PRE - FEASIBILITY REPORT - Welcome to Environmentenvironmentclearance.nic.in/writereaddata/Online/TOR/0… · · 2015-08-28Record of wastewater returned back to process for

Proposed installation of Unit II - Grain Based Ethanol/RS Industrial/ENA Plant {500 KLPD (2X250 KLPD)} & Co-generation Power

Plant {40 MW (2X 20 MW)} in Existing Distillery Plant

At Village Mansoorwala, Tehsil Zira, District Ferozepur, Punjab

Pre Feasibility Report

Malbros International Private Limited 1

PRE - FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY

(I) Introduction

Malbros International Private Limited is proposing installation of Unit II - Grain Based

Ethanol/RS Industrial/ENA Plant {500 KLPD (2X250 KLPD)} & Co-generation Power Plant {40

MW (2X 20 MW)} in Existing Distillery Plant at Village Mansoorwala, Tehsil Zira, District

Ferozepur, Punjab. The unit will be installed in two phases as mentioned below:

Phase 1:-

a) 250 KLPD Ethanol/ RS Industrial/ ENA Unit

b) 20 MW Co- Generation power plant

Phase 2:-

a) 250 KLPD Ethanol/ RS Industrial/ ENA Unit

b) 20 MW Co- Generation power plant

Grain 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 in

Category ‘A’, Project or Activity - 5(g)(ii) [Non-molasses based distilleries ≥ 60 KLD].

TABLE – 1

SALIENT FEATURES OF THE PROJECT

S. NO.

PARTICULARS DETAILS

A. Nature & Size of the Project

Units Existing Capacity

Grain based Ethanol/RS Industrial/ENA Unit 500 KLPD (2X250 KLPD)

Co-Generation Power 40 MW (2X20 MW)

CO2 Plant 225 TPD (2X 112.5 TPD)

DDGS/ Cattle Feed/ Poultry Feed 300 TPH ( 2X150 TPH)

B. Category of the Project

As per EIA Notification dated 14th Sep., 2006 as amended from time to time; the project falls in Category ‘A’, Project or Activity - 5(g)(ii) [Non-

molasses based distilleries ≥ 60 KLD]. C. Location Details

Village Mansoorwala

Tehsil Zira

District Ferozepur

State Punjab

Latitude 30055’07.61’’ N to 30055.03.56”N

Longitude 74057’32.56” E to 74057’35.13’’ E

D. Area Details

Total Project Area 14.8 ha (36.5 acres)

Greenbelt/Plantation 4.9 ha (~33 % of the total project area) has been proposed as Green






Area (ha) belt/Plantation

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

1. Nearest Village Ratol Rohi (~1 km in WSW Direction)

2. Nearest Town/City • Nearest Town:- Zira (~6 km in NNE direction)

• Nearest City:- Talwandi (~7 km in West direction) 3. Nearest National Highway

/ State Highway NH-15 (~1 km in West Direction)

4. Nearest Railway station Talwandi Bhai Railway Station (~ 7 km in SSW direction)

5. Nearest Airport Sri Guru Ram Dass Jee International Airport, Amritsar (~ 88 km in NNW direction)

6. Archaeological important site

No Archaeological important site exists within 10 km radius of project site.

7. National Parks, Wild Life Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors etc. within 10 km radius

No National Parks, Wild Life Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors etc. lies within 10 km radius of the project site.

8. Reserved Forests (RF) / Protected Forests (PF) etc. within 10 Km. radius

No Reserved Forests (RF) / Protected Forests (PF) etc. lies within 10 Km. radius of the project site.

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

No river lies in 10 km radius of the project area.

F. Cost Details

1. Total Cost of the Project

Rs. 583 Crores

2. Cost for Environment Management Plan

o Capital Cost - Rs. 58 Crores. o Recurring Cost - Rs. 10 Crores / annum.

G. Basic Requirements for the project

Water Requirement (KLD)

4110 m3/day (for first run fresh water requirement would be 10958 m3/day) Source: Canal Water & Recycled Water

Power Requirement (MW)

9.0 MW Source: Proposed 40 MW (2X20 MW) Captive Power Plant & D.G. Sets- 3 X 1000 KVA (for Back-up purpose only)

Man Power Requirement

800 persons Source: Unskilled / Semi-Skilled - Local Area; Skilled- Local & Outside

H. Working Days for Distillery

350 days/ annum

1.1 ENVIRONMENTAL MANAGEMENT PLAN

Particulars DETAILS

Air Quality Management

Possible Sources Boilers, Proposed 40 MW (2X20 MW) Co-generation Power Plant, Transportation vehicles, D.G. Sets etc.

Emissions � ESP will be installed with the proposed boilers.

� Adequate boiler stack height will be maintained.

