emissions � Bag Filter and Trema Cyclone along with stack height of 35 m is installed with the boiler to control the particulate and gaseous emissions due to combustion of fuel.

� CO2 generated during the fermentation process is being/ will be collected by utilizing CO2 Scrubbers and sold to authorized vendors.

� All the roads are asphalted to control the fugitive dust emissions

� Proper servicing & maintenance of vehicles is being/will be carried out.

� Greenbelt around the periphery and within premises is already in place and same will be maintained.

Monitoring Ambient air quality and stack emission is being / will be regularly monitored to ensure that ambient air quality standards and suggested limits on stack emission loads would be met honestly at all the time.

Water Management

Management � The project is being/will be based on “Zero Effluent Discharge”.

� Fresh water requirement of the project is being/ will be met by Ground Water. Efforts will be made to conserve as much water as possible by recycling and reuse.

� Grain Slops (Spent Wash) is being/will be taken through Centrifuge Decanters for separation of Suspended Solids separated as Wet Cake.

� Thin Slops from the Decanter Centrifuge is being/will be partly recycled back to




process (30-35%) and partly taken to Thins Slops Evaporation Plant for concentration of remaining solids to form a Syrup. This Syrup is being fed to bio-digestor for recovery of bio-gas followed by anaerobic sludge separator & aeration system, final out let after aeration is then taken to MEE/RO system for water recovery, the concentrate from MEE is recycled to decanter for solid recovery.

� DWGS is being/ will be taken to a dryer operating on steam and is dried to make it DDGS – Distillers Dried Grain Solubles.

� The process condensate is being/will be cooled and collected into a neutralization tank with sufficient residence time. After Neutralization, this process condensate will be recycled into process.

Noise Management

Management � Proper maintenance, oiling and greasing of machines at regular intervals.

� PPEs like earplugs and earmuffs to the workers exposed to high noise level.

� Development of greenbelt/plantation for 33% of the total plant area.

� Regular monitoring of noise level is being/will be done.

� D.G. sets are being provided with acoustic enclosures to control the noise level within the prescribed limit.

Solid & Hazardous Waste Management

Management � Solid waste from the grain based operations generally comprises of fibres and proteins in the form of DDGS, which will be ideally used as cattle feed.

� Ash from the boiler is being/will be sold to brick manufacturers.

� Used oil & grease generated from plant machinery/gear boxes as hazardous waste is being / will be sold out to the CPCB authorized recyclers.

Greenbelt Development / Plantation

Management � Out of the total plant area approx. 33% of total land is already developed as greenbelt/ plantation and it will be maintained in future also.

� Greenbelt development in and around the plant site helps to attenuate the pollution level.

� Greenbelt has been developed as per Central Pollution Control Board (CPCB) guidelines.

� Native species have been planted in consultation with the local DFO.

Odour Management

Management � Odour will be primarily controlled at source by good operational practices, including physical and management control measures.

� Better housekeeping will be maintained with good hygiene condition by regular steaming of all fermentation equipment.

� Use of efficient biocides to control bacterial contamination.

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

� Avoiding staling of fermented wash.

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




2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of Project and Project Proponent

Ashoka Distilleries & Chemicals Private Limited, incorporated under the companies act 1986

having its registered office at Gehlab Road, Village and tehsil, Hathin, District- Palwal, Haryana,

India and head office at 501, Chiranjeev Tower, Nehru Place, New Delhi, India.

The 80 KLPD distillery was installed in 1992 and since then the company is complying with all

the directions being given to them by the concerned regulatory authorities including 3

member high power committee (Special Sect. MoEF, Chairman CPCB & Chairman HSPCB)

appointed by the Honourable Supreme court in January 2001. The Company is engaged in

manufacturing of rectified spirit, neutral spirit, country liquor (Indian herbal drink) and IMFL

(Whiskies, Rums, Gin etc.). It is an ISO 9001-2000 and HACCP certified Company.

(ii) Brief description of nature of the project



5 MW) within existing plant premises at Village & Tehsil Hathin, District Palwal, Haryana. Grain

is being/will be used as a raw material which is easily available from the local market.

