1.0 EXECUTIVE SUMMARYenvironmentclearance.nic.in/writereaddata/... · The Distillery unit has...

M/S. KARTHIK AGRO IND PVT LTD., PRE-FEASIBILITY REPORT MOLASSES /GRAIN BASED DISTILLERY PLANT DISTILLERY

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1.0 EXECUTIVE SUMMARY

1.0 INTRODUCTION

M/s. Karthik Agro Ind Pvt Ltd., has proposed to expand its Molasses /Grain Based Distillery Plant

from 65 KLPD to 80 KLPD in its existing Distillery Plant at Sy. No. 92,93,94, Hoolageri Village,

Badami Taluk, Bagalkot District, Karnataka State.

As per EIA Notification dated 14th September 2006 as amended from time to time; the project

falls in Category ‘A’, Project or Activity - 5(g) Molasses based distilleries.

The Company is operating distillery for manufacture of Superfine Extra Neutral Alcohol (ENA)

and Fuel Ethanol in this location. They have created facility for using grains and molasses as raw

material. The unit has started its operation during the year 2009.

Molasses /Grain is used as a raw material which is easily available from the local market.

The unit has 40 Acres of land in the name of “Karthik Agro Industries Pvt. Ltd., Hoolageri,

Badami Taluk, Bagalkot District.

The project details are stated in below table 1.0.

TABLE 1.0:- PROJECT DETAILS

S.NO. PARTICULARS Details

1 Nature & Size of

the Project

Molasses /Grain Distillery Plant with 65 KLPD Capacity now proposed to expand to 80 KLPD.

2 Category of the

Project As per EIA Notification dated 14

th September 2006 as amended

from time to time; the project falls in Category ‘A’, Project or

Activity - 5(g)(i) Molasses based distilleries.

3 Location of the proposed project / address (complete with survey nos.)

M/s Karthik Agro Industries Pvt. Ltd, Sy. Nos. 89, 92, 93, 94,96 of Hoolgeri Village & Sy No. 9 of

Kerkalmatti Village, Badami Taluk, Bagalkot District, Karnataka

State.


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4 Size of the industry (Small Scale / Large Scale….industrial unit?)

Large Scale

5 Total plot area 40 acres

6 Total project cost in crores

Total cost of the Existing Project: Rs.80.62 Crores and after

expansion the total project cost is Rs. 80.94 crores.

7 No. of employees 150

8 Latitude 16° 8'28.49"N

9 Longitude 75°35'38.70"E

10 MSL in m 575

11 Greenbelt/Plantation

14 acres

12 Cost for Environment Management Plan

40 Lakhs

13 Water Requirement in KLD

The total fresh water requirement for molasses based process is 1076 & Grain based process is 878 KLD

14 Power Requirement in KVA

500 from HESCOM during emergency and 1.4 MW for Home load from captive plant.

1.1 ENVIRONMENTAL MANAGEMENT PLAN( EMP)

Particulars DETAILS

Air Quality Management

Possible Sources Existing Boilers, 16 TPH 1 No. and Co-generation Power Plant,

Transportation Vehicles, D.G. Sets etc.

Emissions and Existing

Control measures

➢ Oxides of Sulphur, Nitrogen and Particulate matter

➢ Adequate boiler stack height is maintained.

➢ Existing DG Set (500 KVA) also have adequate stack of height as

per CPCB Guidelines.

➢ Adequate measures for Fugitive Dust Emissions are being taken.

➢ All the internal roads are asphalted.

➢ Existing Green Belt (14 Acres) developed around the periphery &

internal areas within the premises of the plant will help in

attenuating the pollutants emitted by the plant.


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Monitoring Ambient air quality and stack emissions are being monitored

regularly to ensure that ambient air quality standards are met

Water Management

Management ➢ The project is based on “Zero Effluent Discharge”.(ZLD)

➢ Fresh water requirement of the project is being met by

Ghataprabha River.

➢ Water & recycled water. Efforts are being 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 is being maintained

➢ Spent lees generation from distillation column is being recycled

partly to the columns for dilution and balance is being used for

cooling tower makeup.

➢ Domestic waste water generated from the plant is being treated

in Septic Tank and Soak pit.

➢ Effluent Treatment Plant (ETP) has been installed and treated

water from ETP is being recycled back to the process and

remaining is being used for green belt development.

Noise Management

Management ➢ Proper maintenance, oiling and greasing of machines at regular

intervals is adopted

➢ PPEs like ear plugs and ear muffs to the workers exposed to high

noise level.

➢ Development of Green Belt for 35% of the total project area.

➢ Regular monitoring of noise level.

➢ D.G set is provided with acoustic enclosures to control the noise

level within the prescribed limit.

Monitoring

➢ Regular monitoring of noise levels is being carried out and

corrective measures in concerned machinery is adapted

accordingly as and when required.

Solid Waste Management

Management ➢ Solid waste from the Grain/Molasses based operations generally

comprises of Fibers and proteins in the form of DDGS (Distillers

Dried Grain Soluble), which is being ideally used as Cattle Feed.


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➢ Ash from the Boiler is being sold to Bricks manufacturers.

➢ Used oil & grease generated from plant machinery/Gear boxes

are hazardous wastes is being used as lubricant for chains /

conveyer belts within premises.

Green belt Development/ Plantation

Management ➢ 35% of total project area has been developed under green

belt/plantation with diverse species.

➢ All the barren areas are vegetated.

➢ Native plant species is 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 is the primarily controlled at source by good operational

practices, including physical management control measures.

➢ Better housekeeping is being maintained with good hygiene

condition by regular steaming of all fermentation equipment.


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2.0 INTRODUCTION

2.0 INTRODUCTION OF THE PROJECT/BACK GROUND INFORMATION




IDENTIFICATION OF PROJECT AND PROJECT PROPONENT

Karthik Agro Industries Pvt, Ltd. (KAIPL) is located at Hoolageri village in Badami Taluk, Bagalkot

District. It is registered under Company’s Act 1956 vide Registration No.

U15323KA2007PTC041485, during 2006-07. The Department of Excise, Government of

Karnataka has issued latest Distillery License number - ECD/05/REV/Bagalkot/2015-16, Date

24.6.2015.

The Company has set up a distillery for manufacture of Superfine Extra Neutral Alcohol (ENA)

and Fuel Ethanol in this location. They have created facility for using grains and molasses as raw

material. At present only molasses is used as raw material for distillery operation. The unit has

stated operation during the year 2009.

The Distillery unit has Multi-pressure vacuum distillation technology. It has obtained necessary

statutory clearances and approvals from the Government departments.

2.1 BRIEF DESCRIPTION OF NATURE OF THE PROJECT

M/s. Karthik Agro Ind Pvt Ltd., is proposed to expanding the Molasses /Grain Based Distillery

Plant from 65 KLPD to 80 KLPD in Existing Distillery Plant at Sy. No. 92,93,94, Hoolageri Village,


1. Expansion of Molasses /Grain Based Distillery Plant capacity. : - Molasses /Grain Based

Distillery Plant from 65 KLPD to 80 KLPD in Existing Distillery Plant.

2. Change of fermentation process: - Continuously fermentation process to Fed Batch

fermentation process.


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2.1.1 Brief description of Fed Batch Process

1. The Fermentation plant consists of 9 fermenters operating independently and also

convertible as series by connecting them for continuous operation. The fermenters are

connected with accessories like, plate heat exchanger for cooling, air spargers, broth mixer

and air blower etc. Each has capacity to produce 235 m3/hour (705 m3/day) fermented wash

with 11% v/v alcohol to feed 80 KLPD distillery plant. The fermentation section has 9

fermenters of 210 m3 working volume capacity each. So, 3 fermenters are used as one batch

and another 3 fermenters for subsequent use. So there are 3 spare fermenters as stand by or

for grain based fermentation process. The fresh yeast culture is used every time to improve

fermentation process yield to achieve 11% v/v alcohol instead of 8% v/v alcohol in normal

fermentation process. Due to higher percentage of alcohol in the fermented wash, the yeast

from these fermenters cannot be used.

2. Fed Batch fermentation process is used for fermentation process, where 11% v/v alcohol

concentration in fermented wash is achieved and fresh yeast is used for every batch. It has 3 extra

fermenters, they can increase capacity by 30% to the existing.

3. Yield and quality of product are of high standard.

2.1.2 Major difference b/w continuous & Fed batch Fermentation process

Sl.

no.

Description Continuous Fed batch

1 Alcohol yield in

%

8 % 11 %

2 Yeast generation Less More

3 Spent wash Based on Molasses

: 728 KLD

Based on Grain

:699 KLD

Based on molasses 530

KLD

Based on Grain :694

KLD

4 Spent lees &

Condensate

Based on Molasses:

660 KLD

Based on Molasses : 668

KLD

Note: Continuous Process spent wash generation is 612 KLD by considering

116 m3/Day Recycle. If process disturbs due to molasses quality variation that

time spent wash generation will be 728 KLD.