� DG Sets will also have adequate stack of height as per CPCB Guidelines.

� Adequate measures for Fugitive Dust Emissions will be taken.

� All the internal roads will be asphalted.






� Development of Green Belt around the periphery & within the premises of the plant will help in attenuating the pollutants emitted by the plant.

Monitoring Ambient air quality and stack emission 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 will be based on “Zero Effluent Discharge”.

� Fresh water requirement of the project will be met by Ground Water, Canal Water & recycled water. Efforts will be made to conserve as much water as possible by recycling and reuse.

� Record of wastewater returned back to process for utilization in Fermentation/cooling tower and to gardening will be kept.

� Process condensate from MEE will be recycled back to the process for Grain dilution and cooling tower make up.

� Spent lees generation from distillation column will be recycled partly to the columns for dilution and balance will be used for cooling tower make up.

� Domestic waste water generated from the plant will be treated in Septic Tank/STP and treated water will be used in green belt development.

� Effluent Treatment Plant will be installed and treated water from ETP will be recycled back to the process and remaining will be used for green belt development.

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 Green Belt for 33% of the total project area.

� Regular monitoring of noise level.

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

Monitoring � Regular monitoring of noise levels will be carried out and corrective

measures in concerned machinery will be adapted accordingly to the possible extent.

Solid 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 will be sold to Brick manufacturers.

� Used oil & grease generated from plant machinery/Gear boxes as hazardous waste will be sold out to the CPCB authorized recycler.

Green belt Development/ Plantation

Management � 33% of total project area will be developed under green belt/plantation.

� All the barren areas will be vegetated.

� Native plant species will be planted in consultation with local horticulturist.

� Green belt development along with the road & plant boundary will attenuate noise level arrest dust and improve the environment in surrounding.

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

The Oasis Group has Hotels of star category at Mussoorie and Delhi under the world known

management group Carlson and brand name Country Inn & Suites by Carlson”

The group is also in luxury goods business under the brand name of “Dillano Luxurious

Jewels” which caters to the niche business class and participates in elite jewellery exhibitions

such as Wedding Asia etc.

Oasis Group, India Based Group are well known and highly reputed in the Luxury/hospitality

liquor/ business. The Group has wide distribution network for both Indian and foreign made

liquor in number of states. They have been engaged with this activity for more than 5 decades.

At present the group owned five running Distilleries, two bottling Units and expanding and

diversifying into different business at fast pace.

The Oasis Group is a highly reputed conglomerate with diverse interests that include Distillery,

Liquor Retailing, Hotels and Constructions. The Group’s rapid growth on Indian corporate

scene rests on its strong foundation of professional management and astute collective

enterprises. Over the last 15 years, the Malhotra Group has grown into a diversified

business and industrial house with a high growth rate and a total commitment to persistent

growth.

The group was founded by Shri Om Prakash Malhotra. It is his foresight and vision that has

promoted the organization to take its present shape. Its present Chairman and Director, Mr.

Deep Malhotra, a second-generation entrepreneur, carries with him rich experience coupled

with sharp commercial acumen. The Group has a team highly qualified, experienced, trusted

persons with a right mix of technocrats, Finance Experts and management professionals.

Group Companies:-

1. Country Inn & Suites By Carlson (A Unit of Diamond Resorts Pvt. Ltd.), Mussoorie

2. Oasis Resorts Pvt. Ltd., Delhi

3. Dillano Luxurious Jewels Ltd., Delhi

4. Oasis Commercial Pvt. Ltd., Haryana

5. Oasis Overseas Pvt. Ltd., Haryana






6. Malbros International Pvt. Ltd, Punjab

7. Oasis Distilleries Ltd, Indore

8. Gauravh Wines Pvt. Ltd., Punjab

9. Om Sons Marketing Pvt. Ltd, Punjab

10. Malbros Enterprises Pvt. Ltd, Delhi

11. Calx Paper Pvt. Ltd, Delhi

12. Gee Emm Bros. Distributors Pvt. Ltd., Delhi

13. Vijeta Beverages Pvt. Ltd., Rajasthan

14. Gautam Wines Pvt. Ltd., Punjab

ALCOHOL MANUFACTURING:- The Alcohol Distillation Unit has been designed as per multi

pressure distillation technology which gives maximum of output which minimum of input

energy. The ENA being made at our Plant meets best industrial specifications.

TRANSPORT:- Over the past few years the company has increased the number of vehicles in its

transport division. The supply of Bottled liquor in the state and outside the state is done by the

company’s own trucks. Whereas the company has also purchased 6 numbers of Tankers out of

which 2 are of 40 KL and 4 are of 25 KL each. All the tankers are of SS 304. ENA/RS is being

supplied thru these tankers all over India.

