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PRE-FEASIBILTY REPORT FOR THE EXPANSION AND MODIFICATION OF EXISTING
MOLASSES BASED DISTILLERY PLANT FROM 60 KLPD TO 70 KLPD.
At
Sy. Nos. 49/2B/1 & 2, 57/2D & 2E, 58/1B,
58/1A/3, 66/4D, 85/2, 87, 93/2/3, 95/1 & 107/2,
Siddapur village, Jamkhandi Taluk,
Bagalkot District, Karnataka State.
Submitted by
M/s. Siddapur Distilleries Limited., Siddapur village, Jamkhandi Taluk, Bagalkot District, Karnataka State.
Environmental Consultants
M/s. AQUA TECH ENVIRO ENGINEERS, (Environmental Engineers & Consultants) # 3391, 6th Main, 3rd Cross, RPC Layout,
Vijayanagar II Stage, Bengaluru – 560 040. Tele Phone: 080: 23141679
1
Contents Sl. No. Description Pg. No
CHAPTER 1 EXECUTIVE SUMMARY
1-6
1.1 Introduction 1
1.1.1 Preamble 1
1.1.2 Project at a glance 2
1.1.3 Water requirement and wastewater treatment and discharge
details
3
1.1.4 Quantity of water required and wastewater generated 4
1.1.5 Air pollution details 5
1.1.6 Noise pollution details 6
1.1.7 Solid waste details 6
1.1.8 Environmental Impacts and Management Plan 6
CHAPTER 2 INTRODUCTION OF THE PROJECT/ BACKGROUND
INFORMATION
9-13
2.1 Introduction Of Project Proponent 9
2.2 Brief Description About The Nature Of The Project 10
2.3 Need For The Project And Its Importance To The Country
And/Region
10
2.4 Demand Supply Gap 11
2.5 Export Possibility 12
2.6 Domestic/Export Markets 12
2.7 Employment Generation (direct and indirect) Due To The
Project
13
CHAPTER 3 PROJECT DESCRIPTION
14-48
3.1 Type Of Project 14
3.2 Location Of The Industry 14
3.3 Basis Of Selecting The Proposed Site 16
3.4 Size/Magnitude Of Operation 16
3.5 Products Manufactured 16
3.5.1 Manufacture process technology 16
3.5.2 Process Description-70 KLD based on Molasses 17
3.5.3 Manufacturing Process for Molasses based Ethanol 19
3.5.4 Brief Description of Fed Batch Process 22
2
3.5.5 Major difference b/w continuous & Fed batch Fermentation process
23
3.5.6 Block Diagram of Existing 60 KLPD Plant 25
3.5.7 Block Diagram of Existing 70 KLPD Plant 26
3.6 Raw Materials 27
3.6.1 Storage Facility for Raw Materials and Products 27
3.7 Machinery and Equipment Details 28
3.8 Solid Waste and Hazardous Waste 39
3.8.1 Domestic Solid Waste Re-use 39
3.9 Water, Energy/Power Requirement and Source 40
3.9.1 Water 40
3.9.2 Power 40
3.10 Wastes Generated & Scheme For Their Management/Disposal 40
3.10.1 Water Demand and Wastewater/effluent Discharge 40 3.10.2 Treatment of Effluents and Disposal 41
3.11 Air Pollution Details 47
3.12 Noise Pollution Details 47
3.13 Solid Waste Details 47
3.14 Schematic Representations Of The Feasibility Drawing 48
CHAPTER 4 SITE ANALYSIS
49-55
4.1 Site Connectivity 49
4.2 Land Form, Land Use & Ownership 50
4.3 Topography 50
4.4 Existing Land Use Pattern 51
4.5 Existing Infrastructure 51
4.6 Soil Classification 51
4.7 climatic Data from secondary sources 53
4.7.1 Temperature 54
4.7.2 Relative Humidity 54
4.7.3 Rainfall 54
4.7.4 Atmospheric Pressure 54
4.7.5 Cloud Cover 54
4.7.6 Wind 54
4.8 Social Infrastructure 55
CHAPTER 5
3
PLANNING BRIEF 58-58
5.1 Planning Concept 58
5.2 Population Projection 58
5.3 Land-Use Planning 58
5.4 Assessment Of Infrastructure Demand 58
5.4.1 Water Supply & Sewerage Infrastructure 58
5.5 Amenities/Facilities 58
CHAPTER 6 PROPOSED INFRASTRUCTURE
59-64
6.1 Industrial Area (Processing Area) 59
6.2 Residential Area (Non Processing Area) 59
6.3 Green-Belt 59
6.4 Social Infrastructure 64
6.5 Connectivity 64
6.6 Sewerage System 64
6.7 Industrial Waste Management 64
6.8 Solid Waste Management 64
6.9 Power Requirement & Supply Source 64
CHAPTER 7 REHABILITATION & RESETTLEMENT PLAN
65
CHAPTER 8 PROJECT SCHEDULE & COST ESTIMATES
66-67
8.1 Time Schedule 66
8.2 Estimated Project Cost 66
CHAPTER 9 ANALYSIS OF PROPOSAL
68
4
LIST OF TABLES
Table no. Description Pg. No 1.1 Project at Glance 2
1.2 Water Requirement and Wastewater Treatment and Discharge Details
3
1.3 Water Consumption and Discharge 4
1.4 Sewage/wastewater treatment and discharge 5
1.5 Sources of air pollution, type of fuel used, APC details 5 1.6 Solid Waste Generation during the Operation Phase 6
1.7 EMP during the Operation Phase 6
3.1 Major difference b/w continuous & Fed batch Fermentation process
23
3.2 Raw Materials Requirement 27
3.3 Technical Specifications for 60 KLPD Distillery Plant Continuous Fermentation and Multi pressure Distillations
28
3.4 Solid Waste Generated 39
3.5 Solid Waste Generation During the Operation Phase 39
3.6 Water Consumption and Discharge 40
3.7 Sewage/Effluent Treatment and Discharge 41 3.8 Sources of Air Pollution, Type of Fuel Used, APC Details 47
3.9 Solid Waste Generation during the Operation Phase 47
4.1 Connectivity of Project Site 49
4.2 Existing Land Use Pattern 51 4.3 Meteorological Data of Bagalkot for the Year 2016 53
4.4 List of Infrastructural Facilities in the Surroundings 55
5.1 Land Use Pattern 58
8.1 Project Cost for expansion of Distillery Plant capacity from 60 KLPD to 70 KLPD.
66
5
List of Figures
Fig. no. Description Pg. No 3.1 Google Map Showing Project Site 14
3.2 Map showing the Project Site Location on District Map of Bagalkot
15
3.3 Plant layout plan 15 A
3.4 Flow Chart Of Existing & Proposed Environmental Management Plan (EMP)
44
3.5 Feasibility & environmental assessment process 48
4.1 Google map showing connectivity to Project Site 49 4.2 Topo map 50
4.3 Wind Rose diagrams 56
6.1 Green Belt Photographs 60
List of Annexure
Annexure Description A Land Records
B Environmental Clearance and Compliance Report
C Drawings
M/s Siddapur Distilleries Limited.,
Pre-Feasibility Report Page 1
CHAPTER 1
EXECUTIVE SUMMARY
1.1 INTRODUCTION
1.1.1 Preamble
Amendment of the Environmental Impact Notification No. S.O. 60(E) dated 27.01.1994,
issued by the MoEF, Govt. of India has made mandatory under Schedule-I of EIA notification
for 30 different activities to obtain NOC (No Objection Certificate) from the State Pollution
Control Board and Environmental Clearance from the Ministry of Environment & Forests,
Govt. of India. This amendment to the EIA Notification is effective from 14.09.2006.
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
proposed project is Expansion/Modification of Distillery plant.
The proposed expansion and modifications envisages changing the process technology and
increasing the capacity of distillery plant. There is no additional Water & air pollution is
added.
M/s. Siddapur Distilleries Limited., has proposed to expand and modified its Molasses Based
Distillery Plant from 60 KLPD to 70 KLPD through process modification in its existing
Distillery Plant at Sy. Nos. 49/2B/1 & 2, 57/2D & 2E, 58/1B, 58/1A/3, 66/4D, 85/2, 87,
93/2/3, 95/1 & 107/2, Siddapur village, Jamkhandi Taluk, Bagalkot District, Karnataka State.
The unit has 30 Acres of land in the name of “Siddapur Distilleries Limited., Siddapur village,
Jamkhandi Taluk, Bagalkot District, Karnataka State.
Molasses is used as a raw material which is easily available from our parent sugar factory i.e
Shri Prabhulingeshwar Sugars & Chemicals Limited (SPSCL) and nearby sugar factory.
Distillery plant capacity.
1. Existing :- 60 KLPD
2. Proposed :- 70 KPLPD
M/s Siddapur Distilleries Limited.,
Pre-Feasibility Report Page 2
1.1.2 Project at Glance
Details are appended in the following table 1.1 below.
Table 1.1:- Project at Glance
Sl.No. Details 1 Project Expansion and modification of Molasses Based Distillery
Plant from 60 KLPD to 70 KLPD through process modification in its existing Distillery Plant – “M/s. Siddapur Distilleries Limited.,”
2 Project developers M/s. Siddapur Distilleries Limited., at Sy. Nos. 49/2B/1 & 2, 57/2D & 2E, 58/1B, 58/1A/3, 66/4D, 85/2, 87, 93/2/3, 95/1 & 107/2, Siddapur village, Jamkhandi Taluk, Bagalkot District, Karnataka State.
3 Location of the site Sy. Nos. 49/2B/1 & 2, 57/2D & 2E, 58/1B, 58/1A/3, 66/4D, 85/2, 87, 93/2/3, 95/ & 107/2,
4 Constitution of the Organization
Public Limited Company
5 Raw materials Sl.No. Particulars Quantity MT/Month
EXISTING 1 Molasses 6720
2 Deformer 3.0
3 Urea 1.3
4 DAP (Di-ammonium Phosphate)
1.2
PROPOSED 1 Molasses 7800
2 Deformer 3.5
3 Urea 1.5
4 DAP (Di-ammonium Phosphate)
1.4
6 Product/s proposed to be manufactured with production capacities? #
Distillery plant capacity.
1. Existing :- 60 KLPD
2. Proposed :- 70 KPLPD
7 Project cost? Total cost of project is Rs. 1,16,00,000/-
8 Total man power requirement during construction
phase occupancy
phase
Construction phase: No construction activity is envisaged Operational phase: 115 employees (Existing Plant Manpower utilized )
9 Proposed trees to be planted?
Tress planted – 50,000 Nos Around compost yard & Plant Surroundings Trees proposed to be planted- 2,000-3,000 No.s Every year.
