PRE FEASIBILITY REPORT -...

M/s Triveni Engineering and Industries Ltd, Unit - Distillery PRE-FEASIBILITY REPORT

PRE – FEASIBILITY REPORT

FOR

ESTABLISHMENT OF PROPOSED

MOLASSES/GRAIN BASED DISTILLERY

HAVING CAPACITY: 160.0 KLD (MOLASSES

BASED)

OR

120.0 KLD (MOLASSES BASED) + 40.0 KLD

(GRAIN BASED) ALONGWITH 7.0 MW CO GEN

POWER

AT

VILLAGE: SABITGARH,

BLOCK: KHURJA & TEHSIL: KHURJA,

DISTRICT: BULANDSHAHAR, UTTAR

PRADESH

BY

M/s TRIVENI ENGINNERING & INDUSTRIES LTD,

UNIT – DISTILLERY


Establishment of Molasses / Grain based distillery having capacity 160.0 KLD molasses based or 120.0 KLD molasses based

+ 40.0 KLD Grain based distillery at Village: Sabitgarh, Post: Karora, Distt; Bulandshahr (UP) 1

PRE - FEASIBILITY REPORT

1.0 Executive Summary

(I) Introduction

Triveni Engineering & Industries Ltd, Unit – Distillery is proposing Molasses / Grain based Distillery.

Proposed distillery will be run on two mode , first 160.0 KLD molasses based operation and second mode

is 120.0 KLD (Molasses based) + 40.0 KLD (Grain based) along with 7.0 MW of Co-Generation Power

Plant at Village : Sabitgarh, PO : Karora,, Tehsil - Khurja , District – Bulandshahar, Uttar Pradesh.

Triveni Engineering & Industries Ltd having 7 Sugar mills, 6 Co – generation unit and 1 distillery spread

over 8 locations in Uttar Pradesh. With seven sugar units located across Uttar Pradesh, Triveni is one of

the largest integrated sugar manufacturing companies in India.Group altogether has a capacity of sugar

cane crushing to about 61,000 TCD. Name of the sugar units and respective capacities are as under:

• Khatauli, Muzaffarnagar : 16,000 TCD

• Deoband, Saharanpur : 14,000 TCD

• Ramkola Kushinagar : 6,500 TCD

• Sabitgarh, Bulandshehar : 7,000 TCD

• Chandanpur, JP Nagar : 6,000 TCD

• Raninagal, Moradabad : 5,500 TCD

• Milak Narainpur, Rampur : 6,000 TCD

Triveni presently operates four co-generation power plants, one at Deoband, two at Khatauli and one at

Sabitgarh unit with combined capacity of 80 MW. Apart from the co-generation facilities, the company

also has two incidental co-generation plants at Chandanpur & Milak Narayanpur with a total capacity of ~

23 MW.

Triveni entered the distillery business in 2007 with an aim to integrate its sugar operations and to reduce

the impact of its cyclicality, with the commissioning of one of the largest single stream molasses based

distilleries in India in Muzaffarnagar district in U.P.

The proposed plant is adjacent to nearby Sugar Mill named Triveni Engineering & Industries Ltd, Unit:

Sugar, Sabitgarh having 7000 TCD capacity and for this proposed distillery project Molasses and Bagasse

will be sourced from nearby and adjacent sugar mills.

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

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




TABLE – 1

Salient Features of the Project

Sr No Particulars Details

1 Nature and Size of Project Proposed Molasses/Grainbased distillery

having capacity 160 KLD (Molasses based

operation only) or 120.0 KLD (Molasses

based) + 40.0 KLD (Grain Based) along

with 7.0 MW Co-generation Power Plant

{Proposed plant either run on 100 %

molasses based operation or 120.0 KLD

Molasses based + 40.0 Grain based (only

at one mode at a time)}.

2 Category of the Project As per EIA Notification dated 14th Sep.,

2006 as amended from time to time; the

project falls in Category ‘A’, Project or

Activity - 5(g).

3 Locations Details

Village Sabitgarh

Block Pahasu

Tehsil Khurja

District Bulandshahar

State Uttar Pradesh

Latitude 28˚11’47.02” N

Longitude 78˚00’02.04” E

Toposheet No 53L/3, 53L/4 and 53H/16.

4 Area Details

Total Plant Area Total land for proposed Distillery – 30.0

Acre or 12.14 Hectare

Greenbelt / Plantation Area ~33% of the project area will be covered

under green belt plantation of 4.00 Hectare.

5

Environmental Setting Details (with approximate aerial distance & direction

from plant site)

Nearest Village Aterna – 1.8 Km in East direction,

Karora – 1.14 km in North west direction,

Sabitgarh – 0.94 in South east direction.