(ii) Brief description of nature of the project

Malbros International Private Limited is proposing 500 KLPD (2X250 KLPD) Grain Based

Ethanol/RS Industrial/ENA Unit along with 40 MW (2X20 MW) Cogeneration Power Plant at

Village Mansoorwala, Tehsil Zira, District Ferozepur, Punjab. Grain 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 in

Category ‘A’, Project or Activity - 5(g)(ii) [Non-molasses based distilleries ≥ 60 KLD].

(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. The use of

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






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

in coming years. Ethanol is an alcohol fuel that is added to petrol in some countries to lower

cost to the consumer, reduce consumption of oil, and lessen the environmental impact of

transportation. Mixed fuels are rated by the amount of ethanol contained; for example,

common blends are E10, which contains 10% ethanol, and E15, which contains 15% alcohol.

Another common blend is E85, also known as flex fuel, in which the ethanol ranges from 51% in

winters to 83% in summers.

In addition, though ethanol reduces air particulate pollution, its production results in fairly high

greenhouse gas emissions and negates any the environmental benefit of the shift from fossil

fuel.

The biggest concern with the addition of ethanol to India's fuel supply is that it will take up

scarce land set aside for grazing and other crops to grow fuel. With the demand likely to be

huge, there is bound to be a shift in land use from food crops to fuel crops. Agriculture will

become even more intensive. Without adequate reforms and education in the agricultural

sector to increase productivity, the shift to fuel crops will result in food price inflation. The

savings from reduced oil imports will be spent instead on subsidies and higher food prices.

Furthermore, technology can improve at two ends - energy efficiency at the EV end and

greater storage capacity at the EVB end. The latter would translate into better performing

vehicles without the consumer having to regularly upgrade his EV.

In the path of company’s growth and development this proposed 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 Ethanol 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

The possibility of alcohol export is very good. So Indian industries export alcohol in African,

Europe & Asian countries which is very profitable now a days. After setup of this type of

alcohol industries government can collect more revenue.






(vii) Domestic / Export Markets

Presently the big Indian players in alcohol production and bottling are United Spirits Ltd, ABD

Pvt Ltd, Radico khaitan Ltd, Globus Spirits Ltd etc. So they try to fulfil the current requirement

of alcohol in domestic as well as export market.

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

Direct and indirect employment will be generated due to the proposed project. During

construction phase, employment opportunity to approximately 1000 persons is estimated.

The total manpower requirement for the proposed project will be 800 persons (inclusive of on

roll employees and on contract employees).

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






Figure - 1: Location Map

Proposed installation of Unit II - Grain Based Ethanol/RS Industrial/ENA Plant {500 KLPD (2X250 KLPD)} & Co-generation Power Plant {40 MW (2X 20 MW)} in Existing Distillery Plant




(iii) Key Plan

Figure - 2: Key Plan

Proposed installation of Unit II - Grain Based Ethanol/RS Industrial/ENA Plant {500 KLPD (2X250 KLPD)} & Co-generation

Power Plant {40 MW (2X 20 MW)} in Existing Distillery Plant


Form–I / Appendix–I


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

particularly the environmental considerations gone into should be highlighted.

No alternative site has been taken into consideration.

Following factors were considered while selecting the site:-

� Suitable source of raw material.

� Location in rural area ensures adequate availability of manpower at marginally

lower rates, compared to metro cities of India.

� Nearness to NH-15 which makes it easier to transport raw materials & Products.

� There is no National Park, Biosphere Reserves, Tiger Reserves, Reserved / Protected

Forests within 10 km radius of study area.

(v) Size or magnitude of operation

The total proposed production is 500 KLPD (2X250 KLPD) Grain Based Ethanol/RS

Industrial/ENA Unit along with 40 MW (2X 20 MW) Cogeneration Power Plant at Village

Mansoorwala, Tehsil Zira, District Ferozepur, Punjab.

The process includes basic raw material requirement, sizing of equipment, utilities &

services, infrastructure facilities & sources of waste generation, their quantity, treatment

& safe disposal of the waste.

S. No. Units Capacity

1. Ethanol/RS Industrial/ENA unit 500 KLPD (2X 250 KLPD)

2. Co-Generation Power Plant 40 MW (2X 20 MW)

(vi) Project Description with Process Details (a schematic diagram/flow chart showing

the project layout, components of the project etc. Should be given)

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 :

Grains are procured from various sources, such as FCI Storage godowns through agencies

and are unloaded into large Storage Silos after Pre-Cleaning. Storage Silos are specially






designed to keep the Grains in good condition for longer durations and also avoid its

deterioration and theft, etc. It is being proposed to have 30 – 45 days of Grain Storage

facility in the Distillery.