As per EIA Notification dated 14th Sep, 2006 as amended from time to time, the project falls

under Category ‘A’, Project or Activity - 5(g).

(iii) Need for the project and its importance to the country and or region

Advancement in science and technology has created so many products that have enhanced

the quality of human life in every passing year. The human race is largely dependent on

industrialization for up gradation in quality of life. Progress of the nation is judged through its

economic growth which is largely dependent on industrial productivity. In Indian economy

(which is agro based) many industries are dependent over agricultural produce for production

of luxury and need based commodities. Alcohol has assumed a very important place in the

Country’s economy. It is a vital raw material for a number of chemicals. It has been a source of

revenue by way of excise duty levied by the State Government on alcohol liquors. It has a

potential as fuel in the form of power alcohol for blending with petrol in the ratio of 20:80.

The use of alcohol for the purpose of potable liquor is as high as its use for industrial

purposes. The Country Liquor is mainly used by the common masses.

According to analysts, the Indian Ethanol industry is expected to witness accelerating growth

in coming years with the consumer base likely to expand amidst rising disposable income. The

domestic alcoholic drinks market is estimated around $13 billion and has been growing at a

compounded annual growth rate in excess of 10% in the past few years. The growth rate is

higher than other major Asian markets like China and South Korea, etc.

In the path of company’s growth and development this project will serve as yet another

milestone.




(iv) Demand- Supply Gap

Not required in this project. This depends on Excise department.

(v) Import vs. Indigenous Production

Indian market could not meet present alcohol demand. So they import alcohol 5-7% of total

demand. As far as ENA production is concerned, Indian market play a vital role at both

domestic & international level. So they require produce the more alcohol to meet the demand.

(vi) Export Possibility

There is being / will be possibility of export of alcohol to Australia, African, European & Asian

countries.

(vii) Domestic / Export Markets

Market depends on Excise department.

(viii) Employment Generation (Direct and Indirect) due to the project

The total manpower requirement after the proposed expansion project will be 150 persons.

3.0 PROJECT DESCRIPTION

(i) Type of Project including interlinked and independent projects, if any.

No, this project is not an interlinked project.

(ii) Location (map showing general location, specific location, and project boundary &

project site layout) with coordinates – Location map attached.




Figure - 1: Location Map




Figure - 2: Plant Layout




Figure 3: Key Plan




(vi) Details of alternative sites consideration and basis of selecting the proposed site,

particularly the environmental considerations gone into should be highlighted.

Since the proposed capacity expansion will be done within the existing plant premises and no

additional land will be required; therefore, no alternative site has been considered.

(v) Size or magnitude of operation



5 MW) within existing plant premises at Village & Tehsil Hathin, District Palwal, Haryana.

Units Existing Capacity Total Capacity after Expansion

Grain Based Distillery (KLPD)

80 KLPD 160 KLPD

Co-generation Power Plant (MW)

2 MW 5 MW

(vi) Project Description with Process Details

Process Description

Distillery Unit - Production from Grain:

• Grain storage

• Grain cleaning, milling and flour handling

• Slurry preparation & liquefaction

• Multi pressure alcohol distillation

• Alcohol daily receivers & bulk storage

• MEE & Dryer

MAIN PLANT & MACHINERY

1. Grain Storage & Milling

Grain received from trucks/ trollies are being unloaded in grain storage go-downs and taken

for its milling for required sieve size with set of roller/ hammer mills and allied equipment and

stored in flour silos for use in process.

2. Slurry Preparation

Grain flour is being diluted in slurry tanks in required ratio with process water/ decanted spent

wash/ condensates/ lees. The temperature & pH of slurry adjusted suitably and part of the

liquefaction Enzyme is used for proper gelatinization of slurry and it would be taken in JET

COOKER where the cooking temperature is suitably raised say around 120ºC. this slurry passes

through a holding coil (about 10 minutes) is taken in flash vessel and in Liquefaction tank on

ward.

3. Liquefaction.

In liquefaction process the rest of the liquefaction Enzyme is being added and the

temperature of the slurry is maintained around 90ºC, after converting the starch to dextrin’s

the slurry is being cooled transferred to Fermentation tanks.