Nearest Town & City Khurja– 13.29 Km in North west,




Shikarpur –9.01 km in north

Bulandshahar– 24.98 km in North west.

Nearest National Highway / State

Highway

SH - 63- Khurja city to Chhatari town

(0.1 km in south direction)

NH - 91 – Ghaziabad to Kanpur

(10.5 km in south west direction)

SH - 18 – Meerut – Badaun

(9.5 km in north direction)

Nearest Railway station Khurja Railway Station (16.92km in NW

direction)

Dhanwar Railway Station (13.4 km in

south direction)

Nearest Airport IGI New Delhi (~ 92.08 km in SW

direction)

National Parks, Reserved Forests

(RF)/ Protected Forests (PF),

Wildlife Sanctuaries, Biosphere

Reserves, Tiger/ Elephant

Reserves, Wildlife

Corridors etc. within 10 km radius

No National Park, Wild Life Sanctuary,

Biosphere Reserve, Tiger / Elephant

Reserve, Wildlife Corridors, Reserved

Forests (RF) / Protected Forests (PF) etc.

falls within 10 km radius of the plant site.

River / Water Body (within 10 km

radius)

River :Kaali Nadi (3.94 km in NE

direction)

Upper Ganga Canal ( 2.57 km in S

direction)

6 Cost Details

Total Project Cost 20000.0 Lakhs

Cost for Environment Management

Plan

Capital Cost:5600.0 Lakh or 56 Crores

Recurring cost:Rs3.2 Crores /Annum

7 Basic Requirements for the project

Fresh Water Requirement Mode 1, 160.0 KLD

Molasses based

operation Or

Mode 2, 120.0 KLD

Molasses based

operation + 40.0

KLD Grain based

Operation

1296.0 KLD(@8.1

KL/KL of

Products)

1380.0 KLD (@ 8.6

KL/KL of

products)




Source :Ground Water

Power Requirement 4.5 MW

Source –Co Generation Power Plant – 7.0

MW (In House)

Man Power Requirement 148.0 (Source:- Unskilled / Semi-Skilled -

Local Area; Skilled- Local & Outside)

8 Product Mix Ethanol /ENA/RS

9 Working Days 365.0 Days

2.0 Identification of project and project proponent

Triveni Engineering and Industries Ltd are having 7 Sugar mills, 6 Co – generation unit and 1 distillery

spread over 8 locations in Uttar Pradesh. With seven sugar units located across Uttar Pradesh, Triveni is

one of the largest integrated sugar manufacturing companies in India. Group altogether has a capacity of

sugar cane crushing to about 61,000 TCD. Name of the sugar units and respective capacities are as under:

• Khatauli, Muzaffarnagar : 16,000 TCD

• Deoband, Saharanpur : 14,000 TCD

• Ramkola Kushinagar : 6,500 TCD

• Sabitgarh, Bulandshehar : 7,000 TCD

• Chandanpur, JP Nagar : 6,000 TCD

• Raninagal, Moradabad : 5,500 TCD

• Milak Narainpur, Rampur : 6,000 TCD

Triveni presently operates four co-generation power plants, one at Deoband, two at Khatauli and one at

Sabitgarh unit with combined capacity of 80 MW. Apart from the co-generation facilities, the company

also has two incidental co-generation plants at Chandanpur & Milak Narayanpur with a total capacity of ~

23 MW. Triveni entered the distillery business in 2007 with an aim to integrate its sugar operations and

to reduce the impact of its cyclicality, with the commissioning of one of the largest single stream

molasses based distilleries in India in Muzaffarnagar district in U.P.

Now Triveni Engineering and Industries Ltd is proposing Molasses/ Grain based Distillery having

capacity 160.0 KLD molassed based (mode – 1) or 120.0 KLD molasses based + 40.0 KLD Grain

based(mode -2) distillery along with 7.0 MW of Co-Generation Power Plant at adjacent toTriveni

Engineering and Industries Ltd, Unit : Sugar, Village Sabitgarh, Block : Pahasu, Tehsil: Khurja, District -

Bulandshahar, Uttar Pradesh.




2.1 Brief description of the project

Brief description of the project Proposed site meets the guidelines prescribed by Ministry of

Environment, Forest and Climate Change for setting of an industry. Geographical coordinates of the site

are 28˚11’47.02”N, 78˚00’02.04”E. It is located approximately 0.1 km away from State Highway No. 63

(Khurja city to Chhatari town) and National highway no. 91 i.e. Ghaziabad to Kanpurroad is

approximately 10.5 km away from the site and approach road is connected at Dashara Kheri village.