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2.1.3 Distillation plant:

Fermented wash with about 11% v/v Ethanol is preheated in two stages-in the beer heater using the

rectifier vapours and then in the fermented wash PHE using spent wash. The preheated wash is then

fed to the degasifying column to remove residual CO2 and volatile matters. The wash then flows to

analyzer column, which acts as a stripper. The Ethanol vapours are concentrated in the Rectifier

Column to produce Ethanol Alcohol of 95 % V/V strength. A trace stream of spirit is drawn off as

impure spirit (IS) (about 2 % of plant capacity) to remove the concentrated volatile compounds. The

high-grade Ethanol (95 % v/v) is taken as a draw from the upper trays of the rectifier column. Some of

the aldehydes are also removed. Then it passes down twentieth plates in the wash column. Steam is

introduced into the base of this column through re-boiler and on passing up the column; it strips of all

the Ethanol from the wash. The spent wash is discharged from the bottom of the wash column.

Ethanol vapours of the twentieth plate in the column passes into the base of the rectifying column and

vapours passing up the column, is rectified under the action of reflux. An appropriate small fraction of

the condensate from the final condenser is tapped off for heads separation. The final product is

tapped from one or two plates below the top most plate of the column to the product receiver. This

condensate is diluted with the requisite amount of process water in the dilution bottle and re-distilled

in the heads column. By this method the aldehyde can be separated from Ethanol.

To produce ENA, 95% rectified spirit diluted with soft water to reduce alcohol to 35% and same is fed

to the de-hydration column through re- boiler applying the steam, liquid starts to boiling, then these

vapours enter to bottom of the rectification column and apply the steam through re- boiler of the

column, then vapours condensed in the condenser and liquid fed to the refining column to get super

fine quality of ENA. Arrangements made for the removal of "Fusel oil and Light oils" from appropriate

points in the rectifying column, which are cooled, washed and decanted (fusel oil only) in the fusel oil

decanter and taken to the receiver.

2.1.4 General difference between continuously fermented processes to Fed Batch

fermented process.

Batch process The molasses obtained from the sugar industry is first diluted to bring down the concentration of sugar from 40- 45% to 18 - 19%. Using a portion of the diluted molasses a yeast culture is developed from an inoculums. After 4-6 hours, when the culture has developed fully, the remaining molasses is mixed and allowed to ferment for 30 hours. The pH is maintained around


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4-4.5 by addition of sulphuric acid. As the reaction is exothermic, the contents of the fermentation tank are kept at 32-330C circulating through plate heat exchanger. After fermentation is complete the yeast sludge is removed from the bottom and the fermenter wash is pumped to the analyser column for distillation using steam. The mixture of alcohol vapours and steam is collected at the top of the column and alcohol free spent wash is discharged from the bottom. The alcohol and the steam stream are fed to rectification column where water and alcohol vapours condense at different levels and rectified spirit is withdrawn. The bottom water from this stage is called spent lees.

Continuous Process In this process yeast is recycled. Fermentation and distillation is coupled to get a continuous supply of fermented mass for the distillation column. The advantage of the process is that a highly active yeast cell initiates the fermentation rapidly but process disturb if quality of molasses is not good. Bio-still process is one of the continuous processes, which is a trade name in which molasses is fed to the fermenter at a constant flow rate. The flow rate of molasses is controlled to maintain the sugar and alcohol concentrations in the wash at 0.2% or lower and 6-7% respectively. The waste streams comprise spent wash which is the main source of wastewater, spent lees and yeast sludge. Spent lees are usually mixed with the spent wash. The yeast sludge is disposed separately after drying. In addition wastewater may be generated from the bottling, fermentation tank cooling and washing and utility sections of the plant, which is used as a diluents for the treated spent wash.

2.15 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.


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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 green house 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.

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

another milestone.

2.2 DEMAND- SUPPLY GAP&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 are requiring producing the more alcohol to meet the

demand.

2.3 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 days. After setup of this type of alcohol

industries government can collect more revenue.


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(i) 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.

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

Direct and indirect employment is being generated due to the proposed project. The total

man power requirement for the proposed project is 150 persons (inclusive of on roll

employees and on contract employees).


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3.0 PROJECT DESCRIPTION

3.0 LOCATION OF THE PROJECT SITE




The project location map & Google maps is shown below fig 1.0 & 2.0 and project site plan

is shown in fig 3.0

3.1 LAND & BUILDING REQUIREMENT

The plant is existing in an area of 40 Acres at the existing facility of Karthik Agro Industries

Pvt. Ltd., at Hoolageri village, Kerakalmatti Village, Badami Taluk, Bagalkot district,

Karnataka.


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FIG 1.0 LOCATION MAP


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FIGURE 2: GOOGLE MAP

PROJECT SITE


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FIGURE 2.1: GOOGLE MAP OF 10 KM RADIUS OF THE PROPOSEDP

ROJECT SITE

M/S. KARTHIK AGRO IND PVT LTD.,PRE-FEASIBILITY REPORT MOLASSES /GRAIN BASED DISTILLERYPLANT DISTILLERY

- 15–

FIGURE 3: PROJECT SITE PLAN


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3.3 FUEL REQUIREMENT

The unit has sanctioned 500 KVA power connection vide letter no. CEIG/EI- 3/18059-62, date

03.09.2009 and connected 500 KVA power by Electrical Inspectorate, Government of

Karnataka. The unit has 500 KVA transformer. The contract demand connected load is 80 KVA

and 250 KVA transformer for lifting water from Ghataprabha river, which is 12 kms away from

the factory site.

It has 500 KVA silent DG set for augmenting power cuts. For distillery operation, the co-gen

power plant of 1.4 MW is installed. The power plant operates throughout the year, since the

distillery operates continuously throughout the year. The generated power from co-gen plant

is being fully utilized for captive purpose (distillery operation).

The power requirement is 300 kWh for fermentation & distillation, 250 kWh for evaporation,

75 kWh for fuel ethanol, 100 kWh for bio methanation and 175 kWh for cooling tower. Total

power requirement for the operation of distillery and associated activities is 900 kWh.

3.4 MANPOWER REQUIREMENT

At present 150 people are working in the industry and are sufficient for proposed project.

3.5 RAW MATERIAL DETAILS

Grains & Molasses is the main raw materials. A detail of the raw material used in the plant is stated in below table. 2.0


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Table 2.0:- Details of the Raw Material

Sl No Particulars Quantity in MT/Month

EXISTING

1 Molasses 7300

2 Bagasse 4200

3 Defoamer 5.0

4 SMBS(Sodium Meta Bi Sulphate)

1.0

5 Urea 1.5

6 DAP 1.0

PROPOSED

1 Molasses 9000

2 Bagasse 4500

3 Defoamer 5.5

4 SMBS 1.0

5 Urea 1.5

6 DAP 1.0

3.6 MACHINERY AND EQUIPMENT DETAILS

3.6.1 MECHANICAL DESIGN BASIS

i. Design of fermenters, pre-heaters etc.

a) Wind pressure:150kg/m2

b) Seismic factor: 0.04 (IS 1893 Page16)

ii. Static equipment-SS fermenter designed as per API650

iii. All structures supported laterally to the structural members and no direct

load due to wind and seismic forces have been considered. All tanks like

fermenters, beer well, etc. supported /rested using civil foundation.

iv. Specifications of the material of construction for the equipment as per

generally ASTM 240 SS sheets and coils. Material of construction for copper

column trays, body flanges for columns and condensers of KBK standards.


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v. The material of construction of all the body flanges and bolts-CS and gaskets

of KBK standards.

vi. All pressure vessels-distillation columns, condensate pots, etc. designed as

per ASME Sec. VIII Div. I.

vii. All shell and tube type of heat exchangers designed as per TEMAC.

viii. The baffle thickness in case of the above heat exchanger is restricted to3mm.

viii. Hydro Testing of critical equipment carried out before dispatch.

ix. Piping and valve specifications as per ANSI standards. Pipes-CS ANSI B36.19

and SS 304 ANSI B36.19

x. Valves

xi. Flanges-ANSI B 16.5 150# and Stub End- MSSP 43Type

xii. Instrumentation specification as per ISA & KBK standards.


- 19–

3.6.2 BOUGHT OUT MAKE AND DESIGNS DESIGN CODES FOR

EQUIPMENT:

i. Pressure vessels and distillation columns-ASME

ii. Storage tanks-API

iii. Heat exchangers-TEMA

iv. Piping and valves-DIN/JIS

v. Instruments-ISA

Sl. No. Valve Design code

End connection Testing

Miscellaneous

1 Ball BS 5351 Rating- 150 #

Flange ANSI B 16.5, 150#

BS-5146

Port- Regular

2 Globe BS 5352/18731 Rating 150#

-

3

Gate

API 600, 602, 603,

604 & BS 1414 Rating 150#

ANSI B 16.5, 150#

API 598

-

4

Butter- fly

Mfg std. BS 5155/ API 609

Testing std. BS 5155/ API

598

Rating-PN 10

-


- 20–

3.6.3 MAKE OF BOUGHTOUT EQUIPMENT MANUFACTURERS’ BRAND:

1) Mixer: GMM Flogger/Jangia/Lightner

2) Gear pump: Tushaco /Johnson

3) Molasses feed: Tushaco/Johnson

4) Ultra filter: Millefare/Piarted

5) Centrifugal pump: Kirloskar/Johnson/Microfinish/Kishor

6) Blower: Kay Iran/PPI/VindiVac

7) PHE: Alfa Laval/Tranter

8) Separator: Alfa Laval/GGL/GEA

9) Decanter centrifuge: Alfa Laval/GEA/Humboldt/Hiller

10) Motor: Bharat Bijlee/Astom/CromptonGreaves

11) DCS: Siemens/Honeywell/Yokogawa/ABB

12) Flow meter:E&H/Emersion

13) Magnetic: Rosemount/E&H

14) PG: Wika

15) Rotometer: IE/Eureka

16) Solenoid valve: Avcon/Rolex

17) Steam fluids: Emerson

18) TG:Wika

19) DPT:E&H/Simens

20) IP Converter: ABB

21) Actuated valve: Tyco/Delvel

22) RDPS: Spirex Marshall

23) PRS: Spirex Marshall

24) Control valve: Samson:

25) Electrical cable: Polycab

26) CT: Paharpur

M/S. KARTHIK AGRO IND PVT LTD., PRE-FEASIBILITY REPORT MOLASSES /GRAIN BASED DISTILLERYPLANT DISTILLERY

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27) Vacuum pump: PPI/VINDI/ROOTS

28) Air compressors: Atlas Copco

29) Air drier: DryTech

30) Load cell: Nova

31) Butterfly valve: Crane/Delval/Intervalve

32) Gate valve: Audco/BDK

33) On-off valves: Tuco/TFB

3.6.4 EQUIPMENT

Sl. No.