M/s Siddapur Distilleries Limited.,
Pre-Feasibility Report Page 3
10 Species of trees to be planted?
Silver Wood, Teak wood, Coconut, Asoka Trees, Mango trees, Neem , Bheema Bamboo, Cassia fistula, Alstonia scholaris, and several native species
11 Groundwater recharging pits details?
Storm water recharge pits are provided
12 Elevation of the project site with respect to MSL?
618 m above MSL; Latitude: 16°26'17.03"N ; Longitude: 75°16'16.77"E
13 Total area of the project?
1,21,541.84 SQM (about 30 Acres)
14 Ground water quality?
Portability of water is tested and can be used for drinking.
15 Noise levels? Noise levels are within the standard limits. 16 Facilities provided
for the workers during construction phase at site?
No construction activity is envisaged, The proposed expansion and modifications envisages changing the process technology and thereby increasing the capacity of distillery plant.
1.1.3 Water Requirement and Wastewater Treatment and Discharge Details Water requirement and waste water generation details are appended in the following table 1.2 below.
Table 1.2:-Water Requirement and Wastewater Treatment and Discharge Details Sl. No. Particulars Details
A Water, wastewater details
1 Water supply sources Krishna River water supply
2 Total water requirement The total fresh water requirement for molasses based process is 940 KLD
3 Total wastewater generated The waste water generated from the industry is 593.2 KLD
4 Treatment/Disposal details Existing Effluent Treatment Plant
B Air pollution details
1 Sources of air pollution DG set 2 Air pollution control units
provided * DG set stack height as per the stack height calculation for 1000 KVA - 1 no. is 31 m AGL.
C Solid/Hazardous wastes
1 Source of solid waste Domestic sources and industrial effluent.
2 Total quantity of solid waste generated
Domestic solid waste – 23 kg/day Hazardous solid waste
Sl. no
Hazardous waste Existing Proposed
1 Fermenter Sludge 20 TPD 26 TPD
2 Waste oil generation from DG set
300 LPA
300 LPA
M/s Siddapur Distilleries Limited.,
Pre-Feasibility Report Page 4
3 Treatment/Disposal of solid wastes
* The domestic wastes are segregated at source and collected in bins. The organic portion of the solid wastes will be composted and recyclable portion will be disposed to the recycler for scientific recycling.
1.1.4 Quantity of Water Required and Wastewater Generated The total quantity of water requirement for the industry is about 770 KLD. The break-up of the consumption of water is as presented in Table 1.3.
Table 1.3 Water Consumption and Discharge Sl. No
Particulars Existing water Consumption in KL / Day(60KLPD)
Particulars After Expansion water
Consumption in KL / Day(70KLPD)
1 Water consumption details
a Fresh water for molasses dilution
423.0 Fresh water for molasses dilution
253.0
b Cooling Tower Make Water
432.0 Cooling Tower Make Water
432.0
c Domestic 4.5 Domestic 4.5
d Gardening 70.0 Gardening 70
e Others 5.5 Others 5.5
f Floor washing 5.0 Floor washing 5.0 Total 940.0 Total 770.0
2 Waste Water generation details a Spent Wash (ZLD,
Bio-methanation followed by Composting )
420.0 Spent Wash (ZLD, Bio-methanation followed by Composting)
420.0
b Spent Leese (Treated effluent used for irrigation or greenbelt development )
80.0 Spent Leese (Re-use in Process or cooling Tower make up)
70.0
c Process Condensate water(Treated effluent used for irrigation or greenbelt development )
80.0 Process Condensate water(Re-use in Process or cooling Tower make up)
100.0
d Sewage Domestic ( Septic Tank Followed Soak fit)
3.2 Sewage Domestic ( Septic Tank Followed Soak fit
3.2
Total 583.2 Total 593.2
M/s Siddapur Distilleries Limited.,
Pre-Feasibility Report Page 5
Note: - 1) Sanctioned raw water quantity is 940 KLD from irrigation department Govt. of Karnataka & MoEF , New Delhi . 2) Maximum fresh water requirement for molasses based process is 770 KLD (For Proposed Expansion).
WASTEWATER TREATMENT AND DISPOSAL DETAILS
The treatment methods and the final disposal of each type of wastewater generated is
appended in the table 1.4
Table 1.4 Sewage/wastewater treatment and discharge
Sewage/effluent generated from
Treatment provided Final disposal point
(a) Domestic Sewage is treated septic tank Disposed in Soak pit
(b) Industrial RSW is treated with Full-fledged ETP with collection tanks are provided.
RSW is treated with Bio-methanation followed by Bio-Composting To archived ZLD Concept
(c) Industrial Spent Leese Spent leese is treated with the phyiso-chemical treatment and re-use in cooling tower make up or process dilution purpose
1.1.5 Air Pollution Details
The major air pollution sources from the industry are DG set. These sources are provided with stacks of adequate height so as to disperse the emanating flue gases containing SPM, oxides of sulfur and nitrogen without affecting the ground level concentrations.
The sources of air pollution, type of fuel used, fuel consumption and chimney heights for each of the air pollution sources of the proposed project are indicated in the following table 1.5.
Table 1.5 Sources of air pollution, type of fuel used, APC details
SI. no.
Stack attached to
Fuel used Fuel consumption
Number of stacks
Stack/s height
Air pollution control unit
Predicted emissions
1 D.G. set – 1000 KVA – 1 No.
HSD 58.75 L/hr
1
31 m AGL
Stack SOx, NOx, SPM
M/s Siddapur Distilleries Limited.,
Pre-Feasibility Report Page 6
1.1.8 Noise pollution details The major source of noise pollution in the industry is the DG set for which acoustic enclosure is provided. Also ambient noise levels will be ensured within the ambient standards by inbuilt design of mechanical equipment and building apart from vegetation (tree plantations) along the periphery and at various locations within the industry premises. 1.1.9 Solid waste details The quantity of solid waste generated from the proposed industry is detailed in the following table 1.6.
Table: 1.6 Solid Waste Generation during the Operation Phase
Total no. of employees 115 Assuming per capita solid waste generation rate as 0.20 kg/capita/day
Quantity of solid waste generated 23 kg/day
Organic solid waste : 60 % of the total waste 14 kg/day
Inorganic solid waste : 40 % of the total waste 9 kg/day
Disposal of domestic solid waste The domestic wastes are segregated at source, collected in bins and composted.
1.2 ENVIRONMENTAL MANAGEMENT PLAN (EMP) The environmental management plan is detailed in below table 1.7.
Table: 1.7 EMP during the Operation Phase
Particulars
DETAILS
Air Quality Management
Possible Sources Existing D.G. Sets, Transportation Vehicles etc.
Emissions and Existing
Control measures
➢ Oxides of Sulphur, Nitrogen and Particulate matter
➢ Existing DG Set (1000 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 (25 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 emissions are being monitored regularly to
ensure that ambient air quality standards are met.
M/s Siddapur Distilleries Limited.,
Pre-Feasibility Report Page 7
Water Management
Management ➢ The project is based on “Zero Effluent Discharge”.(ZLD)
➢ Fresh water requirement of the project is being met by Krishna
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 33% 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 Molasses based operations generally
comprises of yeast sludge separated by mechanical using
decanter machine and collected in tractor troll which is being
composted and used as manure.
➢ Used oil & grease generated from plant machinery/Gear boxes
are hazardous wastes is being used as lubricant for chains for
Compost yard Aero-Tiller Machines within premises.
Green belt Development/ Plantation
Management ➢ 33% of total project area has been developed under green
belt/plantation with diverse species.
➢ All the barren areas are vegetated.
M/s Siddapur Distilleries Limited.,
Pre-Feasibility Report Page 8
➢ 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.
Odor Management
Management ➢ Odor 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.
M/s Siddapur Distilleries Limited.,
Pre-Feasibility Report Page 9
CHAPTER 2
INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION
2.1 INTRODUCTION OF PROJECT PROPONENT Siddapur Distilleries Limited is a Public Limited Company registered under the Company’s
Act 1956 in the year 2003 bearing Registration No.08/32213 dated 07/07/2003 having its
Registered Office at 2nd Block, 1st Floor, “Sukrut” Building, Opp:K.C.Park Main Gate, P.B.
Road, Dharwad and plant site at Siddapur Village, JamkhandiTaluk, Bagalkot District.
Siddapur Distilleries Limited has installed 60 KLPD Distillery Plant in the year 2004-05.
Distillery plant is based on continuous fermentation and multi-pressure vacuum distillation
technology to produce good quality potable grade Rectified Spirit, Extra Neutral Alcohol and
Fuel Alcohol to meet the requirements of Potable Alcohol Consumers, Pharmaceuticals
Industries and Oil Companies for blending with petrol. Distillery Plant was supplied by Mojj
Engineering System Ltd., Pune and started its trial and Commercial production on 05th
November, 2004.
Siddapur Distilleries Limited is a sister concern of Shri Prabhulingeshwar Sugars & Chemicals
Limited, having 12,000 TCD Sugar Plant at Siddapur Village, Tq.Jamkhandi, Dist.Bagalkot
having its Registered Office at 1st Floor, “Sukrut” Building, Opp.K.C.Park Main Gate,
P.B.Road, Dharwad.
Shri Prabhulingeshwar Sugars & Chemicals Limited is a Public Limited Company consisting
about 14,000 members holding Equity & Preference shares. The Company owns about 200
acres of land near Siddapur village, Tq.Jamkhandi, Dist.Bagalkot. The Company has
established its factory in the said area with all the infrastructure facilities like Staff Quarters,
Guest House, Workers Quarters, Canteen, School, Medical and Bus facility etc. The initial
crushing capacity was 2500 TCD. The capacity was expanded from 2500 TCD to 8000 TCD
during the year 2009 -2010, 8000 to 10000 TCD during the year 2010-11 and finally to 12000
TCD in the year 2015-2016 with a view to crush all the available sugarcane in the area of
operation.
M/s Siddapur Distilleries Limited.,
Pre-Feasibility Report Page 10
2.2 BRIEF DESCRIPTION ABOUT THE NATURE OF THE PROJECT
M/s. Siddapur Distilleries Limited., has proposed to expand and modified its Molasses Based
Distillery Plant from 60 KLPD to 70 KLPD through process modification in its existing
Distillery Plant at Sy. Nos. 49/2B/1 & 2, 57/2D & 2E, 58/1B, 58/1A/3, 66/4D, 85/2, 87,
93/2/3, 95/1 & 107/2, Siddapur village, Jamkhandi Taluk, Bagalkot District, Karnataka State.
The unit has 30 Acres of land in the name of “Siddapur Distilleries Limited., Siddapur village,
Jamkhandi Taluk, Bagalkot District, Karnataka State.
Molasses is used as a raw material which is easily available from our parent sugar factory i.e
Shri Prabhulingeshwar Sugars & Chemicals Limited (SPSCL) and nearby sugar factory.
1. Existing :- 60 KLPD
2. Proposed :- 70 KPLPD
2.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND/REGION
India is the largest producer of sugarcane as well as sugar in the world. The sugar industry
occupies a pride of place in rural economy. Most of the sugar industries are located in rural
areas providing employment to rural masses.