2. Grain Cleaning, Milling and Flour Handling :

The grain is lifted in bucket elevators, screened followed by removal of stones and iron

matter. Cleaned Grains are then milled using dry milling process in Hammer Mills. The

flour is fed through the bucket elevator and conveyed to the Batch Tipping Machine

through a Screw Conveyor. The flour addition is metered through the Batch Tipping

Machine with load cell arrangement, before transferring the flour to the Slurry Tank

through another Screw Conveyor (pre-masher) for slurry preparation process. It is being

proposed to have 4 x 16 TPH as milling paraphernalia for this Distillery.

3. Slurry Preparation & Liquefaction :

Grain flour and process water is fed at controlled rate to Initial Liquefaction tank. Mixed

slurry is taken to the Initial Liquefaction Tank where additional quantity of water is added

as per requirement. Viscosity reduction Enzyme and stabilizing chemicals and a portion of

liquefying enzyme are also added at this stage. 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 the Retention Vessel. The retention vessel has 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 and is therefore susceptible to enzyme attack for

liquefaction.

The gelatinized mash from the Flash Tank is liquefied in the Final Liquefaction Tank where

liquefying enzyme (alpha-amylase) is added. The liquefied mash is cooled in Mash Cooler

and transferred to Saccharification cum fermentation section. This process initiates the

formation of sugar.

The gelatinized mash from the Flash Tank is liquefied in the Final Liquefaction Tank where

liquefying enzyme (alpha-amylase) is added. The liquefied mash is cooled in Mash Cooler

and transferred to Saccharification cum Fermentation section.






4. Hiferm-Nm Saccharification and Instantaneous Fermentation:

Yeast Activation:

Yeast seed material is prepared in water-cooled Yeast Activation Vessel by inoculating

sterilized mash with Active Dry Yeast. Optimum temperature is maintained by cooling

water. The contents of the Yeast Activation Vessel are then transferred to Fermenter.

Saccharification & Instantaneous Fermentation:

The Liquefied starch slurry comprising Dextrins is partly taken for Yeast development in

Yeast Activation vessel and majorly transferred into the Fermenter. Amyloglucozydase

and other nutrient Enzymes are first added to Saccharify the Starch Slurry causing

formation of Sugars. Immediately, the Active Yeast is introduced in the system for

simultaneous Fermentation. The process of fermentation is to convert the fermentable

substrate into alcohol. To prepare the mash for fermentation, it may have to be diluted

with water. The pH of the mash is adjusted by the addition of acid. Yeast is available in

sufficient quantity to initiate fermentation rapidly and complete it within the cycle time.

At the start of the cycle, the fermenter is charged with mash and contents of the Yeast

Activation Vessel. Significant heat release takes place during fermentation. This is

removed by passing cooling water through the Fermenter PHE’s to maintain an optimum

temperature. The recirculating pumps also serve to empty the fermenters into Beer Well.

After the fermenters are emptied, they are cleaned with water and caustic solutions and

sterilized for the next batch. The carbon dioxide evolved during the process is vented to

atmosphere after recovery of alcohol in a scrubber.

5. Ethannol Distillation :

Fermented wash from wash holding tank T-01 is pumped by wash feed pump P-01 to the

top of degassing column (C-2) after preheating the same in beer heater E-02 and spent

wash heat exchanger E-01. The vapors along with non-condensable gases from the top of

degassing column (C-02) are rectified in Heads column (C-03), to expel the high volatiles,

technically known as heads. Bottom liquid from the degasser flows into analyzer column

(C-01) where alcohol is stripped from the liquid. The liquid from bottom of analyzer

column (C-01) is completely stripped of alcohol and is pumped out by thick slop discharge

pump P-02 through heat exchanger E-01 where it preheats the fermented wash before it

enters degassing column. The slop from the analyser column will be feed in to

decanter.The dilute alcohol vapors from near the top of analyzer column (C-01) are

condensed first in beer heater (E-02) while exchanging heat with wash feed and then in

analyzer condenser (E-03). Degasser and analyzer operate under vacuum. The






condensate from E-02 and E-03 is collected in Rectifier Feed Tank V-02. The vapors for

stripping alcohol are generated from analyzer column bottom liquid in the analyzer

column re-boiler (E-04) by using the rectified column top vapors, as discussed

subsequently.

Vapors from the top of heads column (C-03) are condensed in heads column condenser

(E-06) and then in head column vent condenser (E-07). Part of the condensate is returned

to column C-03 as reflux while a small portion is taken out as an impure spirit cut. Liquid

from bottom of C-03 is also taken into Rectified feed tank V-02.

Dilute alcohol water mixture from rectifier feed tank (V-02) are pumped by rectifier feed

pump (P-04) through rectifier feed pre-heater E-11 in to rectifying column (C-04). Rectifier

and its associated equipment work under pressure so that these vapors can supply the

necessary heat for generating the vapors.