Equipment Capacity Quantity No.

Head MWC

Material of construction

Type

1 Molasses transfer pump

20 Ton/ Hr.

1 W + 1 SB

50 Casing: CI/CS: Impeller/ Gear

Gear

2 Molasses pump with gear box (VFD Type) & motor

15 Ton/ Hr.

1 W + 1 SB

50

3 Yeast cream transfer pump

4 m3/Hr. 1 W + 1 SB

15 Casing & Impeller SS316

Centrifugal

4 Distillation feed pump

35

m3/Hr.

1 W + 1 SB

50

5 Yeast chiller pump

1 W + 1 SB

6 Yeast chiller unit

10 TR - - - -

7 Air filter - 1 - - HEPA 8 Air blowers 700 NM3/

Hr., 1.5Kg /

Cm2 (g) Pressure

2 W + 1 SB

- CI with SS internals

Water ring type Blower


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9 Nutrient tank with agitator

1m3 1 - SS304 Vertical/ cylindrical

10 Defoam tank - 1 -

11 Biocide tank - 1 - 12 Biocide pump 1 m3/Hr. 1 W + 1

SB 15 CI Metering

13 Nutrient pump - 14 Defoam pump Casing

CI/CS Gearpump

Gear


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Sl. No.


Head MWC Material of construction

Type

15 CIP solution pump

35

m3/Hr.

2 50 - -

16 Air compressor with air drier & receiver

- 1 W + 1 SB

- - -

17 Biocultural development section consisting of series of vessels with increasing volume

5 - SS304 Vertical/ cylindrical

Vessel-I 12 Litr. Glass cylinder

Vessel-II 0.08, 0.8, 4 m3

Vessel-III 25 m3 x 2 no. (MS Epoxy)

Vessel-IV Thickness 4 mm for all vessels with temp. & level controller, automatic pH monitoring system, ratio controller, etc. Vessel-V& VI

with PHE for cooling

18 Continuous mixed bio- reactors -

9 SS304 Vertical/ cylindrical

19 Top mounted agitators (25 RPM speed)- All fermenters with level controller, automatic, temp., pH monitoring system

275 m3, Bottom Plate-4 mm, shell4 mm each, roof 3 mm with MS

stiffeners as per design


- 24–

Sl. No.

Equipment Capacity Qnt. in No.

Head MWC Material of construction

Type

20 Buffer tank-API 120 m3 Bottom plate-8

mm, shell-

6,5,4,4,3 mm each, roof-4 mm

with stiffeners

1 MS Epoxy coated

Vertical/ cylindrical

21 Continuous molasses broth mixer

- 7 SS304 Static

22 Fermented mash coolers- plate heat exchangers

- 5 - SS316 plate & EDPM gasket with 10% spare

PHE

23 Fermented wash recirculation pump

300/250/ 200

5+1 15 Casing & impeller SS316

Centrifugal

24 Air sparing assembly for bio culture vessel & fermenters

-

7 sets SS304 Suitable for each

equipment

25 Continuous stabilizer tank

90 m3, Thickness-bottom- 8mm, shell- 6,5 &4 mm, roof-4 mm, load cell

1 - MS Epoxy coating

Cylindrical/ vertical


- 25–

26 Acid tank 11 m3 1 - Carbon steel

27 Acid pump 1 m3/Hr. 1W+1SB

15 Metering pump Alloy-20

28 Alcohol vapour recovery column

Dia. 1200 mm, No. of tras-6, 200

mm tray spacing,3 mmi thick

2 - SS304 -


- 26–

Sl. No.



Type

29 Molasses weighing

system with weighed

molasses tank

Thickness- bottom

plate- 5 mm, shell-

5,4,4 mm, roof-4 mm, load cell-API

1 Load cell type weighing

system with

scale (30 m3

weighed molasses receiving

tank)

Nova

30 Process molasses mass

flow meter

5 Suitable for 65KL

fermentation

31 Water header 1 KBK Standard material

32 Air header 1 KBK Standard MS material

33 CO2 Header 1 KBK Standard SS material

Sl.

No.

Equipment Capacity Qty. No. Specification Material of

construction Type

34 Safety system for

fermenter 5 Dia 250 mm,

Ht.300 mm

SS 304 Cylindri

cal/

vertical 35 CIP solution tank Volume

10 m3

3 -

Piping & valve

instrumentation-

- Lot - - -


- 27–

3.6.5 DISTILLATION AND INTEGRATED EVAPORATION

3.6.5.1 COLUMNS

Sl. No.

Column Details Qty. No.

Tray Column Material of

construct ion

Type No. Spacing

mm Shell mm Dia mm

1 Primary & degasser 1 Hot insulated

20/6 750 5/4 2150/ 1150

SS 304 Grid cap / sieve 2 Pre-rectifier

cum exhaust 50/14 300 4 2300/1 Babbl

e cap 3 Aldehyde 45 200 4 950 4 Rectifier cum

exhaust- top 42 trays in copper

75 5 1850

5 Hydro extractive distillation

50 250 3 1500

6 Defusel 50 930

7 Refining 50 200 4 1080 Copper

3.6.5.2 REBOILERS

Sl. no.

Reboiler Details Qty. No. HTA m2 Material of construction

Type

1 Primary column 2 200 SS 304 Shell & tube 2 Pre-rectifier 1 150

3 Hydro extractive column 1 40

4 Defusel column 1 50

5 Refining column 1 90

6 Rectifier 1 350

7 Aldehyde 1 30


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3.6.5.3 CONDENSERS

Sl. No.

Condenser Details Qty. No. HTA m2 Material of construction

Type

1 Rectifier vent 2 10 SS 304 Shell & tube 2 Aldehyde column 1 25 3 Pre-rectifier 1 150 & 24 4 Hydrovent 1 15 5 Refining 1 60 6 Defusel vent 1 5+50

3.6.6 OTHER EQUIPMENT

Sl. No.

Condenser Details Qty. No.

Capacity HTA

m2 Material of constructio

n

Type

1 Rectifier Column bottom PHE

1+1 - - SS 316 plate with

EPDM gaskets

Plate

2 Mash pre-heater(W>H) 1 - 85 SS 304 Shell & tube 3 Main product coolers 2 - 25 4 Impure spirit coolers 2 - 3

5 Fusel cooler 4 - 1 6 Fusel separators 2 - - Vertical/

cylindrical 7 Gas liquid separators 2 - - Cylindrical 8 Reflux and process tank 7 - - SS 304 9 Condensate tank 1 - - MS 10 Water & steam header 3 - Carbon steel 11 Mash pre-heater using

spentwash 1+1 - - SS 316

Plate with EPDM gasket

-Plate

12 Pumps 10+10 - - SS 316 casing & impeller

-

13 Vacuum pump 1+1 740

Nm3

- SS internals Water ring type

14 Vent scrubber 1 - - SS 304 Column

15 Overhead water tank 1 40 m3 - MS Rectangle

16 Decanter centrifuge with accessories

1 3

m3/Hr.

- - -


- 29–

Sl. No.

Condenser Details Qty. No.

Capacity HTA

m2 Material of

construction

Type

17 DCS with two set and 100% redundant

- - -

18 Air compressor-Atlas make

2 94.5 cfm.

- -

19 Integrated evaporators, vapour liquid separators &pumps

3 each

- 150

m2 SS 304, shell & tube thickness- 4 mm

Falling film & forced recirculation

20 Water treatment plant for filtered water, soft water, and DM Water

21 Fire fighting system including fire hydrants and fire extinguishers

22 Piping and valve electrical and instruments

23 Laboratory equipment

3.6.7 ANHYDROUS ALCOHOL SECTION

Sl. No.

Details Qty. No.