Table 2.1,

Project Highlights

Sr No Name of the proponent M/s. Triveni Engineering and Industries Ltd,

Unit: Distillery

1 Location of the project At village – Sabitgarh, Block :Pahasu , Tehsil :

Khurja, Dist.-Bulandshahar, Uttar Pradesh,

2 Land Total land allocated =12.14 Hectare.

No need of acquisition of new land as, it is already

under the possession of the project proponent

(industrial land use) and the open plot withinexisting

premises will be developed into a new distillery.

3 Project 160.0 KLD Molasses based Distillery

Or

120.0 KLD Molasses based + 40.0 KLD Grain based

Distillery along with 7.0 MW Co gen power.

4 Product Rectified Spirit / Extra Neutral alcohol / Ethanol

5 Operation days per annum 365.0 Days

6 Main Raw Material Mode 1 Mode 2

Molasses

(100 %

Molasses based)

Molasses

(120.0 KLD

Molasses)

Grain

(40.0 KLD

Grain)

720.0 MT/Day 540.0 MT/Day 88.0 MT/Day

7 Total Water Requirement Mode 1 Mode 2

160.0 KLD Molasses

based operation Or

120.0 KLD Molasses

based operation + 40.0

KLD Grain based

operation

1296.0 KLD(@8.1

KL/KL of Products)

1380.0 KLD (@ 8.6

KL/KL of products)

8 Source of Fresh Water Ground Water

9 Fuel Mode 1 Mode 2

Bagasse (238.0 T/Day) Bagasse (288.0 T/Day) +




+ SLOP (356.0 KLD) SLOP (306.0 KLD)

Source: Adjacent and nearby Sugar Mills

10 Steam Mode 1 Mode 2

160.0 KL Molasses

Based

120.0 KL

Molasses

Based

40.0 KL

Grain

Based

54.0 TPH 44.0 TPH 14.0 TPH

11 Effluent Treatment System 100 % Molasses based operation (Mode – 1):

Spent wash will be concentrated in Multi effect

evaporation and then used as fuel in incineration

boiler of capacity 60.0 TPH along with bagasse/other

biomass.

Secondary effluent like MEE condensate and Blow

down, lees will be treated in Secondary ETP and

reutilised in process and other use.

Or

120.0 KLD (Molasses based) + 40.0 KLD (Grain

based) operation (Mode – 2):

Molasses based: Spent wash will be concentrated in

Multi effect evaporation and then used as fuel in

incineration boiler of capacity 60.0 TPH along with

bagasse/other biomass.

Grain based:Spent Wash (Slops) generation from

Distillation, will be sent through separation of

suspended solids in Decanter Centrifuge, part Thin

Slops are concentrated in Multi-effect evaporators to

form a Thick (Protein) Syrup, which is mixed with

the Wet Cake DWG separated earlier from

Decanters. This interim product called DWGS has

30-32% w/w Solids is subject to drying in a rotating

steam tube bundle dryer to deliver a value added by-

product – DDGS – Distillers Dried Grains with

soluble and which has min. 90% Solids and max.

10% moisture. This DDGS sells as Cattle Feed /

Poultry Feed / Fish Feed based on its Protein

Content.

12 Manpower Approx 148.0 Number




13 Total Project Cost 20000.0 Lakhs

14 Capital expenses for

Environment management

5600.0 Lakhs

2.3 Need of project and its importance to the country and region

As an agro based industry, Sugar industry in India is dependent on monsoon. Its financial viability

drastically gets affected due to weather conditions as well as market. Therefore, it is forced to explore the

alternative products from the available resources so as improve its financial stability. Molasses based

distillery is one of such an alternative. Because raw material availability i.e. molasses is fulfilled in-

house, sugar mills produces own power (electricity). Therefore, the management of the factory has

planned to establish a 160.0 KLPD molasses/grain based distillery.

In India, mainly three types of alcohol are popularly produced, i.e. rectified spirit (RS), extra neutral

alcohol (ENA) and anhydrous alcohol (AA). Of these, RS is used for large number of industrial,

scientific, laboratory, medical and many other applications. Thus, demand for the same is immense and it

is ever increasing. ENA is used for making liquors and other alcoholic beverages. AA is a fuel alcohol; it

is used for blending with petrol in the ratio of maximum 26:7.