The molasses is used mainly for production of ethyl alcohol. There are more than 350
distilleries in the country with annual installed capacity 4.295 billion liters of alcohol
production and licensed capacity 4.527 billion liters. The alcohol production in the year
2007 was 2.3 billion liters. At present the state of Karnataka is having 35 distilleries.
Molasses is considered as one of the valuable by-products of sugar industry. The total
molasses availability in the country was around 85.49 lac MT in 2005-06 and increased up to
131.11 Lac MT in 2006-07 and to 113.11 Lac MT in 2007-08. However, molasses produced in
the country in the year 2008-09 was 65.42 Lac MT. In the ensuing crushing season, the
crushing of cane and molasses will be highest and the required quantity will be available to
all the distilleries in the state.
CAPACITY OF DISTILLERY:
Normally distilleries are expected to work for 270 days in a year and most of the distilleries
in India have adopted seasonal working of their distilleries in view of the fact that they can
receive surplus steam and power from their sugar factories. It is an important consideration
to keep the cost of production low. Some factories have installed independent boiler and
turbo-alternator to run the Distillery unit during off season. This will help the distilleries to
use all available molasses.
M/s Siddapur Distilleries Limited.,
Pre-Feasibility Report Page 11
Following few suggestions shall be useful for proper designing of the distillery:
1) Management should take efforts to supply molasses in adequate quantity to the
distillery.
2) Both distilleries and sugar factories should have adequate molasses storage tanks of
mild steel.
3) As per the latest norms of CPCB, all distilleries are required to achieve “Zero Liquid
Discharge” (ZLD) of spent wash. Therefore, necessary measures should be taken by the
management to achieve Zero Liquid Discharge (ZLD) and prevent any kind of pollution in
surrounding area.
Molasses is risk as it has a property of auto – combustion and its BOD is as high as
9, 00,000 mg/lit. Thus, even a small escape can result in large scale fish kill. Bagasse if not
baled can become air-borne fugitive with high SPM nuisance. We shall attempt to minimize
this by using some fraction of molasses and bagasse.
This is precisely the main objective of this project, which will be supported by low or no
discards and conservation of resources. This type of plant is likely to be more viable in view
of present situation, when the Organic Chemicals have demand in the particular market and
Global inflow of money is permissible. This has a foreign-exchange saving/ earning potential.
Ethanol has assumed a very important place in the economy of the country. It is used as a
raw material for number of organic chemicals, as a potential fuel in the form of power
alcohol when blended with petrol and as an ingredient in beverages. Use of ethanol as a
main ingredient in beverages is well known. Further, it is a major source of revenue by way
of excise duty to the State Governments. The economic and social significance of alcohol
production has of late assumed considerable importance all over the world. The importance
and utility of ethanol as an industrial raw material for manufacture of variety of organic
chemicals is now being increasingly appreciated all over the world. This is partly due to the
escalating costs of these chemicals produced through petrochemical route consequent and
abnormal increase in crude oil prices. Crude oil which was sold at 2 dollars per barrel in 1969
is now around 135 dollars. The price is predicted to increase rise further depending upon
International situation and with depletion/exhaustion of petroleum resources of the world.
Hence the proponents have proposed to expand and modified its Molasses Based Distillery
Plant from 60 KLPD to 70 KLPD through process modification in its existing Distillery.
2.4 DEMANDS‐SUPPLY GAP
Molasses is a very important by-product of the sugar industry. The profit earned by
conversion of molasses to alcohol shall be much higher than the value released by sale of
molasses. There is a good demand for alcohol in the country as production and consumption
of alcohol in India is quite balanced. The target of alcohol demand as projected in the
perspective plan for chemical industry, prepared by government of India, Ministry of
M/s Siddapur Distilleries Limited.,
Pre-Feasibility Report Page 12
Industry, Department of chemical and petrochemicals is 2400 million liters per annum by
year 2000. In addition, now days, there is a good potential to export alcohol out of country.
Alcohol has assumed a very important place in the economy of the country. The importance and utility of alcohol is well known as an industrial raw material for manufacture of a variety of organic chemicals including pharmaceuticals, cosmetics, potable alcohol etc. This is partly due to high costs of products produced through petroleum route, consequent to the phenomenal increase in petroleum price. Further, it is a potential fuel in the form of power alcohol when blended with petrol. Alcohol is a substitute to the imported petroleum. Being produced from renewable source it is an environmental friendly product. Large demand is also anticipated for its use as fuel. Use of alcohol as an ingredient in beverages is well known. It is a major source of revenue by way of excise duty for the State Governments. It follows that the supply of industrial alcohol to chemical and drugs units in the country will
remain below normal for some more time.
In order to maintain proper rate of growth of Industries, production of alcohol must
increase. Denatured spirits are rectified spirit made unfit for drinking by addition of
chemicals, which have strong disagreeable odor and which cannot be easily separated from
spirit. The Denatured Spirits are taxed at a nominal rate so that their use in industry
becomes economical.
Ethanol has a potentiality as fuel in the form of “power alcohol” for blending with petrol.
This trend is continuing and will continue in view of the fact that potable liquor has larger
revenue generating potential for the Governments. The demand for alcohol will always be
there for industrial purposes. Further the use of alcohol in automobile fuel will enhance the
demand for alcohol. Other than the above mentioned major requirement, alcohol is also
being used in the production of many downstream chemicals including drugs, polymers,
plastic, etc.
2.5 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.
2.6 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 fulfill the current
requirement of alcohol in domestic as well as export market.
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2.7 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO PROJECT. M/s. Siddapur Distilleries Limited will give direct employment to local people based on qualification and requirement. In addition to direct employment, indirect employment shall generate ancillary business to some extent for the local population.
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CHAPTER 3
PROJECT DESCRIPTION 3.1 TYPE OF PROJECT The proposed project is expansion and modification of Molasses Based Distillery Plant from
60 KLPD to 70 KLPD through process modification in its existing Distillery Plant.
3.2 LOCATION OF THE INDUSTRY M/s. Siddapur Distilleries Limited., is established at Sy. Nos. 49/2B/1 & 2, 57/2D & 2E,
58/1B, 58/1A/3, 66/4D, 85/2, 87, 93/2/3, 95/1 & 107/2, Siddapur village, Jamkhandi Taluk,
Bagalkot District, Karnataka State. Google Map Showing Project Site is shown in Fig 3.1
Fig 3.1 Google Map Showing Project Site
618 m above MSL; Latitude: 16°26'17.03"N ; Longitude: 75°16'16.77"E
PROJECT SITE
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Fig 3.2 Map showing the Project Site Location on District Map of Bagalkot
LOCATION MAP
LOCATION
MAP OF THE
PROJECT SITE
M/s Siddapur Distilleries Limited.,
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Fig 3.3 Plant Layout Plan
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3.3 BASIS OF SELECTING THE SITE
The efficient functioning of any industry mainly depends on the availability of its basic requirements viz. raw materials, fuel, power, water, manpower etc. The industry is established in Siddapur village, Jamkhandi Taluk, Bagalkot District, Karnataka State. The choice of the land confers several advantages, which are summarized below.
1. The site is well connected by roadways. 2. Water will be supplied from Krishna River. 3. Power will be supplied from M/s Shri Prabhulingeshwar Sugars & Chemicals Limited (SPSCL). 4. No incidence of cyclones, earthquake, floods or landslides in the region.
3.4 SIZE/MAGNITUDE OF OPERATION The industry “M/s. Siddapur Distilleries Limited.,” is a large scale industrial unit with a total capital investment of the Expansion project is Rs.1.16 crores. The total production capacity proposed is 70 KLPD. 3.5 PRODUCTS MANUFACTURED
3.5.1 MANUFACTURING PROCESS TECHNOLOGY
Rectified Spirit production is based on Fed Batch Fermentation Technology with yeast
recycle using yeast separators for production of ENA and RS. Yeast strain used has property
to form flocks and settle faster than sludge present in the medium. Thus separation and
recycle of sludge is avoided employing the special strain of yeast. The yeast cream obtained
by settling is subjected to centrifugal yeast separation, acidified and then reactivated in the
dilute molasses medium. The reactivation stage brings back the yeast to normal stage and
performs better compared to recycling yeast without reactivation stage. Yeast separation
employing yeast separators ensures separation of maximum yeast bio-mass and
maintenance of required Yeast concentration in the medium leading to higher fermentation
efficiency, higher productivity and generation of less quantity of spent wash.
Adequate space has been provided for foaming to minimize the requirement of antifoam
compound.
Effective wash cooling and monitoring of parameters viz fermentation temperatures, pH,
YCS, contamination level, residual sugars and alcohol concentration will ensure highest
fermentation efficiency and better yield per MT of molasses.
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3.5.2 PROCESS DESCRIPTION – 70 KLD BASED ON MOLASSES
Rectified Spirit production in the plant is based on Fed Batch Fermentation Technology.
Production of Rectified spirit is mainly carried under the following three steps.
1. Dilution - Preparation of molasses for fermentation
2. Fermentation - Production of alcohol from fermentable sugars in molasses soln.
3. Distillation - Product Recovery
Each of the above steps of production are detailed below:
Dilution
Molasses available from sugar mills (Our parent company Shri Prabhulingeshwar Sugars &
Chemicals Ltd.) contains solid content between 76-90 % and sugar content varies between
45 and 50 %
The main dilution operation occurs in a diluter where the solid concentration is brought
down to 20 – 25o Brix. The bulk of this diluted molasses is fed to the fermentation tank while
a small quantity is further diluted to 10 – 15o Brix and used for preparation of the final yeast
inoculum. Propagation of yeast for the final inoculation is done in successive stages in
volumes of 10, 100, 1000 and 10,000 liters where in each stage 10 parts of diluted molasses
is inoculated with 1 part yeast culture.
Fermentation
Fermentation in the fermentation tank continues for about 15 to 20 hours after the final
inoculum is added to it. The basic reaction in the fermentation process is
C6H12O6 ----- 2 C2H5OH + 2 CO2 + 26 calories
Glucose Ethyl Alcohol + Carbon dioxide + Energy
Yeast seed material is prepared in water-cooled yeast vessels by inoculating molasses with
yeast. The contents of the yeast vessel are then transferred to the yeast activation vessel.
The purpose of aerated yeast activation vessel is to allow time for the yeast cell
multiplication.
Fermentation:
The purpose of fermentation is to convert the fermentable sugars into alcohol. During
Fermentation, sugars are broken down into alcohol and Carbon dioxide. Significant heat
release takes place during Fermentation. Fermentation temperature is maintained at
optimum level by forced recirculation heat exchangers.
Fermentation process on Fed batch mode which is very feasible for the molasses having
higher valve of volatile acids by using culture yeast .Which offers you the flexibility of
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running the process in Fed batch. Inoculation of yeast culture is 20% filling of molasses is
13 hours ,total fermentation period 24 -28 hours and residuals sugars is controlling at >
1.60% and achieved the average Alcohol is 10-11% then finally total spirit yield will be 270-
280 MT of molasses.
In this Fed batch fermentation to increase in the alcohol in wash. The plant capacity will be
increased by 10-15%. However the steam consumption will be remain same and the
generation of Spent wash will be reduced by 3-4% by this process optimum efficiency can be
achieved.