The condensate from E-04 is then pumped as Reflux to rectifying column C-04. Rich

alcohol vapors at a concentration of 95.5% v/v from top of rectifying column (C-04) are

condensed first in Analyzer (E-04) and then in Reflux Vent Condenser (E-05). The liquid

from E04 and E-05 are collected in Rectifier Reflux Tank (V-01). Part of the liquid from E-

05 may be drawn off as impure spirit. The impure spirit cut will be maintained as little as

possible to maintain aldehyde levels to meet the required limits in Absolute Alcohol.

Liquid from the reflux tank (V-01) is pumped by Product Pump (P-03) partly as product

and partly as reflux to the top of the Rectifying Column (C-04). The necessary rectifying

vapors to C-04 are generated by boiling the C-04 bottom liquid in Rectifier Column Re-

boiler E-08 using medium pressure steam. Some side streams are drawn from rectifier

column as light and heavy fractions of higher alcohols called fusel oils and cooled in fusel

oil coolers E-09 and E-10 and are mixed with water and allowed to separate out in fuel oil

separator F-01. All vents from E-03, E-07, V-02 and E-05 are connected to Vent Gas

Absorber (C-05) where the vent gases are scrubbed with water to recover entrained

alcohol. The scrubber water is used for washing the fuel oils in fuel oil separator to

recover alcohol from the fuel oil fractions. The absorber vent is connected to vacuum

pump (G-01) which is used to create vacuum in the analyzer and degasser.

Absolute alcohol is manufactured by dehydration of Rectified Spirit. The process adopted

here is based on Pressure Swing Adsorption (PSA) system using Molecular Sieves (3-A).

The flow scheme is shown in above referred flow diagram.

Rectified spirit, after preheating by waste hot streams, is vaporized and superheated in E-

03 and E-04 by using medium pressure steam at 6 Kg/cm2g pressure. Hot vapors at






kg/cm² g pressure and 130° C temperature pass through PSA column S-01A/S-01B where

the water vapors are retained while water free alcohol is released as vapors. The vapors

are condensed in E-07 and E-08 and collected as Absolute Alcohol. When the molecular

sieve bed is saturated with water the alcohol vapors are shifted to the other tower and

the first tower is taken for regeneration. Regeneration is done first by pressure releasing

and creating vacuum and then by elutriating with dehydrated alcohol vapors from the

tower in dehydration operation. The vapors are condensed in E-06 and E-05 and the vent

vapors are recovered through scrubber C-02. Vacuum can be created vacuum by P-04.

(Eductor may also be considered for this duty). Product is cooled in E-09 and transferred

to Absolute Alcohol receiving tank and then on to storage tank.

6. Alcohol Daily Receivers & Bulk Storage :

Alcohol is first taken to Daily receiver storage tanks, which is based on the State Excise

laws, storage for three days considering the weekly holidays of two days. Thereafter, the

alcohol is transferred to Bulk Storage Tanks after taking the daily receiver Dip. This is

transferred using flameproof pumps. Final dispatch of alcohol is metered and again is

carried out using special flameproof pumps. The Bulk Spirit Storage is proposed to be set

up for 30 days.

EFFLUENT HANDLING SECTION

1. Decantation Section:

Decantation section comprises of Centrifuge Decanters, operating at high rpm which are

used for separation of suspended solids from Spent Slops coming out of Distillation

section. The Wet cake thus separated has 30-35% w/w solids, as removed from bottom of

Decanters. This is directly loaded on the trolleys parked below. Thin slops coming out of

Decanter are collected in a tank and are transferred for part recycle & further for

Evaporation into thick syrup.

2. Integrated Evaporation Section:

The suggested treatment scheme is a 2 FF + Finisher Evaporation Plant for Thin Slops

Evaporation. The following points will elucidate the basic working principle:

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

principle of Falling Film Evaporation have been used, with Plate type Preheaters for

preheating of FEED stream which serves the purpose of energy conservation.

� Analyzer vapour is fed to the first effect evaporator shell side at the given pressure

and temperature as the heating medium.






� The Feed from the Feed balance tank is taken to the PHCOND to make the best

heat recovery.

� The Feed after getting heated to the predetermined temperature in preheater is

fed from the first effect evaporator which is Falling Film Evaporator -1

� The flow path is given below.

INLET FEED - pH cond – E1 – E2 – OUTLET PRODUCT

� Vapours generated in 1st effect VLS (Vapour Liquid Separator) are used as heat

source in the 2nd effect.

� The product at the desired concentration of TS is obtained at the outlet of the

second effect, which is a Falling Film evaporator.

� A Shell & tube type Multi-pass Surface condenser is employed for condensing the

shell side vapours.