4. Simultaneous Saccharification and Fermentation

In fermentation tanks inoculated yeast were added with required nutrients and the

Saccharification Enzyme is added of adequate quantity for simultaneous saccharification and

fermentation of the broth. Here the fermentation temperature is maintained between 30ºC to

32ºC for better results. During process of fermentation CO2 is being produced as by-product

which are being collected and stored for its sales.

5. Multi Pressure Distillation

After completion of fermentation the fermented wash is taken to Multi pressure distillation

column it is being fed to Analyzer column, after raising its temperature through plate type

heat exchangers/ beer heaters. The analyzer column is under vacuum and the distilling heat is

applied through a reboiler by utilizing the heat of alcohol vapors from the Rectification

column which is under pressure. The Analyzer column alcohol vapors are being condensed in

first body of Integrated Evaporator system and the heat of the same drive the Integrated

Evaporation system. The condensed alcohol of analyzer column then being fed to Pre-

rectification column where steam is applied through a reboiler, the steam condensate is being

returned to boiler and the alcohol is concentrated to around 95% v/v from around 52% v/v.

some impure spirit is been taken out as impure spirit which will be sent to Heads column for

further recovery of pure alcohol. The concentrated alcohol (Product) called Rectified spirit is

then being fed to an extractive distillation column where some dilution water along with lees

is applied at around 100ºC for separation of impurities as vapors, which are been taken to

Heads column. The heat drive of the Extractive Distillation column is being managed through a

re-boiler using vapors of Pre-rectification column. The bottom liquid of Extractive Distillation

column is being fed to Rectification column where some impure spirit is taken out as side

draw and the Product is taken out from upper most plates of the column which is being again

fed to a Simmering column which is under vacuum and some impure spirit mainly from its vent

condenser is taken out and the Main product (Neutral Spirit) is taken to its receiver from

bottom of the Simmering column. Here the Heat drive is taken from the vapors of Heads

column through a re-boiler. A by-product called Fusel oil is separated as side draw from heads

column and collected separately after its water washing. The recovered spirit from heads

column is again recycled to Analyzer column and some impure spirit taken as industrial grade

spirit from the vent condenser of the heads column which is been stored separately.

6. Spent Wash

The exhausted liquid after alcohol separation from analyzer column is called spent wash this

contains grain residue is taken to the decanter centrifuges where the suspended solids of

grain residue.




7. Decanter Centrifuge

The spent wash after distillation is being fed to Decanter Centrifuges where suspended solids

of grain residue is separated called DWGS its having around 75% moisture is either sold as

animal feed or dried in a Ring dryer using bio-gas as hot air generator.

8. Integrated Evaporator

The spent wash after separation of the suspended solids (DWGS) is partially utilized for slurry

making and remaining part is being taken to Integrated Evaporation system for concentration

and condensate recovery. The condensate is being either utilized in cooling towers or in slurry

making. The concentrate liquid is being fed to a bio-digester for its utilization and bio-gas

recovery for fuel economy.

9. Concentrate to Bio Digester

This digester is CSTR type and the spent wash after concentration in Integrated Evaporator is

fed to the Bio-digester where the organics present in spent are being digested anaerobically

and the bio-gas containing around 64% of Methane is recovered which is being utilized for hot

air generation for drying of DWGS and part of the bio-gas is utilized in boiler for steam

generation.

10. Secondary Treatment

The spent wash after anaerobic digestion in Bio-digester along with some other stream (floor

washing/ DM/ RO rejects) is taken to settling tank for settlement of Suspended solids, after

the spent liquid is being fed to two stage aeration chambers, with set of clarifiers. The final

outlet from the final clarifier the treated water is being fed to Multi Effect Falling Film

Evaporator.

11. Multi Effect Evaporator

The Multi Effect Evaporator (MEE) is of five effect falling film evaporator, where the aerobic

treated effluent is being fed through set of pre-heaters to its first body, the low pressure

steam is applied through a thermos-compressor for steam economy. This evaporator is under

vacuum and around 90% of condensate is being recovered, the concentrate is being fed to

Decanter centrifuge for solid recovery.