Capacity Head Material of construction

Type

1 Feed pump 1+1 9 m3/Hr. 60 m of alcohol column

SS Internals Centrifuge

2 Feed preheater 1 36 m2 area - SS 304 Shell & tube

3 Recovery column 1 SS 304 with hot insulation, Dia.- 1350 mm, trays-45 no., Shell-3 mm, tray-2,5mm

Bubble cap tray

4 Recovery re-boiler 1 30 m2 area - SS 304, shell-4 mm Shell & tube 5 Super heater 1 25 m2 area -

6 Molecular sieve drum 2 10 m2 vessel - Vertical/ cylindrical 7 Molecular sieve

condenser 1 36 m2 area Shell &

tube

8 Product cooler 1 100 m2 area SS 304, shell-3 mm

9 Weak alcohol condenser

1 5 m2 area

10 Weak alcohol tank 1 2 m2 SS 304 Vertical/

cylindrical 11 Vacuum drum 1 1 m3

12 Weak alcohol 1+1 100 m3/Hr. 60 SS Internals Centrifuge


- 30–

Sl. No.

Details Qty. No.

Capacity Head Material of construction

Type

recirculation pump MWC 13 Product pump 1+1 6 m3/Hr. 25

MWC 14 Vacuum pump 1+1 250 m3/Hr.

Vacuum-635 mm Hg

Water ring

15 Weak alcohol recirculation cooler

1 35 m2 area - SS 304, Shell-3 mm

Shell & tube

16 Molecular sieve support balls with sieve-3A type/ Zeochem ceramic balls-12 & 25 mm, 12 tones total

17 Piping and valve, electrical & instruments

3.6.8 BIOMETHANATION SECTION

3.6.9 EQUIPMENT

Sl. No.

Treatment unit

Volume/ Area

MOC

Mechanical equipment

1 Buffer tank 500 m3 RCC lined lagoon Digester feed pump

2 Thermo phillicigester

Dia.-28 m, SWD-9 m FB-1m

MS CR painted inside

-

3 Flare stack Overall Ht.9 m, Dia,-1 m Level indicator, PG

4 Degasser Overall Ht.10 m, Dia,-3 m

-

6 Gas holder Overall Ht.4 m Dia,-8.5 m

Biogas blower

7 Gas washer tank Height. 4 m Dia,-2.3 m

-

5 Lemella clarifier 200 m2 Surface area MS CR painted inside provided with FRP packs

Sludge recirculation pump


- 31–

3.6.9.1 CRITICAL EQUIPMENT

Sl. No.

Equipment description Quantity

1 Lamella clarifier packs 1 no.

2 Gas compression and distribution system1 1 lot

3 Feed distribution system 1 lot

4 Sludge distribution system 1 lot

3.6.9.2 NON CRITICAL EQUIPMENT

Sl. No.

Equipment Details Qty. no.

1 Raw spent wash feed pump

Horizontal centrifugal pump of 30 m3/hr. discharge & 15 m head, semi open impeller. SS 304 material, coupled with 2,900 RPM, 5HP, 3 Phase squirrel cage indication typemotor

1+1

2 Digester recirculation pump

Horizontal centrifugal pump of 40 m3/hr.discharge & 12 m head, semi open impeller. SS 304 material, coupled with 2,900 RPM, 5HP, 3 Phase squirrel cage indication type motor

1+1

3 Sludge recirculation pump

Horizontal centrifugal pump of 20 m3/hr.discharge & 25 m head, semi open impeller. SS 304 material, coupled with 2,900 RPM, 5HP, 3 Phase squirrel cage indication type motor

1+1

4 Liquid flow meter

Electromagnetic flow meter- flow range 0-25 m3.hr, SS316 material 2” lane size

1

5 Gas flow meter Vertex type to measure instantaneous and integrated flow meter

1

6 Pressure gauge for liquid pressure measurement

Bourdon type pressure gauge with 0.5”NPT connection,

pressure rating 0-5 kg/cm2, 4“ dial size

Lot

7 Pressure gauge for gas pressure measurement

Diaphragm type pressure gauge with 0.5”NPT connection, pressure rating 0-700mmcwg, 4“ dial size

Lot

8 Temperature gauge for panel indication

Dia type with 0-1000C range 2


- 32–

Sl. No.

Equipment Details Qty. no.

9 Manometer for measurement of gas pressure in digester

U tube type encased in wooden casing with range 0-750mm

12

10 Biogas blower Rotary twin lobe type, compressor with biogas flow rate of 700 m3/hr. and pressure rating 3,500 mm wcg, provided with safety valve, non return valve, coupled with 25 HP flame proof motor

1+1

11 Pressure switches for high & low pressure indication & Blower operation 2

12 Flame arrester SS ,biogas flow 700 m3/hr, flanged connection 3

13 Breather valve 200/100 mm dia, dead weight type, pressure setting 500 mm wcg& vacuum setting70 mm wcg

1

14 Level indicator Glass tube with range of 0-1000 mm wcg to measure the water seal in flame stack

1

15 Limit switches Top actuate an audio alarm for high level of gas in holder & to trip the biogas blower for low level of gas holder to arrest the biogas blower at operating level gas holder

2

1. Evaporation section up to 60% Brix

Sl. No.

Details Qty. No.

Capacity Head

m2


Type

1 Feed tank 1 3 m3 - SS 304 Rectangular 2 Vapour liquid

separator 5 - - Gas

liquid separator

3 Surface condenser 2 HTA 150

m2

Shell & tube 4 Product tank 1 10 m3 - Vertical/ cylindrical 5 Condensate tank 1 3 m3 -

6 Feed pump 1+1 3m3/Hr. 25 MWC SS 316- Casing & impeller

Centrifugal

7 Evaporation pump 4+1 8 Recirculation pump 4+1 9 Spent wash pump 1+1 - - 10 Condensate pump 1+1 12m3/Hr. 30 MWC

11 Evaporator 3 2+1

- HTA 150

m2 with 12 m long tubes

SS 304-Tube & shell

Falling film Forced circulation

12 Vacuum pump 1+1 Water ring 13 Pipeline & valve, Electrical & instruments


- 33–

2. Molasses & alcohol storage section

Sl. No.

Storage Tank Identification

Number

Purpose of storage

Capacity (Ltrs.)

Valid up to

1 A-I Molasses storage tanks

5,999,550 29.1.2017

2 A-II 6,000,725 19.9.2019

3 A-III Molasses day storage tanks 145,625 29.1.2017

4 1/A-III ENA Bulk storage tanks

911,690 29.1.2017

5 2/A-IV 911,885 29.1.2017

6 A-V RS<65 OP Bulk storage tank 913,201 29.1.2017

7 A-VI Denatured oil (Spirit) 30,067 29.1.2017

8 A-VII Fusel oil tank 22,302 29.1.2017

9 A-VIII TA Bulk storage tank 158,735 29.1.2017

10 1/A-IX TA receiver tanks

10,039 29.1.2017

11 2/A-X 9,833 29.1.2017

12 3/A-XI 9,763 29.1.2017

13 1/A-XII

ENA daily receiver tanks

78,139 29.1.2017

14 2/A-XIII 77,969 29.1.2017

15 1/A-XIV 78,056 29.1.2017

16 2/A-XV 77,923 29.1.2017

17 1/A-XVI Ethanol daily receiver tanks

78,251 29.1.2017

18 2/A-XVII 77,975 29.1.2017

19 1/A-XVIII ENA bulk storage tanks

905,223 29.1.2017

20 2/A-XXI 912,053 29.1.2017

21 3/A-XX 915,296 6.6.2016

PROPOSED EQUIPMENT DETAILS

1) Simmering/Refining re-boiler

2) Fusel oil column condenser

3) Modification of Analyser re-boiler vapour line.

4) Making Draw provision for Fusel oil column with flow meter arrangement.


- 34–

3.7 PRODUCTION DETAILS WITH PROCESS DESCRIPTION

The manufacture of alcohol broadly consists of following stages:

Preparation of substrate for fermentation

a. In case of Molasses based fermentation

i. Dilution of molasses

ii. Addition of nutrients and culture

b. In case of Grain based fermentation

iii. Cleaning, milling of grain

iv. Slurry preparation / liquefaction

v. Saccharification

vi. Addition of nutrients and culture

3.7.1 Molasses based fermentation

1. Fermentation of substrate containing sugar material

Separation of spent yeast and other suspended materials from fermentation product

(wash)

2. Multi-pressure Distillation with integrated spent wash evaporator

i. Distillation of clarified fermenter product (wart) in distillation columns to separate

aqueous alcohol (40 %) and spent wash

ii. Rectification of aqueous alcohol to separate rectified spirit (RS) containing 95 % alcohol

and spent lees water

iii. Dilution and rectification of rectified spirit to produce extra neutral alcohol (ENA)

iv. Clarification of spent wash


- 35–

3. Dehydration of RS to produce anhydrous or fuel grade ethanol.

Except the operations of substrate preparation all the subsequent operations of alcohol

manufacture are basically similar for any of the raw materials such as molasses, sugar juice or

grain.

3.7.2 MANUFACTURING PROCESS FOR MOLASSES BASED ETHANOL

The manufacture of ethanol through molasses consists of following operations and process. A

typical flow chart for manufacture of ethanol based on molasses is given in Figure.

i. Substrate (Feed) Preparation

Molasses stored in a storage tank is first weighed in a tank with load cells so that accurate

quantity can be fed to the fermentation section. The weighed molasses then transferred from

tank to the diluter in fermentation section where it is diluted with water and fed to the

Fermenter.

ii. Yeast Propagation and Fed Batch Fermentation

In this process the culture containing highly efficient yeast strain ( Hi firm XP ) from Praj ind

Pune is propagated in yeast culture vessel under aseptic conditions,

The ready yeast seed is then transferred from culture vessel number 4 and 5 transpered to

Fermenter. Because of fresh yeast culture and good retention time we will get average alcohol

of 11% in 30 hrretention. The glucose in media gets converted to alcohol and CO2 The gas

liberated during reaction is contaminated with traces of alcohol vapors. It is sent to CO2

scrubber for recovery of ethanol and vented to atmosphere.