� The Pure and the process condensate are collected in receiving vessels.

� Highly efficient operating pumps will be provided for pumping the required fluid.

� The operation of the plant will be under vacuum. Vacuum is created with the help

of a water ring vacuum pump.

� The plant will have high level of automation to get consistent output at required

concentration.

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

maintain a desired vacuum.

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

the vapours.

CONCLUSION

The thick syrup thus obtained is mixed with the Wet Cake obtained from Decanter

Centrifuges using specially designed Ribbon type mixer and this enriches the protein

content in the fibrous suspended solids separated earlier in Decanter. This Protein & Fibre

rich DWGS is directly sellable as Cattle / Poultry Feed. However, in order to increase the

shelf life of such by-product, it is necessary to dry the product, with minimum possible

moisture content.

SYSTEM DESCRIPTION FOR DWGS DRYER

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

suitable feeding system. The Rotary Tube Bundle is enclosed in an insulated dryer housing

and on its outer flights are fixed. Dry saturated steam is to be supplied to the tube bundle






through rotary joint at one end & the condensate is discharged through rotary joint

mounted at other end.

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

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

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

separating fines.

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

Product Screw & Recycle Conveyor.

Entire operation of the Dryer is controlled through Control panel.

SYSTEM DESCRIPTION FOR COOLING & CONVEYING

� DWGS below product screw is discharged into charging hopper of pneumatic

conveying system.

� Rotary feeder feeds it into the conveying line.

� Ambient air is used for conveying.

� The material gets conveyed to product collector & discharged from rotary

discharge valve.

� Exhaust air is vented to atmosphere.

� The conveying system is lean phase suction type, using centrifugal blower as prime

mover. The conveying air quantity is designed considering cooling requirement & to

cool the product before discharge.

Figure - 3: Process flow chart For Grain Based Distillery






B) Power Co-generation 40 MW (2X20 MW)

OPERATIONS

The unit proposes to set-up boiler and power turbine.

2 Nos. X 100 TPH boiler will be installed and based on Coal/Rice Husk/Pet Coke/

Biomass/Natural Gas etc. as available fuel options. This Boiler will operate mainly to

feed steam to grain based operations and 40.0 MW (2X20 MW) power generations

from Turbine.

Proposed 40.0 MW (2X20 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 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 4: PROCESS FLOW CHART FOR COGENERATION 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 Requirements

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 will be Grain. In the present scenario, grains

with different starch content are used like damaged grain feed stock, nakku kinki, maize,

bajra, sorghum, barley 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 Coal, Rice Husk , Pet Coke , Bio Mass, Natural Gas etc .

Table 2

RAW MATERIAL REQUIREMENT FOR GRAIN BASED DISTILLERY

S. No.

Particular Requirements Source of the Raw Material & Mode of

Transportation

1. Grain (Damaged grain feed stock, nakku kinki, maize, bajra, sorghum, barley etc.)

1100-1300 TPD Nearby area and states , by road or

Railway

2. Chemicals Quantity (kg/d)

Sodium Hydroxide (Caustic) 2000 KGS

Enzymes 800-1000 KGS






NH2-CO- NH2 (Nutrients) 2000-3000 KGS

Antifoam Agent 500-600 KGS

Yeast (Active Dry Yeast/Distiller’s Yeast 250-350 KGS

(a) Fuel Requirement

Name of Raw

Material

Quantity (MT per

day) Mode of transportation

Coal, Pet Coke 500-750 TPD By Railway

Rice Husk, Bio Mass 1000-1200 TPD Nearby Road

Natural Gas 500-600 TPD Pipeline

(b) Marketing Area and Mode of transportation of Final Product

The company has explored National and International markets for their products

from proposed unit. The final product will be sold in domestic market as well as it

will be exported. The mode of transportation for domestic market will be by road

and ship for export.

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

should be briefly outlined.

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

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

Waste water will be generated from the process goes to ETP and treated water

after pH corrections is used back again into the various processes and remaining is

used for the horticulture purposes.

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

given.

(a) Water Requirement and Source

The total water requirement for the first run for the proposed project will be 10958

m3/day and after recycling it will be 4110 m3/day.

Source of Water: Canal Water & Recycled Water.