12. Condensate refinement and Polishing Unit

The condensate after MEE is filtered, degassed and disinfected through UV in CRPU for

further uses in process/ cooling towers.




Figure - 4: Process flow chart For Grain Based Distillery

Power Co-generation 5 MW

The unit has existing boilers of 25 TPH, 12 TPH & 6 TPH. Pet Coke/Coal/ Agro fuel and Biogas

are available fuel options. This Boiler will operate mainly to feed steam to grain based

operations and 5.0 MW power generations from Turbine.

After expansion 5.0 MW co-generation plant consists of a high pressure water tube steam

boiler extraction cum condensing steam turbine. Fuel in the steam boiler will be burnt with

the help of air in the boiler furnace. Water will be circulated in the boiler drum and tubes thus

getting heated by the flame burning in the boiler furnace. Water comes out of the boiler drum

Grain

Storage &

Milling

Slurry

Preparation

Fermentation Multi Pressure

Distillation

ENA

/Rectified

Spirit

Spent

Wash

Decanter

Centrifuge

Wet Cake Dryer

DDGS (for

cattle feed)

Concentrate to

Bio Digester

Bio Gas

Secondary

Treatment

Multi

Effect

Evaporator

Condensate

Concentrate CRPU

Recycled

in Process

Integrated

Evaporator Condensate to

CT makeup

Bio

Digester




located at the top of the boiler as steam. Flue gases rise in the boiler furnace and come in

contact with the steam coming out of boiler drum. Steam after coming in contact with flue

gases gets heated up further thus getting superheated. Super-heated steam leaves the boiler

in a pipe. Flue gases after super heating the steam pass through economizer where they pre-

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

through air pre-heaters where they heat the air which is fed to the boiler furnace for burning

the fuel. After air pre heaters flue gases pass through Bag Filter where the dust particles are

collected. The dust is collected from here.

High pressure superheated steam from boiler is passed through a steam turbine, which is used

for distillery process operations. While passing through the turbine, the high pressure and

temperature steam rotates the turbine rotor and an electric alternator mounted on the same

shaft. Electric power is generated by the alternator. This electric power generated is

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

Figure 5: Process flow chart for Co-generation Power Plant

(vii) Raw material required along with estimated quantity, likely source, marketing area of

final products, mode of transport of raw material and finished product.

(a) Raw Material Requirement

The raw materials required for the distillery can be broadly categorized as follows:

• Grain

• Enzymes & Chemicals

• Steam

• Fuel

• Power, etc.




The basic raw material for the manufacturing of Rectified Spirit/Extra Neutral Alcohol/

will be Grain. In the present scenario, grains with different starch content are used like

broken Rice, sorghum, bajra, maize etc. The process requires the above grains to be

milled into specific flour size. Small quantity of sulphuric acid is sometimes required.

The raw material for the boiler fuel will be Pet Coke/Coal/ Agro fuel and Biogas.

TABLE 3

RAW MATERIAL REQUIREMENT ALONG WITH SOURCE AND MODE OF TRANSPORTATION

S. No.

Particular Requirement Source & Mode of Transportation Existing Additional

Total Requirement after proposed

capacity expansion

1 Grain 180 182 ~362 MT/day Through vendors/By road

2 Chemicals

Sodium Hydroxide (Caustic)

60 60 120 kg/ day Nearby Markets/ By road

NH2-CO-NH2 (Nutrients) 450 450 900 kg/day

Enzymes 10 10 20 kg/day

Antifoam Agent 180 180 360 kg/day

Yeast (Active Dry Yeast/Distiller’s Yeast

45 45 90 kg/day

(b) Fuel Requirement

TABLE 4

FUEL REQUIREMENT

Boiler Name of Raw

Material

Existing Requirement

Total Quantity after Proposed Expansion

Source & Mode of Transportation

Existing Boilers 25 TPH and 12 TPH & 6TPH (Standby)

Pet Coke or 42 MT/Day or 78 MT/Day or

Refineries/Local Sellers

Coal or 70 MT/Day or 140 MT/Day or Local Market

Agro fuel 100 MT/Day 190 MT/Day Local Vendor

Bio Gas 13000 NM3/Day 28000NM3/Day Bio-digester

(viii) Resources optimization/ recycling and reuse envisaged in the project, if any, should be

briefly outlined.