After fermentation the sludge containing spent yeast is separated from the wash in a settler

cum decanter tank. Then passes through decanter and disposed as solid waste.


- 36–

iii. Multi-Pressure Distillation

The fermentation wash containing Alcohol, non-fermentable solids and water is supplied to

distillation to separate the alcohol and other impurities, as a continuous flow. The distillation

system is designed for quality ethanol. The system details are as below.

The system consists of 7 columns, namely CO2 stripper, analyzer column, Pre-rectifier column,

Extraction column, Rectification Column, Refining Column, Fusel Oil column.

Wash is fed to de-gasifier cum analyzer column. CO2 and other non-condensable gases are

removed at the de-gasifier unit. Distillate containing 40 % alcohol from analyzer column along

with additional fresh water as lees water is sent to R.S. column. RS as distillate and spent lees as

bottoms are taken out from RS column. In case of ENA production, the RS along with lees or

dilution water is sent to extraction column. Most of the high boiling impurities are removed

from top of this column and from bottom aqueous alcohol is obtained. The latter is taken to

rectification column, and from where 95 % alcohol and spent lees water are obtained as

distillate and bottoms, respectively. 95 % alcohol is further distilled in refining column to

remove low boiling impurities (mainly methanol) Extra Neutral alcohol from is sent to storage

tanks.

The impure spirit from top of RS column, extraction column, rectifier column and refining

column are taken to purification column. Impure spirit is recovered from purification column

and balance alcohol is recycled to RS column. The alcohol containing fusel oil from pre-rectifier

and rectifier column is fed to fusel oil column. The FOC column inputs are so adjusted to get 15

kl /day RS with required concentration at the top.

The top vapors from analyzer column, extraction column and fusel oil column are condensed in

evaporator for spent wash concentration. The rectifier column, fusel oil column and pre-

rectifier column get heat from fresh stream at 3.5 kg/cm2.

Rectification column works under positive pressure. The top vapors from rectifier column are


- 37–

condensed in analyzer column for giving heat to stripper re-boiler. Most of the other columns

work under vacuum.

The spent wash at approximate 15.0 % concentration from distillation is concentrated in a multi

effect evaporator to approximate 55% concentration. This concentrated spent wash will then

be burnt as fuel in the boiler to produce high pressure steam. The steam is then sent to turbine

to generate electric power for captive use. Exhaust steam from turbine is utilized in distillery

plant.

IV. Dehydration of RS to Anhydrous/fuel grade ethanol

Rectified spirit at Azeotropic concentration is pumped by a feed pump to the dehydration plant.

The rectified spirit containing 95 % alcohol and 5 % water will first pass through feed

economizer, then through a vaporizer cum super heater which will convert the rectified spirit

feed to superheated vapors. The superheated vapor will pass through a sieve column, which is

already regenerated and pressurized to working pressure. All the water vapors present in vapor

mixture are adsorbed in the column. Along with alcohol traces of alcohol are also adsorbed in

the column. The Anhydrous alcohol vapors free from water vapors exhausted from the column

are duly condensed in the re-boiler at the recovery column and is further passed through feed

economizer to preheat the incoming feed and then to a final product cooler. After saturation of

sieve column with water, the flow will be shifted to the next sieve column, which is already

regenerated and pressurized. After completion of dehydration cycle, the sieve column

saturated with water is regenerated by evacuation of adsorbed water and alcohol. The

evacuated vapors are condensed. The condensed mixture of alcohol and water is then fed to a

recovery column, which enriches the stream back to azeotropic composition. This sequence of

adsorption and regeneration of sieve column continues.


- 38–

Flow Chart for Molasses Based Ethanol

Molasses Water Yeast Sludge. Alcohol Steam Steam Condenser to boiler

Methanegas to boiler

Fehling film + forced recirculation

Fermentation

Distillation

Condensate

ETP

Send to cooling tower / plantation/irrigation

Evaporation

Biomethanisation

Concentrated Spent wash

Mixed with Bagasse & Husk

Feed to boiler as a Fuel


- 39–


- 40–

3.7.3 MANUFACTURING PROCESS FOR GRAIN BASED ALCOHOL

Substrate preparation consisting grain milling, liquefaction, saccharification and fermentation

are given below. Subsequent operations are similar to that of the process based on molasses. A

typical flow chart of grain based manufacturing scheme is shown in Figure- 4.2.

i. 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.

ii. SLURRY PREPARATION / LIQUEFACTION

Grain flour and process water is fed at controlled rate to Slurry Tank and then the mixed slurry

is taken to the Initial Liquefaction Tank where some more amount of water and enzyme

stabilizing chemicals are added. A portion of the liquefying enzyme is also added here. This

slurry is then "cooked" in the Jet Cooker. The slurry is continuously pumped to a steam jet

cooker where high-pressure steam at 7.5 bar (g) / 170 deg. C rapidly raises the slurry

temperature. The mixture of slurry and steam is then passed through the retention loop which

has several "U" bends in series and 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 further liquefied in the final liquefaction tank where liquefying enzyme (alpha-

amylase and Glycosidase) is added. This process initiates the formation of sugar. The mash is

then cooled in mash coolers and transferred to fermenters.


- 41–

iii. SACCHARIFICATION AND FERMENTATION

Yeast Activation:

Yeast seed material is prepared in Pre-Fermenter by inoculating sterilized mash with culture

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

Fermenter are then transferred to Fermenter.

Fermentation

The purpose of saccharification cum 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 circulating mash through plate

heat exchangers to maintain optimum temperature. The recirculation 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.

Grain meal unit

Fermenter wash is sent analyzer column. The spillage from analyzer column is sent to decanter centrifuge. The sludge from the centrifuge is filtered and dried. The dried mass is referred as grain meal. This is disposed to farmers and dairies for use as cattle feed


- 42–

Fresh Water Grain

FLOW CHART FOR GRAIN BASED ETHANOL PLANT

Condensate water to CoolingTower

GRAINMILLING, SACCHARIFICATION AND

LIQUIFICATION

CO2 &Vap.+ 5H2O

Yeast Culture & Nutrients

FERMENTER GRAIN MEAL

SEPARATOR

ANALYZER COLUMN

Exhaust Wash

CONDENSER

Spent Wash Concentrate

ASH

R.S. COLUMN

ENA COLUMN

Lees Water

Fresh Water

140

Lees water

140

Flue Gas

EVAOPARATOR

BOILER

Bio Mass Fuel

GRAIN MEAL DRYER

Distillate

Grain meal

BIOMETHANATION

PLANT Biogas

Impure spirit, 4

ENA


- 43–

MASS BALANCE FOR GRAIN BASED ETHANOL PLANT


- 44–

4.0 SITE ANALYSIS M/s. Karthik Agro Ind Pvt Ltd., has proposed to expand its Molasses /Grain Based Distillery Plant



The following points considered for expansion of the plant at existing premises.

Proposed activity is within the Distillery plant

The cost of land was also consideration for selecting the site.

Infrastructure facilities, like road, uninterrupted power industrial HT lines,

water, and man power are available at the site.

Availability of water.

APART FROM ABOVE, OUR PROPOSED PROJECT LOCATION REVIEWED BASED ON

THE FOLLOWING

The selected land is non-agricultural land.

The land acquired is sufficient to provide green belt.

The present Air Quality data is within the standards laid by KSPCB.

Connectivity with the major cities for transports the finished product.


- 45–

5.0 PLANNING BRIEF

5.1 LAND USE PLANNING

The Land use pattern details is stated in below table.

Table 3.0:- Land Use Pattern

Sl.No. Description Area in sq m Area in acres Area in percentage (%)

1 Total plot area 1,61,870 40 100

2 Ground coverage area

64,748 16 40

3 Paved area 48,561 12 30

4 Landscape area 48,561 12 30

5.2 GREEN BELT DEVELOPMENT

The industry has developed green belt of 14 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.

5.3 PLANTATION

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. Native tree species have been planted for development of green

belt.

Green belt is a set of rows of trees planted in such a fashion, to create effective

barrier between the plant and surroundings. The green belt 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 is developed in keeping view of the following objectives.

1. Planting of trees in each row is in staggered pattern.


- 46–

2. The short trees are being planted in the first two rows and the tall trees in the

outer rows around the pure view of the project site.

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

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

4. Sufficient spacing is maintained between the trees to facilitate effective height

of the green belt.

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

preferred.

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL)

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

proposed site and is developed in under corporate social responsibilities programs.

5.5 AMENITIES/FACILITIES

The Company is being developed 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.


- 47–

6.0 PROPOSED INFRASTRUCTURE& ENVIRONMENTAL MANAGEMENT PLAN

6.1 WATER REQUIREMENT

The water supply for the project is Ghataprabha River. The total fresh water requirement for molasses based process is 1076 & Grain based process is 878 KLD. The water consumption & effluent generation details is detailed in below tables 4.0 & 5.0.