Distillation:
Fermented wash is preheated in fermented wash preheater and fed to the analyzer column.
The dilute alcohol water vapors from the analyzer top are fed to the Pre-Rectification
column. An impure spirit draw of 3 % is drawn from this column. Bottom liquid from Pre-
Rectified column is fed to the IS purification column. Draw from IS purification column is fed
to purified column.
The purification column is operated under atmospheric pressure and is heated by using
steam. The bottom of this column is maintained at 20%v/v alcohol and is fed to the
rectification/ Exhaust column. A small draw from the top of the column is fed to the IS
Purification column.
The purified rectified spirit is removed from the bottom of the purified column.
The Lees from the Exhaust column bottom is used to pre heat the heat from the purified
bottom to the Rectifier/ Dilution water.
Lower side draws streams are taken from Rectified column to avoid fusel oil build up in the
column. These streams are then taken to the IS Purification column.
The total spent wash generation from the process is estimated to be about 6 kl/ kl of RS
produced.
The total waste water generation from the plant is about 593.2 m3/day.
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3.5.3 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 2 and 3 transferred to
Fermenter. Because of fresh yeast culture and good retention time we will get average
alcohol of 11% in 30 hr retention. 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.
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 8 columns, namely CO2 stripper, analyzer column, Pre-rectifier
column, Extraction column, Rectification Column, Refining Column, Fusel Oil column & HCC
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
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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 condensed in analyzer column for giving heat to stripper re-boiler. Most of the other
columns work under vacuum.
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.
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PROCESS FLOW CHART FOR DISTILLERY
Molasses Arrives
Molasses Weighed & Diluted
Yeast propagated with Molasses in Sterilized Separate vessels
Fermentation
Clarified Wash Tank
Analyzer column
Pre-Rectifier column if required
Rectifier Column
Exhaust column
Reboiler
Fused oil separated and Alcohol Returned
Rectified Spirit
Molecular Sieve Dehydration Bed
Absolute Alcohol / Ethanol
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3.5.4 Brief description of Fed Batch Process
1. The Fermentation plant consists of 4 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 700 m3/hour fermented wash with 11% v/v alcohol to feed 70 KLPD distillery plant. So, 4 fermenters are used. 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 extra fermenters, they can increase capacity by 30% to the existing.
3. Yield and quality of product are of high standard.
4. To convert the existing “Continuous Fermentation System” into “Fed Batch System” to
increase Alcohol content in Fermented Wash from 10.5 % to 11% v/v
5. It consumes less quantity of steam and operates efficiently.
6. Yield and quality of product are of high standard.
7. High Brix fermentation & more Alcohol % in wash i.e 10% to 11% v/v, when compared
to Continuous Process 8% to 9% v/v.
8. For every batch fresh culture is to be added. This will avoid bacterial contamination.
9. Changing process parameter for every batch depending on the Molasses characteristic.
10. Minimize the acid formation in Fermentation Media for getting good quality of
Alcohol & to increase the yield.
11. Due to increase in the Alcohol % in wash, the plant capacity will be increased by 15
to 20%. However the steam requirement remains same.
12. The generation of spent wash will be reduced by 3 to 4%.
13. The term fed signifies that fed is provided at a required rate to fermentation
system
Without getting accumulated.
14. Simple to operate.
15. Proper control on operating parameters.
16. Optimum efficiency can be achieved.
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3.5.5 Major difference b/w continuous & Fed batch Fermentation process
The Major difference b/w continuous & Fed batch Fermentation process is stated in table
3.1
Table 3.1 Major difference b/w continuous & Fed batch Fermentation process
Sl. No.
Description Continuous Fed batch
1 Alcohol yield in % 10.5 % 11 %
2 Yeast generation Less More 3 Spent wash Based on
Molasses : 420 KLD
Based on molasses 420
KLD
4 Spent lees Based on Molasses: 80
KLD
Based on Molasses : 70
KLD
5 Water consumption
940 KLD 770 KLD
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 to 20%. Using a portion of the diluted molasses a
yeast culture is developed from an inoculum. After 4-6 hours, when the culture has
developed fully, the remaining molasses is mixed and allowed to ferment 30hours. The pH is
maintained around 4-4.5 by addition of sulphuric acid. As the reaction is exothermic, the
contents of the fermentation tank are kept at 32 to 330C by circulating through plat sheet
exchanger. Due to increased retention, higher sugar cane and fresh yeast will get higher
alcohol (Average 11% )in fermenter.
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 and forms
another waste stream.
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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 the quality of molasses affects
immediately.
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. 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 diluent for the treated spent wash.
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3.5.6 BLOCK DIAGRAM of EXISTING 60 KLPD PLANT Steam 216 MT CO2 49 MT Process Water 416 KL
Molasses Fermented 224 MT Wash 640
Alc + Water Vap Spent Wash Spent Leese 80 KL
Biogas to Boiler Spent Leese 80 KL
420 KL Conc. Spent Wash
Process Condensate 80 KL
TRSW 420 KL
Treated Water Used for Gardening & Plantation.
Aerobic Treatment Plant
160 KL
Distillation
Fermentation
Evaporator
Biogas Plant
RS/ ENA / Ethanol
Bio-Composting Processing
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3.5.7 BLOCK DIAGRAM of 70 KLPD PROPOSED PLANT
Steam 216 MT
CO2 54 MT
Process Fresh
Water 230 KL
Molasses Fermented
260 MT Wash 660 KL
Alc + Water Vap
Biogas to Boiler Spent Leese 70 KL
Spent Wash
520 KL Spent Wash
Process Condensate Water 100 KL
TRSW 420 KL
Treated Water Used for Process (170 KL)
Fermentation
RS /ENA / Ethanol
Bio-Gas Plant Evaporator
Bio-Composting Processing
Treated with Physiochemical
treatment
Distillation
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3.6 RAW MATERIALS
Molasses is the main raw materials. A detail of the raw material used in the plant is stated in below table. 3.2
Table -3.2 Raw Materials Requirement
Sr No Particulars Quantity MT/Month
EXISTING
1 Molasses 6720
2 Deformer 3.0
3 Urea 1.3
4 DAP 1.2 PROPOSED
1 Molasses 7800
2 Deformer 3.5
3 Urea 1.5
4 DAP 1.4
3.6.1 STORAGE FACILITY FOR RAW MATERIALS AND PRODUCTS Adequate storage facility for Raw materials such as Molasses, Press mud is provided in an
area of 4.0 Acres.
SDL has 3 Nos (three) molasses storage tanks of capacity 6500 MT the storage tanks have
been provided with necessary dyke walls & cooling arrangements as per excise
department’s guidelines.
Storage facility for molasses (6500 MT x 02 Nos.) is also provided by our parent company
M/s. Shri Prabhulingeshwar Sugars & Chemicals Limited (SPSCL).
SDL shall use the existing storage tanks Total capacity of 7500KL (i.e. RS-1183KL, ENA-2725,
FA-3200 & IS-380 respectively) for storage of RS, ENA & Ethanol.
SDL has adopted the following method for treatment of spent wash :
The industry is treating the effluent (Spent wash) in anaerobic digester followed by bio
composting. The area of the compost yard is 31 acres including storage area. Compost yard
provided is as per the MOEF / CPCB guidelines. SDL has provided necessary storage facilities
for the storage of spent wash generated over a period of 30 day.
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3.7 MACHINERY & EQUIPMENT DETAILS The detailed list of machinery & equipments in the industry are appended in the tables 3.3 below
TABLES 3.3: TECHNICAL SPECIFICATIONS FOR 60 KLPD DISTILLERY PLANT CONTINUOUS FERMENTATION AND MULTI PLRESSURE DISTILLATIONS
Sr. No.
Particulars Remarks
1 A B
Molasses Day Storage Tank 1 No. Capacity Material Size Raw molasses pump, Gear type with gear box, drive motors (day storage to weighing section)
550 m3
M.S. 9700 mm Dia x 8224 mm Height. Capacity – 15MT/hr. Drive HP – 10 HP, RPM 1450 Nos. - 1+1
2 Fermentation: Molasses weighing section:
i) Automatic molasses weighing system with duplex stirrer and with receiving tank.
ii) Weighed molasses tank: iii) Capacity:
Material iv) Check weighment with suitable system
approved by weights and measures department.
v) Weighed molasses pump: Gear box & motor, C.I. body with CI wetted parts (Weighing section to diluter) Make – PSP Gear type
Capacity – 20MT/hr. (2 MT/Tip) Volume – 4 m3
20 MT M.S. 20MT/hr. 10 HP, 1450 RPM 1+1 No. Capacity – 22MT/hr. (2 MT/Tip)
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3
Fermentation Section:
i) Yeast vessels with sterilizing & cooling arrangement ( Min.3 mm thick) with filtered & moisture free air & other fitting. MOC
ii) Tank for antifoam agent Volume Material Quantity
YV-I-300 lits. YV-II-3000 lts. Pre – Fermenter - I Cap 50000 Liters Pre – Fermenter - II Cap 60000 Liters SS 304 1 M3
SS 304 1 No.
iii) Cleaning in place tank Volume Material Quantity
10 M3 SS 304 1 No
4 Fermenters: (Gross capacity) with mountings for antifoam dosing air Spurger, sight and light glass, manholes, level indicators, pressure relief device and accessories. MOC
350 M3 each SS 304 4 Nos. with stiffeners sparger and all fittings in contact with wash made. SS 304
5 Plate type heat exchangers HTA m2 (Total) MOC
6 Nos. 156 m2 For fermenter cooling plate SS 316
6 Clarified wash tank Capacity Material
60 m3 SS 304 Clarified wash holding tank (on ground floor)
7 Air blower twin lobe type with motor with air purifier (Bacteria proof)
700 m3/hr. 40 HP, 1 No. CI body with motor twin lobe type
8 Air filters (Bacteria proof) Corrugated HEPA type, 1 No.
9 CO2 Scrubber
0.625 mm diameter. SS 304 Sieve tray type 1 No.
10 Pumps with motor: 1. Antifoam pumps. 2. Process water pump 3. Fermented wash recirculation pump 4. Fermentation Cooling Tower Pumps 5. Pre-fermenter to fermenter pump 6. Yeast vessel transfer pump YV2 & YV3 7. Clarified wash pump (F.W to Distillation) 8. C.I.P. Pump 9. Sludge transfer to Decenter
Capacity / MOC/ Quantity: 0.250 m3/hr. SS304, 1+1 Nos. 50 m3/hr. CI, 1+1 Nos. 240 m3/hr. SS316, 1+1 Nos. 300 m3/hr. SS316, 700 m3/ hr, CI 1+1 Nos. 20 m3/hr. SS316, 1+1 Nos. 3 m3/hr. SS316, 1+1 Nos. 35 m3/hr. SS316, 1+1 Nos. 10 m3/hr. SS316, 1+1 Nos. 10 m3/hr. C.S. 1 No.