Water Requirement for Grain Based Operation

The total water requirement for the Grain based process is estimated at 4110

m3/day, worked out as per details given below:






TABLE - 3 (A)

Total Water Input

S. No. Section Water Consumption (KLPD)

1. PROCESS WATER IN LIQN 1635

2. BOILER FEED WATER 3678

3. DM WATER for DISTILLATION 625

4. SOFT WATER for COOLING TOWER 3750

5. SOFT WATER DISTILLATION 675

6. SOFT WATER PUMPS SEALING 250

7. FERMENTER WASHING 94

8. FLOOR WASHING 219

9. DOMESTIC CONSUMPTION 32

TOTAL 10958

TABLE -3(B)

Total Water Output


1. STEAM CONDENSATE 2582

2. SPENT LEES PR 625

3. SPENT LEES RECTIFER 625

4. SPENT WASH (GRAIN SLOPS) 265

5. WATER IN DDGS DRYER 810

6. CT EVAPORATION & DRIFT LOSSES 3750

7. PUMP SEALING 250

8. PROCESS CONDENSATE 2001

9. BOILER BLOWDOWN 50

TOTAL 10958

TABLE - 3 (C)

Recycle & Utilization Streams


1 STEAM CONDENSATE 2582

2 THIN SLOPS 265

3 R/E to DISTILLATION 531

4 PR LEES TO FERMETATION 94

5 PUMP SEALING 250

6 BOILER BLOWDOWN 50

7 PROCESS CONDENSATE 2001

8 FLOOR WASHING 219

9 PREC LEES TO CT 391

10 R/E to Less to CT 94

11 CT BLOWDOWN 371

Total Recycling / Reutilasation of water per day 6848

TOTAL FRESH WATER INPUT 4110

Hence, fresh water Requirement is 4110 KLPD. Water requirement for first run

would be 10958 KLPD.

Proposed installation of Unit II - Grain Based Ethanol/RS Industrial/ENA Plant {500 KLPD (2X250 KLPD)} & Co-generation Power Plant {40 MW (2X 20 MW)} in Existing Distillery Plant




Figure 5: Water balance Diagram






(b) Power Requirement and Source

The total power requirement for proposed project will be 9 MW, which will be

sourced from own 40 MW ( 2X20 MW), cogeneration power plant.

(c) Steam Requirement

Steam requirement is 149.74 TPH, which will be sourced from proposed Boilers (100

TPH X 2 nos).

TABLE 4

STEAM REQUIREMENT FOR GRAIN BASED DISTILLERY

S. No. Purpose Steam Requirement (TPH)

1. Cooking & Liquefaction 15.79

2. Multi-pressure Distillation 65.20

3. Evaporation (Integrated) 6.25

4. DWGS Drier (DDGS) 52.08

5. Boiler Deaeration 10.41

Total 149.74

Boiler Details

Two Boilers of 100 TPH capacity each with ESP as APCE is sufficient to meet the

requirements. Others details regarding this are mentioned in the table given below:

TABLE – 5

BOILER DETAILS

S.

No.

Details

1. Type of Fuel Coal , Rice Husk , Pet Coke , Bio Mass,

Natural Gas etc

2. Capacity of Boiler 100 TPH X 2 NOS

3. Stack Height 63 MTS

4. Pollution Control

Equipment Measures

ESP

Details regarding the D.G. Sets

3 D.G. sets of 1000 KVA will be installed for the power backup. Details regarding the D.G.

Sets are mentioned in the table given below:






TABLE – 6

DETAILS REGARDING THE D.G.SETS

S. No. Details

1. Type of Fuel HSD

2. Capacity 3 X 1000 KVA

3. Stack Height (above roof level) As per CPCB/SPCB norms

4. Pollution Control Equipment Measures Adequate stack height/ Acoustic

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

management/disposal

o The proposed project is based on “ZERO EFFLUENT DISCHARGE”.

o Grain Slops (Spent Wash) will be taken through Centrifuge Decanters for separation

of Suspended Solids separated as Wet Cake.

o Thin Slops from the Decanter Centrifuge 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 mixed with the Wet Cake coming out

of Decanter Centrifuge and forms part of Cattle Feed. (Also known as Distillers Wet

Grain Solubles - Collectively known as DWGS).

o DWGS is taken to a dryer operating on steam and is dried to make it DDGS –

Distillers Dried Grain Solubles.

o The process condensate is cooled and collected into a neutralization tank with

sufficient residence time. After Neutralization, this process condensate will be

recycled into process and is used for green belt development within the complex.

o Two streams of low BOD lees (White Effluent) comes out is partly used as

fermenter washing and then sent for Cooling, treatment and utilized for RS

dilution. The second part requires only cooling and can be used as Cooling Tower

water makes up directly.

o 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.

o Ash from the Boiler will be sold to Brick manufacturers.

o Yeast sludge will be sent to the Sludge Drying Beds or may be added to the Wet

Cake.

o Used oil & grease generated from plant machinery / Gear boxes & D.G. Set will be

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

partly will be sold to the CPCB authorized recycler.