Table 4: Fresh Water Requirement for Distillery

Sl.no. Description Water consumption in KLD (Molasses Based)

Water consumption in KLD (Grain Based)

1 Domestic 6 6

2 Floor washing (WTP/FLOOR/LAB)

32 32

3 Boiler feed 36 76

4 Process 485 291

5 Dilution of RS 140 140

6 Water presence in molasses 44

-

7 Cooling tower make up water (fresh water)

333 333

Total 1076 878

Note: - 1) Sanctioned raw water quantity is 1500 KLD from irrigation department Govt. of Karnataka. 2) Maximum fresh water requirement for molasses based process is 1076 & Grain based process is 878 KLD.


- 48–

6.2 WASTE WATER GENERATION

The effluent generation details are detailed in below tables 5.0.

Table 5: Waste water generation form Distillery Unit

Sl.no. Description Water consumption in KLD

Discharge in KLD

Water consumption in KLD

Discharge in KLD

Treatment method

Molasses Based Grain Based

1 Domestic 6

5 6

5

Septic tank & Soak Pit

2 Floor washing (WTP/FLOOR/LAB)

32

30

32

30

CPU (Condensate Polishing Unit)

3 Boiler feed

36

8

76

8


4 Process 485 FROM EVP -432

SPENT LEE - 236

291 FROM EVP - 202

SPENT LEE - 229


5 Dilution of RS

140 140

6 Water presence in molasses 44

-

-

7 Cooling tower make up water (fresh water)

333

75

333

75

Cooling water purge - CPU (Condensate Polishing Unit)

Total 1076

786 878

549


- 49–

6.2.1 COMPARISON OF POLLUTION LOAD

1) Water consumption and waste water generation details

Sl.no. Description Grain based Molasses based

Existing Proposed Existing Proposed

1 Water consumption

in KLD

1862 878 1826 1076

2 Waste water generation in

KLD

989 549 1048 786

3 Spent wash 699 694.17 728 530

4 Boiler Ash in TPD

8 8 16 16

5 Fermenter Sludge in TPD

23 23 4 4

Note: -

The water pollution load will be reduced by approximately 25 %.

There is no additional Solid waste generation from the expansion of distillery plant

6.3 DISPOSAL: ZERO DISCHARGE TECHNOLOGY

The major effluents generated in a distillery are:

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 6.62 liters per liter

of spirit produced. For a 80 KLPD distillery the spent wash quantity will be 530 KL per

day. Distillery effluent-spent wash carries one of the highest pollution loads and is

highly acidic in nature.


- 50–

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

husk or baggasse as supporting fuel. The spent wash incineration gives energy output.

Spent lees: The water carried along with the alcohol vapors from the analyzer top is

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 make up 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 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. The typical

characteristics of spent wash is detailed in table 6.0


- 51–

Table 6.0: Typical composition of spent wash:

s Parameter Description

1 Ph 4.0-4.5

2 BOD, mg/l 42,800-47,100

3 COD, mg/l 95,800-1,03,100

4 Total Solids, mg/l 92,600 -98,800

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

6 Total Nitrogen, mg/l 4490-4940

7 Chloride, mg/l 3700-4100

8 Potassium as K, mg/l, 8480-9200

9 Sodium, mg/l 240-280

10 Sulphate, mg/l 2810-3145

11 Phosphorous as P2O5 990-1120

12 Ash, mg/l 50-187

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. 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:


- 52–

Table 7.0: 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 Sulphates 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 biological. Since it contains high BOD, it

putrefies rapidly giving rise to offensive odour. The brown coloris esthetically

objectionable and affects photosynthesis. Prolonged land

irrigationusingspentwashifnotsufficientlydilutedmaycausesoilsickness.


- 53–

6.4. TREATMENT OF EFFLUENTS AND DISPOSAL

The unit generates liquid, solids and air effluents. The mitigation measures for these effluents are

as follows:

6.4.1 SPENT WASH-LIQUID EFFLUENT

The unit generates 530 m3 of spent wash, which contains organic and inorganic chemicals. These

chemicals have nutritive values for agriculture activity. The unit has bio-methanation plant for

reduction of pollution load, where concentration of solids reduces from 10% to 6%.

Thermophillic microbes are used for digesting the spent wash and organic matter in the effluent.

The bio digested effluent is concentrated by evaporation using falling film evaporators (3 nos. in

one set) and forced circulation evaporators (2 nos.in second set), where the volume is reduced

but concentration of solids increase from 5% to 55%. The concentrated effluent has 1,400

Kcal/kg, so it is utilized as fuel along with rice husk, biogas and bagasse. The ash is used as

manure, since it contain plant nutrients like potash, phosphates, etc. The technical details are

provided separately.

6.4.2 MISCELLANEOUS EFFLUENTS

The unit generates 781KLD of miscellany effluent, which is moderately contaminated with BOD &

COD. So, it is subjected to secondary and tertiary treatment, so the treated water is suitable for

reuse in the plant.

The digested effluent from bio digester is sent for extended aeration tank, where it is sufficiently

aerated to oxidize the organic matter. It is clarified in clarifier. The over flow is collected in sump

tank, then chlorinated, filtered and used for cooling tower and greenery development.

Table 8.0: Typical composition of miscellaneous effluent:

Sl.no. Parameter Description

1 Ph 6.8-7.0

2 BOD, mg/l 630-670

3 COD, mg/l 830 -880

4 Total dissolved Solids, mg/l 1600-1900

5 Suspended solids , mg/l 150-200




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6.4.3 DOMESTIC EFFLUENT

The domestic effluents are generated by employees of the unit and canteen waste etc.

This effluent is in smaller quantity and more of organic in nature. It is treated in septic

tank and then disposed through soak pit.

Table 8.1: Typical composition of miscellaneous effluent:

Sl. No. Parameter Description

1 Ph 7.2-7.4

2 BOD, mg/l 280-320

3 COD, mg/l 430 -460

4 Total dissolved Solids, mg/l

800-1000

5 Suspended solids , mg/l 120-160




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6.4.4 TECHNICAL SPECIFICATIONS

i. Receiving sump

The sump is constructed in RCC and internally finished with smooth plaster

and corrosion proof paint.

Capacity: 1500 m3(3 days hold up)

ii. Raw effluent pump

Capacity: 26m3/hr.

Head: Suction 5 m, discharge

Type: CI body, brass impeller, self priming, centrifugal

iii. Mixing chamber

RCC construction with mechanical mixer

Residence period is 3min.

Agitator:1 HP turbine impeller

iv Lime solution feed vessel

Type : Constant feed vessel

RCC Construction


- 56–

vi. Aerobic Digester

Capacity of the reactor:560m3

Material of construction: RCC

Effluent flow rate:820m3/Day

Effluent COD: Inlet-2,200 ppm, outlet-800ppm

Effluent BOD: : Inlet-1,600 ppm, outlet-240ppm

COD laoding:3.3kg/m3/day

Areation tank- Extended aeration type of aerobic reaction. The tank is

constructed in RCC. The aeration is through surface aerator.

Flow rate: 624m3/day

Sludge recirculation pump:420m3/Day

Capacity of the tank: 630m3

Residence period: 18hrs.

BOD inlet/outlet: 240 ppm/30ppm

BOD load: 202kg/day

MLSS: 3,000ppm

Recirculation:50%

F/M ratio: 0.12 (kg/day of BOD/kg of MLSS)

Oxygen requirement & means: 404 kg/day & surface aerator

Capacity of surface aerator & size: 1.5 kg/hr/HP & 15HP

vii. Secondary clarifier

Flow rate:26m3/Hr

Head up period:2hrs.

Type: Circular clarifier with central feed & peripheral overflow &

mechanical sludge scrapping system.


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Size: ID 8 m Straight height 2.5m

Volume: 125m3

Bottomgradient:1:13

Suspended solids: Influent 3000 & overflow 60mg/ltr.

Sludge waste: 18m3/day

viii. Secondary sludge pit-constructed with RCC, used for collection of sludge

from secondary clarifier. It is pumped to aeration tank to maintain desired

concentration of MLSS. Excess sludge is transferred to drying bed.

Sledge flow rate: 10m3/hr.

Capacity: 2 m3 (20 minimum holdup)

ix. Sludge recirculation pump

Capacity: 20m3/hr.

Head: Suction -5 m, discharge-8m

Type: CI, centrifugal & self priming

x. Clarified Effluent sump-It is constructed of RCC, internally plastered

Flow rate (Maximum): 40m3/hr.

Hold up period: 2hrs.

Capacity: 20m3/hr.

xi. Sludge drying bed-Constructed of stone masonry and they are filled with

graded sand & pebbles to a height of 6m.

Free board: 0.3m

Drying cycle: 10days

Capacity of each bed: 8m3


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xii. Tertiary treatment facility

Chlorination-The effluent from secondary treatment is disinfected by treatment

in Chlorine content chamber, where Chlorine dosing facility is provided. The

volume of the chamber is 35 m3 and constructed in RCC.

Sand pressure filter-Sand pressure filter consisting of vessel filled with graded

sand. The disinfected clear treated effluent is being utilized as cooling water

make up and for greenery development.