Table 2.2,

Expected performance of sugar factory for next five years

Season

Cane

Crush

Lac MT

Sugar

Production

Lac MT

Press Mud

Production

Lac MT

Molasses

Production

Lac MT

Molasses

required for

existing

Distillery

Unit Lac MT

Molasses

available

for new

distillery

Lac MT

2017-18 77.5 8.8 2.4 3.5 2.35 1.14

2018-19 85.0 9.6 2.7 3.8 2.35 1.48

2019-20 95.0 10.7 3.0 4.3 2.35 1.93

2020-21 105.0 11.9 3.3 4.7 2.35 2.38

2021-22 105.0 11.9 3.3 4.7 2.35 2.38

Molasses is a by-product of sugar industry. The above table shows the expected availability of molasses

as a raw material for the proposed distillery unit. Since, the cane crushing capacity of various project is

going to increase, thus the molasses production will also increase. In addition, keeping in mind dynamics

situation of sugar production cycle, company also envisage to use B-Heavy molasses as and when it is

viable to use. Therefore, it has decided to install a new distillery (molasses based or Molasses + Grain

Based) of 160.0 KLD along with co gen power 7.0 MW. The distillery unit will be producing,

RS/ENA/AA which are very significant for other industries, medical services, etc. Ethanol is used to

blend with petrol, thus able to save valuable foreign exchange on import of fossil fuel.




2.4 Import vs. Indigenous production

The process is straight line and the technology even for the pollution control/disposal is available

indigenously.

2.5 Export possibility

The finished products viz. Rectified Spirit (RS), Extra Neutral Alcohol (ENA) and Anhydrous Alcohol

(AA) is having great export potential.

2.6 Domestic / Export markets

Market places such as New Delhi, Ghaziabad, Chandigarh, Pune, Surat and Vadodara as well as chemical

industries of Uttarakhand, Uttar Pradesh and Haryana are the potential domestic market for rectified

spirit, ENA as well as AA. ENA could be an exportable product.

2.7 Employment Generation

Proposed project will be generating about 148.0 direct employment opportunities, of which about 80.0

will be for skilled and about 68.0 for unskilled persons. Apart from this, the project is anticipated to give

plenty of indirect opportunities to transporters, shopkeepers and various facility providers such as

schools, medical facilities, etc.

3.0 PROJECT DESCRIPTION

3.1 Type of project

Proposed project is a new installation of 160.0 KLPD molasses/ Grain based distillery. Proposed unit is

based two modes of operation, first (mode – 1) will be 100.0 % molasses based operation for 160.0 KLD

or second (mode – 2) will be 120.0 KLD on molasses based along with 40.0 KLD on grain based.

Proposed unit will be run on single mode at a time, either on mode -1 or mode -2. Molasses is a by-

product from the sugar industry which will be used as raw material in the proposed new distillery and in

grain based operation broken rice / maize / corn etc. will be used as raw material. The project is placed

under item 5 (g) - for distillery unit as ‘A’ category as per EIA Notification, 2006 (as amended in 2009)

and will be appraised at central level.

3.2 Location with coordinate

For EIA Study 5.0 & 10.0 km radial study area is covered and the same is shown on SOI Topo sheets

53L/3, 53L/4 and 53H/16. in the map below Fig: 1.1 & 1.2 respectively.

Latitude and Longitude of the site at four corners and in the centre given below in Table 2.3




Table; 2.3

Latitude and longitude of the project site

Corners Directions Latitude and Longitude

1st East Lat : 28°11’44.98” N, Long: 78°00’09.97” E

2nd South Lat : 28°11’41.34” N, Long: 78°00’01.02” E

3rd West Lat : 28°11’46.24” N, Long: 77°59’53.79” E

4th North Lat : 28°11’59.89” N, Long: 78°00’08.40” E

- Centre Lat : 28°11’47.25” N, Long: 78°00’03.01” E

3.3 Details of alternative site considered and basis of selecting the proposed site:

Alternative sites for the proposed project are not considered, because of following reasons –

I. The project proponent is having land which is adequate for the proposed units as well as ancillary units

thereof such as storage, treatment, disposal units, etc.

II. The present site meets the guidelines for sitting of an industry prescribed by MoEF&CC,

III. Proposed site is situated adjacent to the existing sugar unit. Proposed site is adequate for raw material

availability and fuel.

IV. No rehabilitation or restoration issues involved with the proposed site,

V. The plot is open and barren, thus minimal disturbance to the ecology,

VI. Infrastructure and resources such as road, water, electricity, manpower, etc is already available.




Fig : 1.1, Toposheet Map within 10.0 Km radius.




Fig : 1.2, Toposheet Map within 15.0 Km radius.




Fig: 1.3, Location of Proposed Project Site.