Water as a resource is being/will be recycled at each possible step of the process and latest

technology and methodology has been / will be adopted to conserve and reuse the resources.




(ix) Availability of water it’s source, energy /power requirement and source should be

given.

(a) Water Requirement and Source

Total water requirement existing and after proposed expansion & installation project

will be:-

Existing (KLPD)

Additional (KLPD)

Total after proposed Expansion (KLPD)

674 676 1350

Source: Ground Water

Water Requirement for 160 KPD Grain Based Operation

The total water requirement for the Grain based process is estimated at, worked out as

per details given below:

TABLE - 5 (A)

TOTAL WATER INPUT

S. No. Section Water Consumption (KLD)

1. PROCESS WATER IN LIQN & FERMENTATION 595

2. DM WATER FOR RS DILUTION 545

3. DM WATER FOR BOILER FEED 816

4. MAKE UP WATER FOR VACCUM PUMP & OTHERS 50

5. MAKE UP WATER FOR COOLING TOWER 1100

6. MISC. WASHING WATER 10

7. BLENDING & BOTTLING 165

8. OTHER DOMESTIC USAGE 5

Total 3286

TABLE -5 (B)

TOTAL WATER OUTPUT

S. No. Section Water Consumption (KLD )

1. STEAM CONDENSATE 543

2. SPENT LEES PRC & FOC 160

3. SPENT LEES RECTIFIER 545

4. SPENT WASH (WATER IN WET CAKE & THIN SLOPS) 758

5. MAKE UP WATER FOR VACCUM PUMP & OTHERS 50

6. BOILER BLOWDOWN 15

7. CT EVAPORATION & DRIFT LOSSES 1100

8. WASHING WATER 10

9. DOMESTIC CONSUMPTION 5

10. WATER IN IMFL/CL PRODUCT 100

Total 3286

TABLE - 5 (C)




Recycle & Utilization Streams

S. No. Section Water Consumption (KLD)

1. LEES RECYCLE FOR DILUTION 160

2. STEAM CONDENSATE RECYCLE FOR BOILER 543

3. SPENT LEES (rect) COOLING TOWER MAKEUP 545

4. THIN SLOPS RECYCLE TO LIQN PROCESS 100

5. PROCESS COMDENSATE TO PROCESS 308

6. VACCUM PUMP & SEALING WATER RECYCLE 50

7. PROCESS CINDENSATE TO CT MAKEUP 230

8. Total Recycling /Re-utilisations of water per day 1936

TOTAL FRESH WATER INPUT 1350

TOTAL FRESH WATER INPUT 8.4 KL/KL

Hence, fresh water Requirement is 1350 m3/day. Water requirement for first run would be

3286 m3/day.




Figure 6: Water balance Diagram




(b) Power Requirement and Source

The total power requirement after proposed expansion will be 3.6 MW, which will be

sourced from 5.0 MW Co-Generation power plant.

(c) Steam Requirement

Steam generated from the boiler will be utilized in the generation of 5.0 MW Power

which will be for the own consumption and also for boiler feed water heating and

distillery.

TABLE – 6

STEAM REQUIREMENT

S.

No. Purpose

Exiting Requirement

(80 KLPD)

After Proposed Capacity

Expansion (160 KLPD)

1 Cooking & Liquefaction 3.66 TPH 7.33 TPH

2 Multi-pressure Distillation 10.33 TPH 20.66 TPH

3 DWGS Drier (DDGS) Bio Gas Bio Gas

4 Multi effect evaporator 2.29 TPH 2.87 TPH

5 Boiler De-aeration 1.08 TPH 2.0 TPH

6 others 1.33 TPH 1.33 TPH

Total 18.69 TPH 34.19 TPH

(d) Boiler Details

The unit has existing 3 boilers of capacity 25 TPH, 12 TPH & 6 TPH each. Presently only 25

TPH boiler is running and other two boilers are kept on standby. After proposed

expansion 25 TPH & 12 TPH boiler will operate and 6 TPH boiler will be kept as standby.