6.5EFFLUENT TREATMENT PLANT FLOW CHARTS

1) Distillation


- 59–

2) Distillery effluent treatment (Spent Wash from process)

3) Miscellaneous effluent (Spent lee, evaporation water, Boiler blow down, cooling tower

bleed off& washing water)


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4) Domestic waste water

6.6 POLLUTION PREVENTION AND ABATEMENT PLAN

6.6.1 AIR POLLUTION SOURCES DETAILS

The details of air pollution sources is stated in below tables.

Table 9.0:- Air Pollution Sources Details

1). Boiler

Sl.no. Details

1 Type of Fuel Bagasse, rice husk, biogas and

concentrated effluent

2 Capacity of Boiler 16 TPH X 1 NO.

3 Stack Height 65 MTS

2). DG set

Sl.no. Details

1 Type of Fuel Diesel

2 Capacity 500 KVA x 1 No.

3 Stack Height (above roof level) 3 m ARL

4 Pollution Control Equipment

Measures

Adequate stack height/

Acoustic


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BOILER

The Co-gen power plant is supported by 16 TPH boiler at 3750±15oC temperature, 40

kg/cm2 pressure and 34 kg/cm2 working pressure. The feed water inlet temperature at

Eco. is 1050C. It is an incineration boiler using fuel like rice husk, bagasse, biogas and

concentrated effluent from evaporation section. There is no dearth for fuel availability in

the vicinity of this plant. The generated super-heated steam is passed through steam

turbine for generation of power, then the used steam (waste steam) is utilized for

distillation, evaporation and fuel ethanol manufacturing purpose.

The steam is utilized for distillation 8 TPH, evaporation-4 TPH and-1.5 TPH ethanol. The

total requirement of steam is 13.50 TPH, whereas the boiler Capacity is 16 TPH. The boiler

efficiency is 85%, so the generated steam is adequate for the operation of distillery and

other associated activities. Boiler requires 36 m3/day in Molasses base and 76 m3 per day

Grain base, makeup water to maintain steam production at the required level.

The boiler is manufactured and supplied by Cogent Engineering Pvt. Ltd., Gate no.

823/824, Sanaswadi, Shirur Taluk and Pune District. The boiler manufacturer is well-

known in the industrial field for honoring their commitment in meeting rated capacity and

efficiency. It has been already justifies by using the boiler since 2009 for the purpose of

distillation and other activities. The client list indicates the user of Boiler justifies the

quality, technical superiority and usefulness for the specific requirement.

STEAM:

The unit has installed 16 TPH boiler for generation of steam. The generated steam is being

utilized first to generate 1.40 MW power then exhaust waste steam is used for distillation,

evaporation and fuel ethanol manufacturing purpose. The steam turbine requires super-

heated steam. The waste steam from turbine outlet is sufficient for meeting the

requirement of distillery activities. The quantity of steam required for distillery activities is

13.5 TPH as per the technical details provided by boiler and turbine supplier.


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The steam consumption details are as follows.

Rectified spirit production and evaporation -2.1kg/litre

Anhydrous alcohol (fuel ethanol)-0.6kg/litre

Evaporation plant- 1.5 kg/litre Or

Superfine ENA production integrated with evaporation -3.0kg/litre

Distillation- 2.2kg/litre

Molecular sieve –fuel ethanol-5kg/litre

So the steam production is adequate for both cogen power plant and distillery unit. The

unit did not face any problem regarding steam production and utilization.

6.6.2 AIR POLLUTION CONTROL MEASURES

MDC installed.

For the effective dispersion of the pollutants, 65 ms tack height has been provided.

DG sets of 500 KVA (1 Nos,), stack of adequate height is provided.

All vehicles and their exhausts well maintained and regularly tested for emission

concentration for carbon & carbon monoxide.

Thickness of insulating material with proper fastening has been provided to

control thermal pollution.

Regular preventive maintenance of pollution control equipment is being carried

out for effective functioning of equipment.

Stack emissions is regularly monitored by external agencies on periodic basis.


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6.6.3 ENVIRONMENTAL MANAGEMENT PLAN

The detailed environmental management plan is stated in below table.

Table 10.0:- Environmental Management Plan

Particulars DETAILS

Air Quality Management

Possible Sources Existing Boilers, 16 TPH 1 No. and Co-generation Power Plant,

Transportation Vehicles, D.G. Sets etc.

Emissions and Existing

Control measures

➢ Oxides of Sulphur, Nitrogen and Particulate matter

➢ MDC is installed.

➢ Adequate boiler stack height is maintained.

➢ Existing DG Set (500 KVA) also have adequate stack of height as

per CPCB Guidelines.

➢ Adequate measures for Fugitive Dust Emission sis taken.

➢ All the internal roads are asphalted.

➢ Existing Green Belt (14 Acres) developed around the periphery

&internal areas within the premises of the plant will help in

attenuating the pollutants emitted by the plant.

Monitoring Ambient air quality and stack emissions are being monitored

regularly to ensure that ambient air quality standards are met

Water Management

Management ➢ The project is based on “Zero Effluent Discharge”.(ZLD)

➢ Fresh water requirement of the project is being met by

Ghataprabha River.

➢ Water & recycled water. Efforts are being 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 is being maintained

➢ Spent lees generation from distillation column is being recycled

partly to the columns for dilution and balance is being used for

cooling tower makeup.

➢ Domestic waste water generated from the plant is being treated

in Septic Tank and Soak pit.


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➢ Effluent Treatment Plant (ETP) has been installed and treated

water from ETP is being recycled back to the process and

remaining is being used for green belt development.

Noise Management

Management ➢ Proper maintenance, oiling and greasing of machines at regular

intervals is adopted

➢ PPEs like ear plug sand ear muffs to the workers exposed to high

noise level.

➢ Development of Green Belt for 30 % of the total project area.

➢ Regular monitoring of noise level.

➢ D.G set is provided with acoustic enclosures to control the noise

level within the prescribed limit.

Monitoring

➢ Regular monitoring of noise levels is being carried out and

corrective measures in concerned machinery is adapted

accordingly as and when required.

Solid Waste Management

Management ➢ Solid waste from the Grain/Molasses based operations generally

comprises of Fibers and proteins in the form of DDGS (Distillery

Dried Grain Soluble), which is being ideally used as Cattle Feed.

➢ Ash from the Boiler is being sold to Brick manufacturers.

➢ Used oil & grease generated from plant machinery/ Gear boxes

are hazardous wastes used as lubricant for chain conveyer.

Green belt Development/ Plantation

Management ➢ 35% of total project area has been developed under green

belt/plantation with diverse species.

➢ All the barren areas is vegetated.

➢ Nativeplantspeciesisplantedinconsultationwithlocalhorticulturist.

➢ 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 is the primarily controlled at source by good operational

practices, including physical management control measures.

➢ Better housekeeping is being maintained with good hygiene

condition by regular steaming of all fermentation equipment.


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6.6.4 SOCIO-ECONOMIC ENVIRONMENT

The plant has provided direct and indirect employment and improved infrastructure facilities and are being provided the same incoming 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.

Theindustrywouldhelpinpromotingtheactivitiesrelatedtoenvironmentalawareness 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.

6.6.5 SOLID WASTE & HAZARDOUS WASTE

Solid waste generated from the industry is as follows:

Table 11.0: Solid Waste generated

Type Quantity Storage Utilization/disposal

Grain based Molasses based

Existing Proposed Existing Proposed

Boiler Ash. 8

TPD

8

TPD

16TPD 16 TPD Covered

shed Sold to Bricks Manufacturers and supply to farmers to subsidized rates as a soil conditioning.

Fermenter Sludge

23

TPD

23 TPD

4

TPD

4

TPD

Covered

shed

Dried and then sold to Cattle feed manufacturers and farmers to subsidized rates for use as nutrients.

Hazardous Waste

Waste oil

100 LPA

(Existing)

Sealed

Carboys

Used as lubricant for

chain conveyer within

the premises


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6.6 SAFETY ASPECTS FOR OCCUPATIONAL HAZARDS

1. HAZARD IDENTIFICATION

Safety Audit is being conducted by qualified technical personnel to study the installation and activities of the industry and to suggest measures to protect personnel and property against the risks. The areas of possible hazardous incident are given for follow up action:

i. Fire in fuel/bio-mass storage yard, alcohol storage tanks and diesel storage tanks.

ii. Electric Short circuit and consequent fire accident.

iii. Any likely sort of explosion in Boiler area

iv. Puncture of Boiler tubes.

v. Bursting of pipeline joints.

vi. Fall from high level structures

i. Fire in Fuel/Bio-mass Storage Yard

This may occur on account of external cause. The bio-mass fire since it contains lot of fiber and it may spread slowly because of the high moisture content.

ii. Short circuit and consequent fire accident

The electrical short circuit may happen in any of the plant area due to poor insulation of the equipments.

iii. Explosion Hazard

Explosion is expected due to bursting of high pressure equipments like boiler, turbine and pipe lines involved. The water required for Boiler is pumped and transferred to the boiler by using high-pressure pumps. Also the high-pressure steam generated in the boiler is sent to the turbine through the pipeline. This pipeline will have flanged joints, with sandwich gaskets in between for better sealing. At times, due to water hammering this gasket fails and leads to bursting of the flange joint.

2. SAFETY MEASURES

Safety measures as indicated below are provided in the existing plant to avoid hazards and to provide safety to the plant from any eventualities. During expansion of the plant, additional safety measures is being implemented as per the guide lines. The safety facilities to be provided in the industry are given below.