13 Establishment of Molasses / Grain based distillery having capacity 160.0 KLD molasses based or 120.0 KLD molasses based +

40.0 KLD Grain based distillery at Village: Sabitgarh, Post: Karora, Distt; Bulandshahr (UP)

3.4 Size or magnitude of operation

New molasses and grain based distillery of 160.0 KLD along with 7.0 MW co gen power. Proposed

unit would be run on two modes of operation. First will be 100.0 % molasses based for capacity

160.0 KLD and second will be 120.0 KLD molasses based along with 40.0 KLD grain based.

3.5 Project description with process details

Proposed unit would be run on two modes of operation. First will be 100.0 % molasses based for

capacity 160.0 KLD and second will be 120.0 KLD molasses based along with 40.0 KLD grain

based. Co gen power generation will be 7.0 MW. Triveni Engineering &Industries Ltd, Unit:

Distillery, decided to adopt the latest technology to achieve Zero Liquid Discharge (ZLD) for the

proposed distillery unit.

❖ Manufacturing Process (Molasses based) :

The production process involves the following stages:

1. Fermentation

2. Distillation

Fermentation- Molasses is the chief raw material used for production of alcohol. Molasses contains

about 50% total sugars, of which 30 to 33% are cane sugar and the rest are reducing sugar. During

the fermentation, yeast strains of the species Saccharomyces cerevisieae, a living microorganism

belonging to class fungi converts sugar present in the molasses such as sucrose or glucose in to

alcohol. The continuous fermentation process involves addition of fresh nutrients medium either

continuously or intermittent withdrawal of portion of nutrient for recovery of fermentation products.

In continuous process, fermenter is in constant usage with little shut down and after initial

inoculation of yeast culture, further inoculation is not necessary.

Distillation- After fermentation, the next stage in the manufacturing process is to separate alcohol

from fermented wash and to concentrate it to 95%. This is called Rectified Spirit (RS). For this

purpose, method of distillation is employed. After separation of alcohol, the remaining part is the

effluent of the process i.e. spent wash and spent lees.

Re-distillation to manufacture Extra Neutral Alcohol (ENA)

ENA is prepared by re-distillation of the rectified spirit (RS) for the removal of impurities like higher

alcohols, aldehydes and methyl alcohol. This is done by, remixing rectified spirit with soft water and

distilling it in the ENA column.




Anhydrous Alcohol (AA)

Anhydrous alcohol is an important product required by industry. As per IS specification it is nearly

100% pure or water free alcohol. Alcohol as manufactured by Indian distilleries is rectified spirit,

which is 94.68% alcohol. It is not possible to remove remaining water from rectified spirit by straight

distillation as ethyl alcohol forms a constant boiling mixture with water at this concentration and is

known as azeotrope. Therefore, special process for removal of water is required for manufacture of

anhydrous alcohol.

The various processes used for dehydration of alcohol are as follows

i) Azeotropic Distillation

ii) Molecular Sieves

iii) Pervaporation / Vapour permeation system.

We will use Molecular Sieves process for dehydration of alcohol.

Fig:1.4, Schematic Flow chart of RS / ENA /AA




❖ Manufacturing Process (Grain based)

1. Liquefaction

Single Tank Liquefaction: In liquefaction process, starch is hydrolysed to dextrins. The Liquefaction

is carried out in single liquefaction tank. Feedstock flour is transferred to pre-masher and mixed with

recycle Streams, thin stillage and liquefying enzyme. Slurry from pre-masher is taken to liquefaction

tank where temperature is maintained by injection of direct steam through steam sparger / Ejector.

Necessary retention time is maintained in the liquefaction tank. Slurry pH is maintained by supplying

dilute caustic solution. Contents in slurry tank are kept in suspension by agitation. The Liquefied

slurry is then cooled in slurry cooler using cooling water supply and transferred to pre-fermentation

and fermentation section.

2. Fermentation

Yeast Activation:

Yeast seed material is prepared in Yeast Activation Vessel (Pre-Fermenter) by inoculating sterilized

mash with yeast. Optimum temperature is maintained by circulating cooling water. The contents of

the Yeast Activation Vessel are then transferred to fermenter. The purpose of Fermentation is to

convert the fermentable substrate into alcohol. To prepare the mash for Fermentation, it is diluted

with water.

Yeast is added in sufficient quantity to complete Fermentation to produce alcohol. At the start of the

cycle, the fermenter is charged with mash and contents of the Yeast Activation Vessel (Pre

fermenter). Significant heat release takes place during Fermentation. This is removed by passing the

mash through heat exchangers to maintain an optimum temperature. The re circulating pumps also

serve to empty the fermenters into beer well. CO2 can then be taken to CO2 vent line where it is

vented out. After emptying of fermenter, it is cleaned for next batch.