Details regarding proposed boiler are mentioned in the table given below:

TABLE – 7

BOILER DETAILS

S. No. Particulars Details

1. Type of Fuel Pet Coke/Coal/ Agro fuel and

Biogas

2. Capacity of Boiler 25 TPH, 12 TPH & 6 TPH

3. Stack Height 35 meters

4. Pollution Control

Equipment Measures

Bag Filter and Trema Cyclone




(e) Details regarding the D.G. Sets

Details regarding the D.G. Sets are mentioned in the table given below:

TABLE – 8

DETAILS REGARDING THE D.G.SETS

S. No. Particulars Details

1. Type of Fuel HSD

2. Capacity 3 D.G. Sets 750 KVA, 725 KVA & 500 KVA

3. Stack Height (above roof level) As per CPCB Guidelines

4. Pollution Control Equipment Measures

Acoustic Enclosure / Silencer

(x) Quantity of waste to be generated (liquid and solid) and scheme for their

management/disposal

• The project is being/will be based on “Zero Effluent Discharge”.

• Fresh water requirement of the project is being/ will be met by Ground Water.

• The proposed project is being/will be based on “ZERO EFFLUENT DISCHARGE”.

• Grain Slops (Spent Wash) are being/will be taken through Centrifuge Decanters for

separation of Suspended Solids separated as Wet Cake.

• Thin Slops from the Decanter Centrifuge is being/will be partly recycled back to

process (30-35%) and partly taken to Thins Slops Evaporation Plant for concentration

of remaining solids to form a Syrup. This Syrup is being fed to bio-digestor for recovery

of bio-gas followed by anaerobic sludge separator & aeration system, final out let after

aeration is then taken to MEE/RO system for water recovery, the concentrate from

MEE is recycled to decanter for solid recovery.

• DWGS is being/will be taken to a dryer operating on steam and is being/will be dried to

make it DDGS – Distillers Dried Grain Solubles.

• The process condensate is being/will be cooled and collected into a neutralization tank

with sufficient residence time. After Neutralization, this process condensate is being/

will be recycled into process.

• Solid waste from the Grain based operations generally comprises of Fibres and

proteins in the form of DDGS, which is being/ will be ideally used as Cattle Feed.

• Ash from the Boiler is being/ will be sold to Brick manufacturers.

• Yeast sludge is being/ will be sent to the Sludge Drying Beds or may be added to the

Wet Cake.

• Used oil & grease generated from plant machinery / Gear boxes & D.G. Set is being/ will

be partly used in oiling & greasing as lubrication of external parts of machinery &

partly is being/ will be sold to the CPCB authorized recycler.




4.0 SITE ANALYSIS

(i) Connectivity

The plant site is well connected to NH-2 (8 km in East direction). The nearest railway station is

Palwal Railway station which lies at a distance of approximately 14.5 km in NNE direction and

nearest airport is Indira Gandhi International Airport (60 km in NNW direction).

The site is suitably located with respect to availability of raw material, water, road network,

skilled/semi skilled/unskilled and professional manpower etc. All communication facilities such

as telephone, telefax & internet are available in the vicinity of the plant site.

(ii) Land from Land use and Land ownership

Total plant area is 11.82 ha (29.20 acres). Since, the proposed expansion will be done within the

existing plant premises, thus, no additional land is required. Hence, land ownership will be

considered as industrial type.

(iii) Topography

Palwal is located in the southern part of Haryana and the western part of India, being a part of

the National Capital Region. It shares a geographical boundary with Mewat, Aligarh, Gurgaon,

Faridabad and Delhi. National Highway - 2 passes through the Palwal district. Apart from the

perennial river Yamuna flowing, a 136 km long Kundli - Manesar - Palwal Expressway is being

planned to run through the district.