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11 Piping: Molasses Fermented wash Fermented wash recirculation Process and cooling water CO2 / Air Antifoam agent
MS-“C” class SS304 Sch - 10 SS304 MS Class “C” MS Class “C” MS Class “C”
12 Valves: Fermented wash Process and cooling water CO2 / Air Antifoam agent
CS/ SS304 CI with Neoprene SS304 internals MS
13 Instruments
Instruments as per process requirements.
1 Distillation: CO2 stripping column
a. Diameter b. MOC c. No. of plates d. Type of plates e. Plate spacing f. Thickness: Shell/Plate/Cap.
1000 mm SS 316 8 Nos. Bubble cap Suitable (500 mm) nominal 4/2/1.6 mm
2 Stripping column: a. Diameter b. MOC c. No. of plates d. Type of plates e. Plate spacing f. Thickness: Shell/Plate/Cap.
2200 mm SS 316 Suitable ( 22 ) Bubble cap Suitable (750 mm) nominal 4/2/1.6 mm
3 Pre -Rectifier column: a. Diameter b. MOC c. No. of plates d. Type of plates e. Thickness: Shell/Plate/Cap.
1700 mm Deoxidized copper/ SS 304 Suitable (72) Bubble cap (300 mm) nominal 5/2/1.6 mm
4 Extraction column: a. Diameter b. MOC c. No. of plates d. Type of plates e. Plate spacing f. Thickness: Shell/Plate/Cap.
2000 mm Deoxidized copper Suitable (44) Bubble cap Suitable (300 mm) nominal 5/2/1.6 mm
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5 Rectifier column: a. Diameter b. MOC c. No. of plates d. Type of plates e. Plate spacing f. Thickness: Shell/Plate/Cap.
1475 mm Deoxidized copper Suitable (72) Bubble cap Suitable ( 225 mm) nominal 4/2/1.6 mm
6
Refining column: g. Diameter h. MOC i. No. of plates j. Type of plates k. Plate spacing l. Thickness: Shell/Plate/Cap.
1100 mm Deoxidized copper Suitable (45) Bubble cap Suitable ( 300 mm) nominal 5/2/1.6 mm
7 Fusel Oil column: a. Diameter b. MOC c. No. of plates d. Type of plates e. Thickness: Shell/Plate/Cap.
675 mm SS 316 Suitable (50) Bubble cap ( 250 mm) nominal 3/2/1.6 mm
8 Head Concentration Column a. Diameter b. MOC c. No. of plates d. Type of plates e. Plate spacing f. Thickness: Shell/Plate/Cap.
900 mm SS 304 Suitable (50) Bubble cap (250 mm) nominal (250 mm) 3/2/1.6 mm
9 Aldehyde column (Alcohol scrubber): a. Diameter
b. MOC c. No. of plates d. Type of plates e. Plate spacing f. Thickness: Shell/Plate/Cap.
735 mm SS 316 Suitable (10) Sieve (250 mm) nominal 2.5/2/1.6 mm
10 Re - boiler for stripping column a. HTA b. MOC
275 m2 nominal SS 304/ MS
11 1ST Re -boiler for extraction column a. HTA b. MOC
15 m2 nominal Deoxidized copper / SS304
12 2nd Re - boiler for extraction column a. HTA b. MOC
85 m2 nominal Deoxidized copper/SS 304
13 Re - boiler for rectifier column a. HTA b. MOC
280 m2 nominal Tubes – Deoxidised copper Shell MS with SS contact parts
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14 Re - boiler for fusel oil column a. HTA b. MOC
8 m2 nominal SS304/MS
15 Re - boiler for refining column a. HTA b. MOC
65 m2 nominal SS 304
16
H C C Re - boiler a. HTA b. MOC
25 m2 nominal SS 304 / MS
17 Principle condenser with vapour bottle / evaporator body. a. HTA b. MOC
See evaporator 1st stage
18 Beer heater with vapour bottle /evaporator body a. HTA b. MOC
See evaporator 2nd stage SS316
19 Vapour condenser with vapour bottle a. HTA b. MOC
40 m2 Deoxidized copper / MS
20 Impure spirit cooler a. HTA b. MOC
10 m2 Deoxidized copper / MS
21 ENA cooler a. HTA b. MOC
28 m2 Deoxidized copper / MS
22 R.S. Cooler a. HTA b. MOC
30 m2 Deoxidized copper / MS
23 Fusel Oil cooler a. HTA b. MOC
10 m2 SS 316 / MS
24 Fusel oil de-canter MOC
SS 316
25 Plate heat exchangers a. MOC b. Qty. c. HTA m2
Plate – SS 316, Frame-MS with Anticorrosive coating 4 Nos. 13 + 6 + 4 + 1
26 Steam chest with fittings a. Size b. Accessories
600 mm, 1000 mm long Safety valve, drain, inlet/ Outlet steam valve etc., (1 No.)
27 Cold water tank a. Capacity b. MOC
36 m3 Mild steel
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28 Hot water tank a. Capacity b. MOC
2 m3 Mild steel
29 Piping – MOC a. Fermented wash b. Water, steam c. R.S/ENA d. Impure spirit e. Fusel oil
SS 304 MS Copper / SS 304 Copper / SS 304 SS 304
30 Valve – MOC a. Fermented wash b. Water, steam c. Rectified spirit d. Impure spirit e. Fusel oil
SS with SS 304 internals CI SS with SS 304 internals SS with SS 304 internals SS with SS 304 internals SS with SS 304 internals
31 Instrumentation and controls Flow meters & Rota meters Temperature indicators Pressure gauges Other instruments
1 Set
32 Control panel 1 Set As per process Requirements
33 PLC panel 1 No.
34 Distillation pumps with flame proof motor Type MOC Quantity
Centrifugal SS 316 for contract parts 18 + 18 Nos.
35 Vacuum pump MO Quantity
CI body CI internals 1 + 1
36 Condensate transfer pump SS304
Included in Evaporator section.
37 DCS/PLC Modules and Rack, software and communication cable.
1 Lot
38 PC Pentium III with 15” Monitor and Printer 1 Lot.
39 Software package for SCADA 1 Lot. 40 Instrumentation and control 1 Lot.
41 Energy (power) meter 1 No.
42 Vent condenser for rectifier 5 m2, SS 304
M/s Siddapur Distilleries Limited.,
Pre-Feasibility Report Page 34
SPENT WASH CONCENTRATION SYSTEM SPECIFICATION OF EQUIPMENTS FOR SPENT WASH CONCENTRATION SYSTEM (EVAPORATION)
Sr. No. Particulars Specifications
1 Stripper Bottom Spent Wash Feed to evaporator 1st Body Pump Capacity MOC Type
35 m3/hr SS304 . Centrifugal
2 Three effect evaporator calendria Type HTA m2
MOC Shell Tubes
EV-1 S & T 216 SS
SS 316
EV-2 S & T 170 SS
SS 316
EV-3 S & T 176 SS
SS 316
3 Vapour separator Capacity MOC
Suitable SS 316
4 Product transfer pump Capacity MOC Type
25 m3/hr. SS 304 for contract parts Centrifugal
5 Condensate pump Capacity MOC Type
13 m3/hr. SS 304 for contract parts Centrifugal 1 + 1
6 Vapor duct MOC
SS 304
7 Piping & valves for steam, product condensate, non-condensate etc.
SS 316 / 304 / mild steel
8 Barometeric condenser HTA MOC Type
265 sq mtrs SS 304 Shell & tube / spray
9 Vacuum pump Capacity MOC Type
160 m3/hr. 1 + 1 Qty. SS 304 Water ring vacuum
10 Control panel Included in distillation.
11 Instruments & controls 1 set
12 Circulation transfer pump: 1. Axial flow pump - Capacity 2. Axial flow pump - Capacity 3. Axial flow pump - Capacity 3. Spent wash transfer pump - Capacity
SS 316 for contact parts 1026 m3/hr. 800 m3/hr. 800 m3/hr. 36 m3/hr.
13
Distillation Cooling Tower Pumps
Capacity / MOC/ Quantity: 1100 m3 /hrs, CI 1+1 Nos
M/s Siddapur Distilleries Limited.,
Pre-Feasibility Report Page 35
EQUIPMENT LIST FOR INTEGRATED MOLECULAR SIEVE BASED 55.2 KLPD FUEL/ANHYDROUS ALCOHOL PLANT
Sr. No.
Particulars Qty. Remarks
1
Absorber bed with molecular sieve a) Material of construction. b) Overall dimensions (shell + dish end +
skirt support)
3
-- AISI 304 1200 mm Dia x 6000 mm Ht.
2 Feed Sieve Vaporizer Heater a) Material of construction shell b) Tubes
1
(AISI 304 Wetted Parts)MS AISI 304
3 Feed Economizer – Plate heat exchanger type a) Heat transfer area b) Product Control Part – PHE c) Frame material PHE
1 1.7 m2 SS 316
4 Regeneration Cooler – Plate Heat Exchanger Type
a) Heat transfer area b) Product Contact Part PHE
1 22 m2 SS 316
5 Product Cooler –Plate Heat Exchanger Type a) Heat transfer area b) Product Contact Parts material PHE
1 1.2 m2 SS 316
6
Regeneration Condenser - Plate Heat Exchanger Type
a) Heat transfer area b) Product Contact Parts material PHE
1 22 m2 SS 316
7 Regeneration Tank: a) Capacity b) Material of construction
1
1.4 m3 AISI SS 304
8 Feed Pump with flame-proof motors Capacity Head MOC
2 2.4 m2/hr. 55 mtrs (AISI 304)
9 Flame -proof motors with Pump /starter / push button) Capacity Head MOC
2 2.4 m3/hr. 15 mtrs (AISI 304)
10 Regeneration pumps with flame proof motors Capacity Head MOC
2 20 m3/hr. 65 mtrs (AISI 304)
M/s Siddapur Distilleries Limited.,
Pre-Feasibility Report Page 36
11 Product storage pumps with flame proof motors/ starter/push button Capacity Head MOC
2 40 m3/hr. 25 mtrs (AISI 304)
12 Pumping valves & Instrumentation Piping Alcohol Water Steam Valves Alcohol Water Steam
SS 304 Sch 10 M.S “C” Class M.S “C” Class C. S. IBR SS 304 C.I C.S. IBR
13 Instrumentation & Control: a) Temperature indicator b) Pressure indicator c) Temperature transmitter d) Pressure transfer e) Flow indicators f) Flow transmitter g) Flow indicating controllers h) Control valves i) On Off valve j) Ball Valves k) Globe valves l) Pressure setting valve m) Other local indicators as per the
process requirement
1 Lot
14 Supply of electrical material such as cables, starters, push button, electrical motors: Kirloskar Cromption Greaves Siemens make.