3. Distillation

Wash to ENA Mode

Multi-Pressure distillation system having several distillation columns operating at various pressure

conditions. Heat energy from columns operating under high pressure is utilized for columns

operating under low pressure to optimize the operation for energy consumption.

Following Columns will be under operation

• Analyser Column

• Degasifying Column

• Pre-Rectifier Column cum

• Exhaust Column

• Extractive Distillation Column




• Rectifier cum Exhaust Column

• Recovery Column

• Simmering Column

Pre-heated fermented wash is fed at the top of the degasifying column. Analyser column is provided

with re boiler. Top vapors of analyser column containing all the alcohol in the wash are sent to Pre-

Rectifier column. Rest of the fermented wash flows down the Analyser column and is taken out as

thick slops from Analyser column bottom. Low boiling impurities are concentrated in the Pre-

Rectifier column. A draw of impure alcohol is taken out from the top of the Pre-Rectifier column. RS

draw is taken from the top of Pre rectifier column, which further is sent to Extractive Distillation

column. Dilution water is fed to this column. The Extractive Column operates on the principle of

inversion of relative volatility. Low boiling impurities are separated in the Extractive Distillation

Column & bottom is sent to Rectifier cum Exhaust column. The Rectifier/Exhaust column

concentrates the alcohol to 96% v/v. The spirit is drawn from the upper trays of the Rectification

Column. Fusel oil build up is avoided in the Rectifier cum exhaust column by withdrawing side

streams (fusel oils). ED condensates, fusel oil draw from R/E column are sent to Recovery column

where these fusel oils are concentrated and then sent to decanter where these streams are diluted with

water and fusel oil rich layer is separated. Washings are sent back to the column to recover alcohol.

The spirit Draw from the Rectifier column is sent to the Simmering column where methanol is

separated in the form of a cut from the top and ENA is taken out from the bottom. ENA drawn from

the Simmering Column is taken to the receiver after cooling in ENA cooler.

4. Evaporation

The suggested treatment scheme is a Four Effect (Integrated) plus Two Finisher working on the

principle of falling film Evaporation & Forced circulation. Simmering vapours is fed to the first

effect evaporator shell side and exhust vapour is fed to shell side of finisher at the given pressure and

temperature as the heating medium. The Feed at predetermined temperature is fed from the top of

First effect evaporator. Vapours generated in 1st effect VLS (Vapour Liquid Separator) are used as

heat source in the 2nd effect which is in series to the first effect & so on. A Shell & tube type Multi-

pass Surface condenser is employed for condensing the shell side vapours. The product at the desired

concentration is obtained at the outlet of last effect. Each effect is provided with recirculation cum

transfer pump. The condensate from surface condensers is collected in a common condensate pot.

The condensate is transferred for further treatment / drain by using centrifugal pump. The system

operates under vacuum.

Water-ring vacuum pumps will be used to maintain a desired vacuum. Cooling water from cooling

tower is used in the surface condensers for condensing the vapours.




5. Dryer

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

feeding system. The Rotary Tube Bundle is enclosed in an insulated dryer housing and on its outer

flights is fixed. Dry saturated steam is to be supplied to the tube bundle through rotary joint at one

end & the condensate is discharged through rotary joint mounted of another end.

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

bundles. The heat transfer is primarily by conduction. The water vapors are exhausted through an

Exhaust Blower & passed through a cyclone separator for separating fines.

❖ Dry product partially recycled back to feed conditioner for feed conditioning through Product

Screw & Recycle Conveyor.

❖ Entire operation of the dryer is controlled through Control panel.

Fig: 2.8; Process flow diagram during grain based operation




3.6 Raw Materials required for finished products

Raw materials for the proposed project will be available from the local market. Molasses as raw

material will be available from adjacent inhouse sugar mills. Product wise raw material consumption

is given below:

Sr No Particular Quantity,

MT/Day

Storage Source of raw material &

Mode of Transportation

Mode 1

1. A Molasses 720.0 MT/Day 30 Days Adjacent sugar mills and other

local sugar units.

Tanker will be used for

molasses transport.

Mode 2

1 B Molasses

Grain

540.0 MT/Day

And

88.0 MT/Day

30 Days

30 Days

Adjacent sugar mills and other

local sugar units.

Tanker will be used for

molasses transport.

Nearby market and truck will

be used for transportation.

2. Other Chemicals

Sulphuric Acid 68 kg/Day 15 Days Nearby Market by Truck.