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3. FIRE FIGHTING FACILITIES

i. Water Hydrant System

Fire hydrant system with hose pipe of 7 kg/cm2 pressure with hydrants are located at in bio-mass yard, distillery house, ethanol storage area

A jockey pump and accessories. 40 m3/hr at 70 head

Corrosion protected M.S. underground piping 150 mm dia. and 100 mm and around the

plant as closed lap

single headed hydrants distributed around the plant at about 30 m spacing to supply

pressurized water for fire fighting.

10nos. m. s. hydrant nose cabinet adjacent to each cabinet.

ii. Fire Extinguishers

Fire extinguishers Foam water : 2 each at main office and store. CO2 type : 6 nos. one each at departmental office.

DCP type : 8 nos. each at distillery plant and power plant.

Sand buckets : At different locations

iii. Fire Protective Appliances

Three sets of fire safety appliances each consisting of fire mask (6), face shield (6), fire gloves (12) fire helmet (12), safety belts (6), located at store, power plant and distillery plant, respectively.

iv. Fire Brigade

Fire brigade facilities available at Bagalkot shall be utilized whenever need arises.

4. SAFETY APPLIANCES AND FACILITY

These facilities listed below are kept at administrative building/stores building and are under the control of emergency Coordinator.


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First AID medical units one unit of each department, 4 units at store and 4 units at

ECR

Safety belts

Ear muffs, masks against dusts, aprons against chemical spillage.

Shock proof gloves and mats.

Leather aprons.

Safety items of shoes, gum shoes, hand gloves, helmets, goggles.

Safety ladder.

Face masks & gas masks

Leather gloves.

Breathing apparatus.

Stretchers and oxygen cylinder.

Flame proof battery and lighting.

Ambulance.

Emergency lighting facilities,

Air life line for working in vessels and tanks.

5. EMERGENCY TRANSPORT VEHICLE

One vehicle along with driver is always made available at the factory premise for emergency needs.

6. AMBULANCE

Ambulance facilities available at Company at the time of emergency

7. OCCUPATIONAL HEALTH CENTRE

Safety officer is appointed in the industry. He will co-ordinate and manage occupational health management. A medical facility with qualified doctor and clinical facilities has been created in the industry to meet the factory and residential colony requirement of the health services. Higher medical services shall be availed from the hospitals present in Bagalkot. Health care aspects to be practiced in the industry are indicated below.


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1. Plant Operation

Regular inspection and maintenance of pollution control plants

Regular cleaning of dusts from floor, roads and other lplaces.

Heat insulation of hot surfaces

Wherever necessary, personnel protective appliances has used by the workers.

2. Clean Technology

Measures for Clean Technology are given below for improvement of performance of industry towards production, energy and environment. Good housekeeping is practiced in the industry. Prime importance is given for safety and occupational health. Energy audit is also under implementation.

3. Life Cycle Assessment Study (LCA)

The life cycle assessment study is conducted as per medical standards.

4. Medical Facilities

M/s. Karthik Agro Industries Pvt. Ltd will have an occupation health center to provide following medical services to the employees

Health and safety related displays is exhibited at strategic locations in the industry.

Workers are educated workers on health, hygiene and safety and trained in occupational

health safety.

Regular health check up of the workers is being carried out and health records of individual

workers in form No.16 as per factory Act is maintained.

General treatment and advice to the employee.

Maintenance of Medicines.

Spirometry, Pulse-oxyeometry, X-rays and other routine and specific tests are being

conducted and submitted to authorities.

First aid facilities is being provided at different locations. Further first aiders are being

trained from refuted training institute.

Workers are trained to assist emergency management in case of any such incidences

Housekeeping in the industry and sanitation in utility rooms, canteen. Rest rooms and

other places is given top priority.

House Keeping Training is imparted to 10 workers and 5 supervisors from refuted

management institute.


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7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN The proposed project is expansion of Molasses /Grain Based Distillery Plant from 65 KLPD to 80

KLPD in Existing Distillery Plant. Hence there is no re-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 Amendment in Environmental Clearance and all other

required clearance and will complete after two years of commencement.

(ii) Estimated project cost

Total cost of the Existing Project: Rs.80.62 Crores and after expansion the total project cost is

Rs. 80.94 crores.

Table 12.0 cost of the project

Sl.no. Description Cost in rupees

Existing

1 Land cost 1,87,26,276.00

2 Construction cost 7,63,41,611.00

3 Plant & Machinery

with furniture &

fixtures

71,11,00,000.00

4 Total 80,61,67,887 or say 80,62,00,000.00

Proposed

5 Proposed investment

on plant & machinery

32,00,000.00

Total (4+5) 80.94 Crores

Rupees Eighty Crores Ninety Four Lakhs only

Cost for Environment Protection Measures:

❖ Capital Cost: Rs. 5.8Crores

❖ Recurring Cost/annum: Rs. 40 Lakhs /annum.


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9.0 ANALYSIS OF PROPOSAL

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

factors significantly favor setting up the unit.

Establishment of Plant & Machinery to handle either molasses or grain to

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

Viability of the project is established beyond doubt with Molasses or grain as

input raw materials.

Capital cost considered slow compared to the general trend in the market.

The proposed process and plant and machinery makes the project

environmental friendly.

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

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


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10. OBSERVATIONS &CONCLUSIONS

10.1 OBSERVATIONS

The project in detail regarding the capacity of Distillery, the following conclusion made.

10.2 LAND

(1) M/s. Karthik Agro Ind Pvt Ltd., has proposed to expand its Molasses /Grain Based

Distillery Plant from 65 KLPD to 80 KLPD in its existing Distillery Plant at Sy. No.

92,93,94, Hoolageri Village, Badami Taluk, Bagalkot District, Karnataka State.

(2) The total land is 40 Acres.

(3) The extent of land is adequate and the distillery is in operation.

10.3 BOILER

(1) The unit has 16TPH capacity Cogent boiler for providing steam to 1.4 MW co-gen

captive power plant, 80 KLPD distillery unit for manufacture of Superfine ENA

both from molasses/ Grain.

(2) It is an incineration boiler using bagasse, rice husk, biogas and concentrated

effluent to achieve zero discharge.

(3) The boiler efficiency is 85% so the steam output is 13.50 TPH at 40 kg/cm2,

375±10oC. which is adequate for the existing distillery activity


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10.4 DISTILLERY UNIT

(1) The distillery has with multi-pressure high vacuum distillation technology, where

RS and ENA can be manufactured by switching over RS mode to ENA mode.

(2) It consumes less quantity of steam and operates efficiently.

(3) The technical specifications indicate the material of construction and standards.

(4) Fed Batch fermenters are used for fermentation process, where 11% v/v alcohol

concentration in fermented wash is achieved and fresh yeast is used for every

batch. It has 3 extra fermenters, they can increase capacity by 30% of the

existing.

(5) The PLC based software technology HC 900 developed by Honeywell process

controller is being used for efficient management of distillery.

(6) Yield and quality of product are of high standard.

10.5 POWER

(1) The unit has 500 KVA power connections. Additionally captive power plant with

1.4 MW capacity is also operating along with 500 KVA a silent DG set.

(2) The unit does not export power and did not enter into power purchase

agreement.

10.6 WATER

(1) The water requirement of the unit is met from Ghataprabha river, which is about

12 kms at Chabbi village from the project.

(2) The unit has 19.40 mcft water allotments from Water Resource Department.

Water is pumped from river using 25HP, 4 motor (100 HP).

(3) The ground water source is also available from 3 bore wells in factory premises


- 74–

and 2 bore wells in river bed. The treated water is available and used for cooling

tower and greenery development.

(4) The total fresh water requirement for molasses based process is 1076 & Grain

based process is 878 KL/day water is met from river and Bore well sources.

(5) Common water storage facility has capacity to store 1,66,860

m3 in ground level open tank and sump tanks.

10.7 PLANT & MACHINERY

(1) The equipment balance is in tune with the requirements for the stated capacity

of the unit.

(2) The performance of the distillery indicates that the machinery is of stated

standards and yielding desired quality and quantity of the product.

(3) All the machinery suppliers are well experienced in their respective line activity

and their credentials are supported by client list.

10.8 SUPERFINE ENA

(1) The super fine ENA will have zero ppm impurities and alcohol concentration is

96%v/v.

(2) There is a loss of 1% of RS due to enhancing the concentration of ENA from 95%

to 96% v/v. An additional 3% of RS is reduce due to removal of impurities as

impure spirit (IS).


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10.9 EFFLUENT TREATMENT

(1) The unit generates processed waste and non- processed waste in aqueous form.

This water is being treated and partly re-used for the cooling tower and

remaining for developing greenery.

(2) The concentrated effluent contains 55 to 60% solids is used as boiler fuel along

with other agro fuel.

(3) Bio digester is generating biogas, which is used as boiler feed. It reduces BOD &

COD to 10,000 & 28,000 respectively.

(4) The solid waste generated by boiler in the form of ash, which is rich in nutrients

and may be used as manure for agriculture & horticulture crops.

(5) The air pollution due to boiler flue gas and DG set is being controlled through

MDC.

(6) The DG set has sound proof shell. (Acoustics encloser)

(7) Solid waste as ash, yeast & other sludge is used for land filling.

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