(iv) Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including

area under CRZ)), shortest distances from the periphery of the project to periphery of

the forests, national park, wild life sanctuary, eco sensitive areas, water bodies

(distance from the HFL of the river), CRZ. In case of notified industrial area, a copy of

the Gazette notification should be given

TABLE – 9

ENVIRONMENTAL SETTINGS OF THE AREA

S. NO. PARTICULARS DETAILS

(with approximate aerial distance & direction from plant site)

1. Nearest Village Hathin (1.5 km in NW direction)

2. Nearest City/Town Palwal (14.5 km in NNE direction)

3. Nearest National Highway / State Highway

NH-2 (7.5 km in East direction)

4. Nearest Railway station Palwal (14.5 km in NNE direction)

5. Nearest Airport Indira Gandhi International Airport, New Delhi (60 km in NNW direction)

6. National Parks, Reserved Forests (RF) / Protected Forests (PF), Wildlife Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors etc. within 10 km radius

No National Parks, Reserved Forests (RF) / Protected Forests (PF) Wild Life Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors etc. lies within 10 km radius of the plant site.

7. River / Water Body (within 10 km radius)

Gaunchhi Drain (Adjacent to the plant site in East direction)




(v) Existing Infrastructure

Total plant area is about 29.20 acres (11.82 ha). Proposed expansion will be done within the

existing plant premises. Existing infrastructure includes 80 KLPD grain based distillery along

with 2.0 MW Cogeneration power plant.

(vi) Soil classification

Soils of Palwal district are classified as tropical and brown soils, existing in major parts of the

district. In Hathin block the organic content of soils ranging from 0.41 to 0.75 percent which is

of medium category. In rest of the area organic contents is 0.2 to 0.4 percent and falls in Low

category. The average conductivity of the soil is not more than 0.80 µmhos /cm and the

average pH of the soil is between 6.5 and 8.7. The area comprises almost flat plains traversed

by one ridge running N-S to NNE-SSW direction, divides the alluvium into two parts. The major

river is Yamuna which is a perennial river.

(vii) Climatic data from secondary sources

The climate of Palwal district can be classified as tropical steppe, semiarid and hot which is

mainly characterized by the extreme dryness of the Air except during monsoon months.

During three months of south west monsoon from last week of June to September, the moist

air of oceanic penetrate into the district and causes high humidity, cloudiness and monsoon

rainfall. The period from October to December constitutes post monsoon season. The cold

weather season prevails from January to the beginning of March and followed by the hot

weather or summer season which prevails up to the last week of June. The normal annual

rainfall in Palwal district is about 542 mm spread over 27 days. The south west monsoon sets in

the last week of June and withdraws towards the end of September and contributes about

85% of the annual rainfall. July and August are the wettest months 15% of the annual rainfall

occurs during the non-monsoon months in the wake of thunder storms and western

disturbances.

Normal Annual Rainfall - 542 mm

Normal Monsoon Rainfall: 460 mm

Temperature - 41 C (May & June)

(viii) Social Infrastructure available

Telephone and medical facilities are available in the nearby towns. Adequate infrastructure

has been developed by the company around their existing plant premises. Various

infrastructure development activities, toilets, drinking water facility etc. has been brought into

existence. Other facilities like small shops and markets are existing in the area that supports

the basic lifestyle of the people.

5.0 PLANNING BRIEF

(i) Planning Concept (type of industries, facilities, transportation etc.) Town and country

Planning/ Development authority classification.




The existing industry is distillery industry and proposed expansion will be within the existing

plant premises. Facilities required for the same will be provided as per the requirement.

Transportation of raw material and final product will be done via existing road and rail

network and concrete cement road has been developed within the existing plant premises.

(ii) Population Projection

Temporary influx of people will be there as the managerial and supervisory staff will generally

be outsider. A projection may be made by a governmental organization, or by those

unaffiliated with a government.

(iii) Land use planning (breakup along with greenbelt etc)

Total Plant area is 29.20 acres. Proposed expansion will be set up in the existing plant

premises. No additional land will be required. About 33 % of the total plant area has already

been developed under greenbelt & plantation in order to reduce dust & noise pollution levels

& to increase aesthetic beauty of the area. The same will be maintained.