4.0 SITE ANALYSIS

(i) Connectivity

The project site is well connected to National Highway NH-15 (~1.0 km in West

direction). The nearest railway station is Talwandi Bhai Railway Station (~ 7 km in

SSW direction) and nearest airport is Sri Guru Ram Dass Jee International Airport,

Amritsar (~ 88 km in North 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 project site.

(ii) Land from Land use and Land ownership

Total land requirement for the proposed project is 14.8 ha (36.5 acres) and has been

completely acquired by Malbros International Pvt. Ltd.

(iii) Topography

Topography of the core zone for the proposed project is almost flat.

(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 – 7

Environmental Settings of the Area

S. NO.

PARTICULARS DETAILS

(with approximate aerial distance & direction from project site)

1. Nearest Village Ratol Rohi (~1 km in West Direction)

2. Nearest Town/City Zira (~6 km in NNE direction)

3. Nearest National Highway / State Highway

NH-15 (~1 km in West Direction)

4. Nearest Railway station Talwandi Bhai Railway Station (~ 7km in SSW direction)

5. Nearest Airport Sri Guru Ram Dass Jee International Airport, Amritsar (~ 88 km in NNW direction)

6. Archaeological important site None within 10 km radius

7. National Parks, Wild Life Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors etc. within 10 km radius

No National Parks, Wild Life Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors etc. lies within 10 km radius of the project site.

8. Reserved Forests (RF) / No Reserved Forests (RF) / Protected Forests (PF) etc. lies






Protected Forests (PF) etc. within 10 Km. radius

within 10 Km. radius of the project site.

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

No river lies in 10 km radius of the project site.

10 Soil Type Sierozem & Desert soil

11 Seismic Zone Seismic Zone - III as per IS: 1893 (Part-I): 2002.

(v) Existing Infrastructure

Proposed project is new project. There are no existing infrastructures.

(vi) Soil classification

The soil is of Sierozem & Desert soil type.

(vii) Climatic data from secondary sources

The climate of the district can be classified as tropical desert, arid and hot. The area

receives about 389 mm annual normal rainfalls which is unevenly distributed over

the area in 23 days, out of which about 79% occurs during south west monsoon.

Rain fall in the district decreases from north east to south west.

(viii) Social Infrastructure available

There are primary schools, dispensaries, small hospitals, places of worship in nearby area

of the project site.

5.0 PLANNING BRIEF

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

country Planning/ Development authority classification.

The project is installation of ethanol/RS Industrial/ENA unit within existing distillery.

Facilities required for the proposed project will be provided as per requirement.

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

network and cement concrete road will be developed within the proposed project

area.

(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

Total area required for the proposed project will be 14.8 ha (36.5 acres), out of

which ~33 % of the total project area will be covered under green belt & plantation

in order to reduce noise pollution levels & to increase aesthetic beauty of the area.






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

The Company will assess the demand of infrastructure (Physical & Social) in nearby

area of the proposed site and will be developed in under corporate social

responsibilities programs

(v) Amenities/Facilities

The Company will develop the Amenities/Facilities in nearby area of the proposed

project site as per requirement of local people of the nearby area under corporate

social responsibilities programs.

6.0 PROPOSED INFRASTRUCTURE

(i) Industrial Area (Processing Area)

Approx. 14.8 ha (36.5 acres) areas will be required for proposed unit.

(ii) Residential area (Non Processing area)

Residential colony is not proposed for the project. The local labor will be preferred to

provide employment opportunities.

(iii) Green Belt

Out of the total project area i.e. 14.8 ha, 4.9 ha (~33 % of the total plant area) will be

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

& to increase aesthetic beauty of the area.

(iv) Social Infrastructure

Proposed project 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 proposed project is well connected with Rail and Road.

(vi) Drinking Water

32 m3/day of water will be required for drinking & domestic purpose in the

proposed project which will be sourced from Canal Water.

(vii) Sewerage System

The waste water generated from the sanitary blocks will be disposed off in soak

pit/STP.

(viii) Industrial Waste management

The proposed unit would be based on “ZERO DISCHARGE”.






(ix) Solid Waste 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 will be sold to Brick manufacturers.

� Yeast sludge 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 for the proposed project will be 9.0 MW, which will be

sourced from Co generation power plant of 40 MW (2X 20 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.

Any rehabilitation and resettlement plan is not applicable in this case since there is no

habitation on the proposed site location.

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 project will start only after obtaining Environmental Clearance and all other

required clearance and will complete after two years of commencement.

(ii) Estimated project cost

� Total cost of the Project: Rs. 583 Crores

� Cost for Environment Protection Measues:

� Capital Cost: Rs. 58 Crores

� Recurring Cost/annum: Rs. 10 Crores/ 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.

The project activity and the management will support local administration and provide

other form of assistance for the development of public amenities in the region. Plantation

will be developed in and around the project area. The project will help in improving the

overall status of the area.

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