15 Days storage will be

provided. Sodium

Hydrooxide

(Caustic)

10.0 Kg/Day 15 Days

Enzymes 6.0 kg/Day 15 Days

NH2-CO– NH3

(Nutrient : 46% N2

10.0 kg/Day 15 Days

Antifoam Agent 135 kg/Day 15 Days

3.7 Resource optimization / recycling and reuse envisaged in the project

Optimum utilization of the available resources is strived by the management. These resources include

land, water, steam, molasses and power. Press-mud is a by-product of sugar factory that will be used

for making manure by mixing fermenter sludge and potash rich fly ash generated in the distillery.

Thereby, nutrients will be recycled.

In grain based operation: Spent Wash (Slops) generation from Distillation, will be sent through

separation of suspended solids in Decanter Centrifuge, part Thin Slops are concentrated in Multi-effect

evaporators to form a Thick (Protein) Syrup, which is mixed with the Wet Cake DWG separated

earlier from Decanters. DWGS has 30-32% w/w Solids is subject to drying in a rotating steam tube

bundle dryer to deliver a value-added by-product – DDGS – Distillers Dried Grains. This DDGS sells

as Cattle Feed / Poultry Feed / Fish Feed based on its Protein Content.




3.8 Water Requirement

Water required for proposed project will be different during 100.0 % molasses (mode 1) and 120.0

KLD molasses + 40.0 KLD grain (mode 2) based operation. During 100% molasses based operation

fresh water requirement will be 1296.0 m3/Dayand in molasses + grain based operation fresh water

requirement will be 1380.0 m3/day.Water balance for the proposed distillery unit on both mode is

given in Fig : 1.5 (A – C) .

3.8.1 Availability of water and its source

Necessary fresh water requirement for the proposed project will be met from tube well. Water will be

required for domestic, industrial process and utility purpose. As the area fall in Semi Critical Zone as

per CGWA Ground water assessment 2011. Water level in the ranges from 5.0 – 7.2 m bgl during pre-

monsoon season.




Fig : 1.5 A, Mode -1, Water Balance for 160.0 KLD (Molasses based )




Fig: 1.5 B, Mode 2, 120.0 KLD Molasses based distillery




Fig : 1.5C, 40.0 KLD Grain based distillery




3.8.1 Steam & Power requirement

Steam requirement for the proposed project is 54.0 TPH at 3.5 Kg/cm2 (g) for 160.0 KLD (molasses

based) and 58.0 TPH at 3.5 kg/cm2 (Molasses + Grain Based). Therefore, a new incineration boiler of

capacity 60.0 TPH with 45 Kg/cm2 (g) pressure will be installed and this will supply steam to

proposed 7.0 MW turbo-alternator. It will fulfil the steam as well as power requirement of distillery.

3.8.2 Fuel

Slop and Bagasse will be used as a fuel for the steam generation activity of the proposed industry. The

requirement of Bagasse and slop is given in table below

Fuel Slop Bagasse

Mode – 1,

160.0 KLD (100.0 %

Molasses based)

356.0 KLD 238.0 MT/Day

Mode – 2,

120.0 KLD (Molasses

based) + 40.0 KLD (Grain

based operation)

306.0 KLD 288.0 MT/Day

Source In – House, it is concentrate

from MEE.

Procured from adjacent and

nearby sugar mills / road

transport.

Bagasse will be procured from adjacent sugar mills of our group and other sugar mills present in

nearby areas.

3.8.3 Quantity of waste generation & disposal scheme

During 160.0 KLD Molasses based operation (Mode - 1): Estimated daily total water requirement of

distillery will be (input) 3998.0 m3/d. However, during day-to-day operations 2702.0 m3/day water

will be recycled and thus fresh water requirement will be restricted to 1296.0 m3/day. Effluent in the

form of spent wash will be 1240.0 m3 /day. It will be treated concentrated in Multi effect evaporation

and then concentrate from MEE will be utilised in Incineration fired boiler as a fuel along with

bagasse/other biomass. Flow diagram for spent wash treatment is given in Fig : 1.6.

During 120.0 KLD Molasses based (Mode - 2): Estimated daily total water requirement of distillery

will be (input) 3194.0 m3/d. However, during day-to-day operations 2146.0 m3/day water will be

recycled and thus fresh water requirement will be restricted to 1048.0 m3/day. Effluent in the form of

spent wash will be 910.0 m3 /day. It will be treated concentrated in Multi effect evaporation and then

concentrate from MEE will be utilised in Incineration fired boiler as a fuel along with

bagasse/bagasse/another biomass.