1 Lot
15 Motor control Centre (MCC + PLC Panel) Included in distillation 16 Chilling Plant 2 No. 2 TR + 4TR
17 Chilled water circulation pump Capacity Head MOC
2 Nos. 2.5 m3/hr. 6 mtrs C I
18 Compressor with air dryer Capacity
2 Nos. 1 No
7.5 m3/hr. @ 6 Bar (g) 8 m3/hr. @ 8 Bar (g)
19 PLC modules and rack, software & communication cables.
Included in distillation
20 PLC Pentium III with 15” monitor & printer, Software and SCADA
Included in distillation
M/s Siddapur Distilleries Limited.,
Pre-Feasibility Report Page 37
21 Recovery Column Capacity MOC
1 No.
720 mm Dia 18 Trays, Bubble Caps SS 304
22 Flow meter with totalizer Capacity 1 No. 40 m3/hr.
RECEIVERS & STORAGE FOR RECTIFIED SPIRIT / IMPURE SPIRIT 1 Rectified Spirit Receivers Tanks
Capacity Number
70 m3 3
2 Rectified Spirit Bulk Storage Tank Capacity Number
950 m3 1
3 Impure Spirit Receivers Capacity Number
20 m3 3
4
Receivers (Technical Grade) Capacity Number
20 m3 3
5
Impure Spirit storage tank with a suitable vent condenser & flame arrester. Capacity Number
100 m3 & 150 m3
2
6 Denatured Spirit tank Capacity Number
70 m3 2
7 Flow Meters: Flow meters with totalizer
2 Nos.
8 Alcohol Pumps: Capacity Numbers Material Motors/Starter
20 m3/hr., 40m3/hr. 4 Nos. (2+2), 2 Nos.(1+1) SS 316 Flame proof
RECEIVING & STORAGE TANKS FOR ENA:
1 ENA Receivers Capacity Number
60 m3 3
2 ENA Storage tanks Capacity Number
950 m3 – 03 Nos and 250 m3- 01No & 190 m3 - 2 Nos 6
3 Flow Meter with totalizer Number
1 No.
4 Issue pump set Number
1 + 1
M/s Siddapur Distilleries Limited.,
Pre-Feasibility Report Page 38
Capacity Head MOC
40 m3 20 m C.S. body with SS 316 Shaft & impeller with Single mechanical seal
ABSOLUTE ALCOHOL RECEIVERS AND BULK STORAGE TANKS
1 Absolute Alcohol Receivers Capacity Number
60 m3 3 Nos.
2 Absolute Alcohol Storage tanks Capacity Number
850 m3 - 01 Nos. 950 m3 - 02 Nos 3 Nos..
Flame arrestors / level gauge / nozzle for dip / nozzle for overflow, feed, outlet, suction, Vent condenser for open installation spirit tanks
MOLASSES STORAGE TANKS
1 Molasses Day Storage Tank Capacity Number
800 M T 01 Nos.
2
Molasses Storage Tanks Capacity Number
6500 M T 0 3 Nos.
3 Molasses Unloading Masonry Pit Capacity Number
1100 MT 1 Nos..
M/s Siddapur Distilleries Limited.,
Pre-Feasibility Report Page 39
3.8 SOLID WASTE & HAZARDOUS WASTE
Solid waste generated from the industry is as follows:
Table 3.4 : Solid Waste generated
Sl.
No.
Type Quantity Storage Utilization/disposal
Molasses based
Existing Proposed
1 Fermenter Sludge
20 TPD
26 TPD
Separated by
Decanter machine
&collected in
Tractor Trolley
Mixed with Press Mud converting into organic manure
Hazardous Waste
2 Waste oil
300 LPA
300 LPA
Sealed Carboys
Used as lubricant for
Compost yard Aero
tiller & Composting
Machinery within the
premises.
3.8.1 DOMESTIC SOLID WASTE RE-USE
The quantity of solid waste generated from the proposed industry is detailed in the following table 3.5.
Table: 3.5 Solid Waste Generation during the Operation Phase
Total no. of employees 115
Assuming per capita solid waste generation rate as 0.20 kg/capita/day
Quantity of solid waste generated 23 kg/day
Organic solid waste : 60 % of the total waste 14 kg/day
Inorganic solid waste : 40 % of the total waste 9 kg/day
Disposal of domestic solid waste The domestic wastes are segregated at source, collected in bins and composted.
M/s Siddapur Distilleries Limited.,
Pre-Feasibility Report Page 40
3.9 WATER, ENERGY/POWER REQUIREMENT & SOURCE
3.9.1 Water
The water demand is met from Krishna River water supply. The requirement of water for the
unit is for domestic, industrial purposes. Details are appended in section 3.11.1 later in the
report.
3.9.2 Power
The Proposed power requirement of the Distillery plant is 800 KW/Hr, Distillery has given on lease a 2.50 MW TG set to our parent sugar plant i.e. SPSCL. The required power is available. During off season it shall depend on 1000KVA DG Set only.
3.10 WASTES GENERATED & SCHEME FOR THEIR MANAGEMENT/DISPOSAL
3.10.1 Water demand and wastewater/effluent discharge
The total quantity of water requirement for the industry is about 770 KLD. The break-up of the consumption of water is as presented in Table 3.6.
Table 3.6 Water Consumption and Discharge
Sl No
Particulars Existing water Consumption in KL / Day(60KLPD)
Particulars Expansion water Consumption in
KL / Day(70KLPD)
1 Water Consumption details
a Fresh water for molasses dilution
423.0 Fresh water for molasses dilution
253.0
b Cooling Tower Make Water
432.0 Cooling Tower Make Water
432.0
c Domestic 4.5 Domestic 4.5
d Gardening 70.0 Gardening 70
e Others 5.5 Others 5.5
f Floor washing 5.0 Floor washing 5.0
Total 940.0 Total 770.0
2 Waste water generation details
a
Spent Wash (ZLD, Bio-methanzation followed by Composting )
420.0 Spent Wash (ZLD, Bio-methanzation followed by Composting)
420.0
b
Spent Leese (Treated effluent used for irrigation or greenbelt development )
80.0 Spent Leese (Re-use in Process or cooling Tower make up)
70.0
M/s Siddapur Distilleries Limited.,
Pre-Feasibility Report Page 41
c
Process Condensate water(Treated effluent used for irrigation or greenbelt development )
80.0 Process Condensate
water(Re-use in Process or cooling Tower make up)
100.0
d Sewage Domestic ( Septic Tank Followed Soak fit)
3.2 Sewage Domestic ( Septic Tank Followed
Soak fit 3.2
Total 583.2
Total 593.2
Note: - 1) Sanctioned raw water quantity is 940 KLD from irrigation department Govt. of Karnataka. 2) Maximum fresh water requirement for molasses based process is 770 KLD.
The treatment methods and the final disposal of each type of wastewater generated is
appended in the table 3.7 below
Table 3.7: Sewage/effluent treatment and discharge
Sewage/effluent generated from
Treatment provided Final disposal point
(a) Domestic Sewage is treated septic tank Disposed in Soak pit
(b) Industrial RSW is treated with Full-fledged ETP with collection tanks are provided.
RSW is treated with Bio-Methanisation followed by Bio-Composting To archived ZLD Concept
(c) Industrial Spent leese Spent leese is treated with the phyiso-chemical treatment and re-use in cooling tower make up or process dilution purpose
3.10.2 TREATMENT OF EFFLUENTS AND DISPOSAL
The unit generates liquid, solids and air effluents. The mitigation measures for these
effluents are as follows:
Treatment of Distillery Spent Wash
The existing Distillery plant capacity is 60KLPD and the spent wash generated per
liter of alcohol is maximum 7.0-7.5 liters. However with the changes / optimization made in
our fermentation & Evaporation plant we are generating about 6.0 liter of spent wash per
liter of Alcohol.
M/s Siddapur Distilleries Limited.,
Pre-Feasibility Report Page 42
We have changed the Continuous fermentation process to Fed Batch system where the
spent wash generation is reduced, further to this we are concentrating the Biomethanated
spent wash in distillation column re-boiler so there will be further reduction in the spent
wash generation. The process condensate generated will be treated through Physio
Chemical treatment and recycled back to process plant.
We propose to increase the Distillery capacity from 60 KLPD to 70 KLPD and we have
adequate spent wash treatment facility in existing Effluent treatment Plant.
The spent wash is anaerobically treated in the digester. During this anaerobic
degradation, the organic matters are converted into Bio-gas (55% contains methane) which
brings down the BOD value to 7000 – 8000 mg/lit, from the original level of about 45000 –
50000 mg/lit. The generated Bio-gas is used as fuel in the boiler of our parent sugar factory.
Further, the concentrated spent wash is utilized for Bio-composting using sugar
factory press mud, boiler ash and other waste bagasse to produce useful organic manure.
Bio-composting Process:-
In the Bio-composting system, the process is carried out on a concrete floor yard by
aerobic windrow technology using special aerobic microbial culture. The sugar industry
press mud, boiler ash, waste bagasse and yeast sludge from the distillery are mixed suitably
and bio-activated on the concrete floor. The reaction is an exothermic one which helps to
evaporate the water content and gasses. The necessary windrow moisture for the process
is maintained by spraying of concentrated treated RSW through tanker on the windrows
uniformly and aero tiller machine is used to turn the material, the composting process is
aerobic condition. The Bio-composting process would take about 60 days for completion
and the ready Bio-compost manure is enriched and distributed to the farmers.
Thus, the entire spent wash generation during the alcohol production will be converted into
valuable Bio-compost manure. This environmental management plan is of “ZLD” (Zero
Liquid Discharge) Environmental concept of Pollution Control Boards.
Spent Lees & Process Condensate Water Treatment Plant System
Spent lees and the process condensate water is generated in the range of 170
m3/day we are treating this effluent through the most advanced treatment technique i.e
physio-chemical treatment and treated water is reused in the process plant.
M/s Siddapur Distilleries Limited.,
Pre-Feasibility Report Page 43
Waste Water Generation From Existing & Proposed Distillery
The source of waste water generation from the existing and proposed distillery unit is as below:
Sl No
Particulars
Existing water Consumption in KL / Day(60KLPD)
Particulars Expansion water
Consumption in KL / Day(70KLPD)
1 Waste Water Side
a
Spent Wash (ZLD, Bio-methanation followed by Composting )
420.0 Spent Wash (ZLD, Bio-methanation
followed by Composting)
420.0
b
Spent Leese (Treated effluent used for irrigation or greenbelt development )
80.0 Spent Leese (Re-use in Process or
cooling Tower make up)
70.0
c
Process Condensate water(Treated effluent used for irrigation or greenbelt development )
80.0 Process Condensate
water(Re-use in Process or cooling Tower make up)
100.0
d Sewage Domestic ( Septic Tank Followed Soak fit)
3.2 Sewage Domestic ( Septic Tank
Followed Soak fit 3.2
Total 583.2
Total 593.2
Solid Waste Generation from the Existing & Proposed Distillery
Sl. No.