(iv) Assessment of infrastructure demand (Physical & Social)

The company has assessed the demand of infrastructure (Physical & Social) in nearby area of

the plant site and development activities are being undertaken under corporate social

responsibilities program for rural development initiatives for the upliftment of the nearby

communities from time to time.

(v) Amenities/Facilities

The company has constructed dispensary, canteen etc for the permanent and contract

employees.

The company will develop the Amenities/Facilities in nearby area of the plant site as per

requirement of local people of the nearby area under corporate social responsibilities

programme.

6.0 PROPOSED INFRASTRUCTURE

(i) Industrial Area (Processing Area)

Total plant area is 29.20 acres. Proposed expansion will be done within the existing plant

premises.

(ii) Residential area (Non Processing area) –

There is no residential area within the existing plant premises.

(iii) Greenbelt

A lush green environment has been created in and around the existing distillery. A variety of

trees and plants having fragrance have been planted. Around 33% of total plant area i. e. 9.63

acres has already been developed under greenbelt/plantation.




(iv) Social Infrastructure

Proposed expansion will result in growth of the surrounding areas by increased direct and

indirect employment opportunities in the region including ancillary development and

supporting infrastructure.

(v) Connectivity

The site is well connected with communication facilities like telephone, fax, and wireless as

such, no constraints are envisaged in this aspect as the Tehsil and District headquarters are

near to the site.

(vi) Drinking Water

5 KLPD water is being / will be required for drinking purpose and other use, which will be

sourced from Ground Water

(vii) Sewage Treatment System

The sewage generated from the sanitary blocks is being/will be disposed off in septic tanks via

soak pits.

(viii) Industrial Waste management

The distillery is being/will be based on “ZERO DISCHARGE”.

(ix) Solid Waste Management

� Fly ash from the Boiler would be utilized in nearby brick manufacturing units/land-

filling/as per CPCB guidelines.

� Solid waste from the Grain based operations generally comprises of Fibres and proteins

in the form of DDGS, which is being/ will be ideally used as Cattle Feed.

� Yeast sludge is being/ will be sent to the Sludge Drying Beds or may be added to the

Wet Cake.

(x) Power requirement and source –

The total power requirement after proposed expansion will be 3.6 MW, which will be

sourced from Co-Generation Power Plant of 5.0 MW & D.G. sets (for emergency).

7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

(i) Policy to be adopted (Central/State) in respect of the project affected persons

including home oustees, land oustees and landless labourers (a brief outline to be

given).

Proposed expansion will be done within the existing plant premises. No additional land is

required for the same. Therefore, there will not be displacement of people and hence,

Rehabilitation & Resettlement is not applicable.

8.0 PROJECT SCHEDULE AND COST ESTIMATES

(i) Likely date of start of construction and likely date of completion (time schedule for

the project to be given).




The proposed expansion will start only after obtaining Environmental Clearance and other

statutory permissions. Project will be completed in 2 years period after getting all the

regulatory approvals.

(ii) Estimated project cost along with analysis in term of economic viability of the project.

� Total cost of the Project: Rs. 30.0 crores

� Cost for Environment Protection Measures:

Capital Cost: Rs. 10.0 Crores

Recurring Cost: Rs. 1.0 Crore/annum

9.0 ANALYSIS OF PROPOSAL

(i) Financial and social benefits with special emphasis on the benefit to the local people

including tribal population, if any, in the area.

Proposed expansion project will result in growth of the surrounding areas by increasing

ancillary development and supporting infrastructure. Special emphasis on Financial and Social

benefits will be given to the local people including tribal population, if any, in the area.

Development of social amenities will be in the form of medical facilities, education to

underprivileged and creation of self help groups.

Haryana state will get revenues in terms of taxes. Business opportunities for local community

will be available like transport of alcohol to market, fly ash transport to Brick manufactures,

maintenance & house-keeping contract work etc.

Documents

PFR Report Ashoka - environmentclearance.nic.inenvironmentclearance.nic.in/writereaddata/Online/...Pre - feasibility Report Ashoka Distillers & Chemicals Private Limited 3 process