Solid Waste in MT Mode of Disposal Existing 60 KLPD Proposed 70 KLPD
01 20 .0 26 .0 Mixed with Bio-composting
M/s Siddapur Distilleries Limited.,
Pre-Feasibility Report Page 44
Fig :- 3.4 FLOW CHART OF EXISTING & PROPOSED ENVIRONMENTAL MANAGEMENT PLAN (EMP)
Treatment plant unit list The wastewater treatment plant consist of the following unit operations and unit processes.
Aeration fountain: Ø4.1mtr, MOC: RCC lined
Open Channel: 45m X0.75 mtr (2Nos), MOC: RCC lined
Feed Tank:10 X10 X 15 M , Capacity : 150 M3, MOC: RCC lined
Buffer Tank: 12.50 X 8.00 X 3.00 mtr , Capacity : 600 M3 , MOC: RCC lined
Lars Enviro Structured Media Anaerobic Tank (LESMAT): Ø 32.5mtr X 10.5 mtr Height
Capacity -600 M3/day & Tank MOC – Mild Steel
Pre-Aeration Tank (PAT): 4.40 X 3.50 mtr, Capacity: 50 M3 ,MOC: RCC lined
Clarifier: 7.10X3.20 mtr, Capacity: 100 M3 MOC: RCC lined
Bio-Methanated Overflow Tank: 5.50 X 5.50X 2.00 mtr, Capacity: 50 M3 MOC: RCC
lined
5 Days RSW Storage Tank: Size- 36 x 25 x 3.5mtr capacity – 2500 M3
24 Days RSW Storage Tank: Size- 115.5 x 36 x 3.5mtr capacity – 12500 M3
Compost Yard Details: Press mud storage Area – 6.0Acre, Composting Area –18.0
Acre & Finished Compost Storage Area - 4.0 Acre
M/s Siddapur Distilleries Limited.,
Pre-Feasibility Report Page 45
Typical composition of spent wash
s Parameter Description
1 pH 4.0-4.5
2 BOD, mg/l 45,000-50,000
3 COD, mg/l 1,10,000-1,40000
4 Total Solids, mg/l 95,000 -105,000
5 Volatile solids , mg/l 12,000-30,000
6 Total Nitrogen, mg/l 4,500-5,000
7 Chloride, mg/l 3,500-4,500
8 Potassium as K, mg/l, 8,200-9,500
9 Sodium, mg/l 260-290
10 Sulphate, mg/l 2,500-3,200
11 Phosphorous as P2O5 1,050-1,200
12 Ash, mg/l 45-165
M/s Siddapur Distilleries Limited.,
Pre-Feasibility Report Page 46
ETP FLOW DIAGRAM
Raw Spent Wash
Anaerobic Digester
Storage Lagoon
Treated Physio Chemical system
Re-Boiler/Evaporation
Concentrated Spent Wash
Process Condensate
Reused in Process Section
Press Mud from Sugar Factory
Bio-Composting Process
Compost Manure to Farmers
M/s Siddapur Distilleries Limited.,
Pre-Feasibility Report Page 47
3.11 AIR POLLUTION DETAILS The major air pollution sources from the industry are DG set. These sources are provided with stacks of adequate height so as to disperse the emanating flue gases containing SPM, oxides of sulfur and nitrogen without affecting the ground level concentrations.
The sources of air pollution, type of fuel used, fuel consumption and chimney heights for each of the air pollution sources of the proposed project are indicated in the following table 3.8 .
Table 3.8 Sources of air pollution, type of fuel used, APC details
SI. no.
Stack attached to
Fuel used Fuel consumption
Number of stacks
Stack/s height
Air pollution control unit
Predicted emissions
1 D.G. set – 1000 KVA – 1 No.
HSD 58.75 L/hr
1
31 m AGL
Stack SOx, NOx, SPM
3.12 Noise pollution details The major source of noise pollution in the industry is the DG set for which acoustic enclosure is provided. Also ambient noise levels will be ensured within the ambient standards by inbuilt design of mechanical equipment and building apart from vegetation (tree plantations) along the periphery and at various locations within the industry premises. 3.13 Solid waste details The quantity of solid waste generated from the proposed industry is detailed in the following table 3.9 .
Table: 3.9 Solid Waste Generation during the Operation Phase
Total no. of employees 115
Assuming per capita solid waste generation rate as 0.20 kg/capita/day
Quantity of solid waste generated 23 kg/day
Organic solid waste : 60 % of the total waste 14 kg/day
Inorganic solid waste : 40 % of the total waste 9 kg/day Disposal of domestic solid waste The domestic wastes are segregated
at source, collected in bins and composted.
M/s Siddapur Distilleries Ltd.,
Pre-Feasibility Report Page 48
3.14 SCHEMATIC REPRESENTATIONS OF THE FEASIBILITY DRAWING
A schematic representation of the overall feasibility and environmental assessment process is shown in Figure 3.5.
Fig 3.5 Feasibility & environmental assessment process
Significant
Not
Economic
Feasibility study conducted for newly proposed industry
Statement of intent by proponent
Guidelines for EIA by SEAC/MoEF
Abandon project
Determine the coverage of the EIA - scoping
Describe the environment – baseline study
Describe the project
Identify the impacts
Evaluate the impacts
Mitigation
Preventive measures
Prepare draft EIS
FINAL EIA REPORT
CONSIDER ALL PHASES OF PROJECT –
CONSTRUCTION, DEVELOPMENT, INSTALLATION &
FINAL OPERATION/ PRODUCTION
SO
CIO
-ECO
NO
MIC
ISSU
ES
MO
NIT
OR R
EVIE
W
M/s Siddapur Distilleries Limited.,
Pre-Feasibility Report Page 49
4.1 SITE CONNECTIVITY
Table-4.1 Connectivity to Project Site Sl. No.
Road Distance from the project site (km)
Direction w.r.t. project site
1 SH-34 1.07 East
2 NH-218 44.39 East
3 Bagalakot Railway station 54.35 South East 4 Jamkhandi 6.5google North
5 Gokak Airport 58.99 South West
6 Belgaum 95.13 South West
Note: All distances mentioned are aerial.
Fig- 4.1 Google Map Showing Connectivity to Project Site
CHAPTER 4 SITE ANALYSIS
M/s Siddapur Distilleries Limited.,
Pre-Feasibility Report Page 50
4.2 LAND FORM, LAND USE & OWNERSHIP M/s. Siddapur Distilleries Limited., is Molasses Based Distillery Plant already established at
Sy. Nos. 49/2B/1 & 2, 57/2D & 2E, 58/1B, 58/1A/3, 66/4D, 85/2, 87, 93/2/3, 95/1 & 107/2,
Siddapur village, Jamkhandi Taluk, Bagalkot District, Karnataka State. Now the proponents
intend to expand the Molasses Based Distillery Plant from 60 KLPD to 70 KLPD through
process modification in the existing facility.
4.3 TOPOGRAPHY
M/s. SDL, is located at latitude of 16°26'17.03"N & longitude 75°16'16.77"E at an elevation
of 618 m above MSL. The topo map showing the location of the project site is appended as
fig 4.2.
Fig-4.2 Topo Map
M/s Siddapur Distilleries Limited.,
Pre-Feasibility Report Page 51
4.4 EXISTING LAND USE PATTERN
Table 4.2 Existing Land Use Pattern Sl. No.
Particulars Details Distance from the project site
(km)
Direction w.r.t. project site
1 Agriculture Major activities - scattered Beyond industrial area
-
1 Reserve Forest Jamakhandi 6.1 North 2 Hunasi Katte 5.7 North East
3 Siddapur adjacent -
4 Banahathi 5.2 North West
5 Hulyal 2.9 North East
6 Mantur 7.8 East, South East
1 Water bodies Krishna River 14.3 km North
2 Ghataphrabha left bank canal
1.3 South
3 Jamakhandi lake 5.6 North
Note: a) All distances mentioned are aerial.
4.5 EXISTING INFRASTRUCTURE
The list of existing infrastructure at the project site is 1. Water supply from Krishna River 2. Power supply will be from 800 KW/Hr, Distillery has given on lease a 2.50 MW TG set to
our parent sugar plant i.e. SPSCL. 3. Storm water drainage system is provided
4.6 SOIL CLASSIFICATION As a consequence of growing Demographic pressure, it is planned to increase food
production with an estimated average of 4 tons per hectare from the present 1.5 tons per
hectare to meet the growing demand in the country. Due to the great dependence and
pressure on land and water resources, obviously, there will be an effect on soil quality and
crop productivity. As per some estimates, the soils have been degrading at the rate of one
million hectares per year and 57% of geographical area is affected by various forms of
degradation viz., water and wind erosion, physical and chemical deterioration. The state
department of Agriculture has estimated that about 10% of irrigated (1.27 lakh ha)
command area are affected by problems such as water logging, salinity and alkalinity.
M/s Siddapur Distilleries Limited.,
Pre-Feasibility Report Page 52
Similarly a depletion of ground water levels has also been noticed at an alarming rate in recent times through the rapid depletion of the ground water resources. In this context, it is a great challenge to the scientific community, to evolve and develop appropriate strategies, to increase food production on a sustainable basis.
Nutrients and soil loss is a major problem where excessive leaching of soil occurs, besides
in continuous cropping, without adequate input of fertilizers and organic manure. It is
more rampant in areas where agriculture is practiced in poor or moderately fertile soils
without application of sufficient fertilizer or manure, which certainly leads to decrease in
agricultural production. Loss of soil organic matter, following clearing the natural
vegetation is also another way of nutrient loss. Plant nutrients are also depleted from soil
through crop removal, run off and soil erosion.
The loss of nitrogen by erosion is probably more serious than loss of any other nutrient,
since most of the nitrogen being lost is combined with soil organic matter, which is under
threat of erosion. Actual nutrient status of tank silt was not found to be much different
from that of the soil in the catchment area in studies carried out by the scientists of the Dry
land Agriculture project of the University of Agricultural Sciences, Bangalore and also by
the Department of Agriculture (1997). All such soils need different management and
reclamation measures. Their sustained use depends more on the economic concerns and
identification of sustainable alternative uses rather than agricultural production.
M/s Siddapur Distilleries Ltd.,
Pre-Feasibility Report Page 53
4.7 CLIMATIC DATA FROM SECONDARY SOURCES
Table 4.3: Meteorological Data of Bagalkot for the Year 2016
Month Temperature (0C)
Mean Dew Point Temperature in (0C)
Mean RH % Rainfall (mm) Mean Station level pressure in hPa
Total Amount of Cloud in Octa(1/8 sky)
Mean of Av. Wind speed for
Mean Max
Mean Min. 0830hrs 1730hrs. 0830hrs. 1730hrs. Total Heaviest 0830hrs. 1730hrs. 0830hrs. 1730hrs. 24
hrs.(kmph) Jan 31.8 16.2 17.6 12.3 82 34 0.0 0.0 941.8 938.8 0.6 1.2 5.2
Feb 33.1 18.1 18.4 13.6 80 34 0.0 0.0 940.9 937.4 1.5 2.5 6.2
Mar 35.8 20.1 19.0 9.8 70 24 6.6 6.5 940.9 937.4 2.2 4.1 6.0
Apr 37.7 20.8 20.1 7.7 74 18 67.2 49.0 938.0 933.6 1.3 3.2 7.7
May 36.5 20.9 22.4 14.1 82 33 103.2 44.5 936.3 932.4 4.0 4.8 10.0 Jun 29.6 19.5 21.4 20.2 88 68 102.4 56.4 933.9 932.1 6.9 6.9 12.9
Jul 27.7 21.0 21.0 20.2 90 76 36.4 4.5 933.8 932.1 7.4 7.5 17.9
Aug 28.6 20.5 20.2 18.2 87 62 30.6 10.7 935.9 934.3 6.5 6.9 16.4
Sep 28.9 20.8 20.5 19.1 88 67 170.4 30.3 936.5 933.4 6.9 7.0 12.0 Oct 29.6 20.4 20.0 15.4 84 55 88.1 31.8 938.3 935.2 6.0 6.4 9.7
Nov 29.2 17.6 17.9 11.4 79 39 0.0 0.0 940.6 937.4 3.6 4.7 5.6
Dec 28.9 14.7 15.4 10.4 77 34 0.0 0.0 940.8 937.5 1.5 2.2 6.2
M/s Siddapur Distilleries Ltd.,
Pre-Feasibility Report Page 54
4.7.1 Temperature The mean maximum temperature is observed at (37.7°C) in the month of April and the
mean minimum temperature at (14.7°C) is observed in the month of December. In the
summer season the mean minimum temperature is observed during the month of March
(20.1°C). During the monsoon the mean maximum temperature is observed to be 29.6°C in
the month of June with the mean minimum temperature at 19.5°C during June. The values
are presented in table 4.3.
4.7.2 Relative Humidity
Minimum and maximum values of relative humidity have been recorded. The minimum
humidity is observed to be at 18 % in the month of April and the maximum is 90 % in the
month of July. The mean minimum values of humidity during summer, monsoon, post-
monsoon and winter seasons are 18 %, 62 %, 39% & 34% during the months of April,
August, November and February respectively. Similarly the maximum values are 82 %, 90%,
88%, 82% in the months of May, July, September & January during the summer, monsoon
and post monsoon & winter seasons. The values are presented in table 4.3.
4.7.3 Rainfall
The monsoon in this region usually occurs twice in a year i.e. from June to September and
from October to November. The maximum annual rate of precipitation over this region
ranges between 170.4 mm.
4.7.4 Atmospheric Pressure
The maximum and the minimum atmospheric pressures are recorded during all seasons. In
the summer season, the mean maximum and minimum pressure values are observed to be
940.9 mb in the month of March and 932.4 mb in the month of May respectively. During
monsoon season, the maximum pressure is 935.9 mb and minimum 932.1 mb. The
maximum pressure during the post-monsoon season is observed to be 940.6 mb in
November and minimum pressure is 933.4 mb in the month of September. During the
winter season the minimum atmospheric pressure is 937.5 mb in December and the
maximum is 941.8 mb in the month of January. The values are presented in table 4.3.
4.7.5 Cloud cover
The minimum cover measured in the unit of tenths is 1.2 and the maximum observed cloud
cover is 7.4.
4.7.6 Wind
The data on wind patterns are pictorially represented by means of wind rose diagrams for the entire year as figure 4.3 (for different seasons).
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Predominant wind directions
Season Period Wind direction Summer March to May North West
Monsoon June to September East
Post monsoon October to November South West
Winter December to February North West
4.8 SOCIAL INFRASTRUCTURE
Infrastructure is the basic physical and organizational structures needed for the operation of
a society or enterprise or the services and facilities necessary for an economy to function.
The term typically refers to the technical structures that support a society, such as roads,
water supply, sewers, electrical grids, telecommunications and so forth and can be defined
as "the physical components of interrelated systems providing commodities and services
essential to enable, sustain or enhance societal living conditions”.
Viewed functionally, infrastructure facilitates the production of goods and services and also
the distribution of finished products to markets, as well as basic social services such as
schools and hospitals; for example, roads enable the transport of raw materials to a factory.
Table -4.4 List of Infrastructural Facilities in the Surroundings
Sl. No.
Hospital Distance from the industry
Direction w.r.t. the industry
1 Gurukrupa Hospital 8.14 North
2 Sanadi Hospital 8.04 North
3 Poojari Hospital 18.24 North West
4 Sharan Hospital 18.5 South West
5 Venkatesh Hospital 17.88 South West
6 Sai Aadhar Hospital 12.7 South 7 B.L.D.E Association law college 7.83 North
8 Konnur Science PU college 13.04 North West
9 Bagalakote Railway station 54.35 South East
Note: All distances mentioned are aerial.
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Fig 4.3: Wind Rose Diagrams
1. March to May (summer season)
2. June to September (monsoon season)
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3. October to November (post monsoon season)
4. December to February (winter season)
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CHAPTER 5
PLANNING BRIEF
5.1 PLANNING CONCEPT M/s. Siddapur Distilleries Limited., has proposed to expand and modified its Molasses Based
Distillery Plant from 60 KLPD to 70 KLPD through process modification in its existing
Distillery Plant at Sy. Nos. 49/2B/1 & 2, 57/2D & 2E, 58/1B, 58/1A/3, 66/4D, 85/2, 87,
93/2/3, 95/1 & 107/2, Siddapur village, Jamkhandi Taluk, Bagalkot District, Karnataka State.
5.2 POPULATION PROJECTION The expansion and modification will be done in existing facility no construction activity is envisaged. Total no. of people employed during operation phase: 115 people. 5.3 LAND-USE PLANNING The land use planning is given in Table 5.1
Table 5.1: Land-Use Pattern
Sl. No. Particulars Area (SQM) In % 1 Total plot area 1,21,541.84 100%
2 Hard paved area 10,117.15 08.32%
3 Landscape/Green-belt area 1,00,807.41 82.94% 4 Ground Coverage Area 10,617.28 8.73%
5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND 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.
5.4.1 Water supply & sewerage infrastructure Water demand for the industry is from Krishna River. The domestic sewage generated is treated in septic tank and sent to soak pit. The industrial wastewater is treated in existing Effluent treatment Plant (ETP) for treatment and reuse. 5.5 AMENITIES/FACILITIES Proper site services such as with Drinking water, safety equipments & first Aid is provided to
the workers.
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CHAPTER 6
PROPOSED INFRASTRUCTURE
6.1 INDUSTRIAL AREA (PROCESSING AREA) M/s. Siddapur Distilleries Limited., has proposed to expand and modified its Molasses Based
Distillery Plant from 60 KLPD to 70 KLPD through process modification in its existing
Distillery Plant at Sy. Nos. 49/2B/1 & 2, 57/2D & 2E, 58/1B, 58/1A/3, 66/4D, 85/2, 87,
93/2/3, 95/1 & 107/2, Siddapur village, Jamkhandi Taluk, Bagalkot District, Karnataka State.
6.2 RESIDENTIAL AREA (NON PROCESSING AREA) The non-processing area is green belt and open area.
6.3 GREEN-BELT
The industry has developed green belt of 25 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. The landscape development photos is shown in fig 6.1.
Below.
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.
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.
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Fig 6.1. GREEN BELT PHOTOGRAPHS
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6.4 SOCIAL INFRASTRUCTURE Details Given in Chapter- 4, section 4.8 6.5 CONNECTIVITY The site is well connected with roadways. NH-218 & SH-34 which is about 44.39 km & 1.07
km respectively.
6.6 SEWERAGE SYSTEM Sewage pipes are laid in entire company for the removal and disposal of mainly non-harmful
liquid wastes from the offices and domestic waste, these liquid wastes are sent to septic
tank & soak pit.
6.7 INDUSTRIAL WASTE MANAGEMENT The industrial wastewater is treated in existing Effluent Treatment Plant for treatment reuse. 6.8 SOLID WASTE MANAGEMENT The domestic garbage is composted within the industry premises & the product will be used as manure for green-belt/landscape development. Used oil & grease generated from plant machinery/Gear boxes are hazardous wastes is being used as lubricant for chains / conveyer belts within premises. 6.9 POWER REQUIREMENT & SUPPLY SOURCE
The Proposed power requirement of the Distillery plant is 800 KW/Hr, Distillery has given on
lease a 2.50 MW TG set to our parent sugar plant i.e. SPSCL. The required power is available.
During off season it shall depend on 1000 KVA DG Set only.
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CHAPTER 7 REHABILITATION & RESETTLEMENT PLAN
M/s. Siddapur Distilleries Limited., is an existing industry. The expansion and modification
will be done in the existing facility. No home outsets/land outsets are expected & hence no
rehabilitation plan is envisaged.
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CHAPTER 8
PROJECT SCHEDULE & COST ESTIMATES 8.1 TIME SCHEDULE The time schedule for completion of the proposed project is given in the following table
Particulars Time schedule
Start of construction activity Existing plant Completion Existing facility
8.2 ESTIMATED PROJECT COST Total capital investment on the proposed Project is detailed in table 8.1 as under.
Table 8.1:- Project Cost for expansion of Distillery Plant capacity from 60 KLPD to
70 KLPD.
1) Fermentation House Expansion Work
Sl
No Description
Approx Value
of Project Cost
(Rs.)
1 SS 304 Fermenter Tank Capacity -350 m³ 22,20,000.00
2 Fermenter tank Centrifugal Pumps with Motor
Model: 150/26N (2 Nos) 3,10,000.00
3 Fermenter & Pre - Fermenter Plate Heat Exchanger 10,00,000.00
4 Magnetic Flow Meter for F3, F4 & pre - Fermenter tank 3,15,000.00
5 Digital Variable Area Flow Meter for pre -Fermenter Tank 30,000.00
6 Consumable Materials including Welding Rod & Gas 1,60,000.00
7 Pipe & Pipe Fittings including Butterfly Valves & Ball
Valves 6,00,000.00
8 SS 304 Ejector 1,80,000.00
9 SS 304 Pre-Fermenter Tank Capacity -60 m³ 3,25,000.00
10 Pre - Fermenter Tank Pump with Motor 3,50,000.00
Total- A 54,90,000.00
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2) Distillation Plant Expansion Work
Sl
No Description
Approx Value of
Project Cost (`)
1 Stripper Main Condenser 80 m2 7,80,000.00
2 Refining Re-Boiler 65 m2 9,00,000.00
3 Distillation Cooling Tower pump with motor 15,00,000.00
4 Electrical Cables & Accessories 3,60,000.00
5 New ENA Bulk Storage Tank of Capacity 950 m³ 25,70,000.00
Total -B 61,10,000.00
Total (A+B) 1,16,00,000.00
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CHAPTER – 9
ANALYSIS OF PROPOSAL
Observing the demographic pattern of the study area it can be inferred that occupational pattern is a mixture more of agriculture rather industrial. The proposed project will increase the employment potential by creating direct and in-direct employment opportunities and thus be beneficial for the local and nearby populace The management of the industry gives preference to local people with both direct and indirect employment. 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 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 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.