During 40.0 KLD Grain based operation (Mode - 2): Estimated daily total water requirement of

distillery will be (input) 1111.0 m3/d. However, during day-to-day operations 767.0 m3/day water will




be recycled and thus fresh water requirement will be restricted to 332.0 m3/day. Effluent in the form

of spent wash will be 313.0 m3 /day. It will be will be sent through separation of suspended solids in

Decanter Centrifuge, part Thin Slops (290.0 KLD), out of total thin slop 121 KLD recycle to

Liquefaction and rest 154.0 KLD are concentrated in Multi-effect evaporators to form a Thick

(Protein) Syrup (20.0 KLD), which is mixed with the Wet Cake DWG(36.0KLD) separated earlier

from Decanters. This interim product called DWGShas 30-32% w/w Solids is subject to drying in a

rotating steam tube bundle dryer to deliver a value-added by-product – DDGS – Distillers Dried

Grains with soluble (18.0 MT/Day) and which has min. 90% Solids and max. 10% moisture. This

DDGS sells as Cattle Feed / Poultry Feed / Fish Feed based on its Protein Content.

Other Effluent: In both mode 1 & Mode 2, the remaining moderately polluted effluent due to spent

lees and evaporating condensate will be treated in polishing unit and recycled in the same unit.

Estimated domestic effluent will be 16.0 m3/d, which will be treated separately in septic tank and soak

pit. Quantity of waste to be generated & scheme for their disposal is given in the following chart.

Fig: 1.6, Mode – 1, Flow Chart of Spent Wash treatment strategy (160.0 KLD)




Fig:1.7, Mode – 2, Flow Chart of Spent Wash treatment strategy (120.0 KLD).




Fig: 1.8, Mode – 2, Flow Chart of Spent Wash treatment strategy (40.0 KLD, Grain Based).




Fig: 1.9, Flow Chart for condensate polishing unit for molasses based operation




3.9.1 Solid waste

The proposed industrial activity could generate solid waste in the form of yeast and ETP sludge, boiler

ash. These are biodegradable material. The quantity and disposal technique is given briefly in the

following Table 2.3.

Table: 2.3,

Solid waste generation and disposal

Sr

No

Waste Mode -1 Mode – 2 Uses / Disposal

1 Total Ash 67.5 MT/Day 59.3 MT/Day Due to high potash content, will be

used as manure.

2 Yeast Sludge 16.0 MT/Day 14.9 MT/Day Will be mixed with press mud of

Sugar mill and sold to the farmer.

3 Condensate

polishing unit

sludge

5.0 KLD 4.5 KLD Will be mixed with press mud of

Sugar mill and sold to the farmer.

4 Cattle Feed

DDGS

Nil 18.0 MT/Day Will be sold

3.9.2 Air Emission and control

One incineration boiler of capacity 60.0 TPH will be used with working pressure of 45 Kg/cm2. Bag

filter of 125 % capacity system will be attached to the boiler. DG Set with adequate stack height and

acoustic enclosures will be installed for the proposed project.

3.9.3 Noise pollution

The plant and equipment will be specified and designed with a view to minimize noise pollution. The

major noise producing equipment will be provided with sound proof devices and silencers. DG set will

be provided with acoustic enclosures. Ear Plugs and ear muffs will be provided to the workers in

utility section. Greenbelt will be developed.

3.9.4 Health and Safety Measures

Triveni Engineering and Industries Ltd, Unit - Distillery strives to provide hygienic & safe work place

and continually improve the effectiveness of Health & Safety system.

To meet these objectives the TEIL will;

❖ Comply all relevant Laws, regulation, statutory provisions & codes of practice,

❖ Continually asses risks & hazards so as to evolve establish & upgrade hazard control measures,

emergency preparedness, & risks mitigation and correct the deficiency identified in timely

manner.




❖ Ensure safe handling, storage, use and disposal of all substance & materials which are classified

as hazardous to health & environment,

❖ Create awareness in employees by providing appropriate training, motivation information’s so as

to create individual sense of duty, responsibility & participations & an institutionalize culture of

continually improvement in safety, health & environment matters,

❖ Make supervisors responsible for implementation of the safety precautions, use of safety devices,

& the safety of the people,

❖ Empower employees at all levels to be responsible & accountable for their personal health &

safety,

❖ Fire protection system will be provided in accordance to the local fire authorities regulations. The

firefighting system will consist of a hydrant network. It also incorporates suitable firefighting

equipment and flameproof lighting and power control arrangements.

❖ Portable fire extinguishers will be provided in strategic locations in new construction area.

3.10 Schematic representation of the feasibility drawing which give information of EIA purpose

Figure 3.6: Procedure of Environmental Clearance




4.0 SITE ANALYSIS

4.1 Connectivity

The site is well connected by road, railway. It is approx0.1 km and 9.5 km away from the state

highway no. 63 (Khurja City to Chhatari town) and State Highway no. 18 (Meerut - Badaun)

respectively. Approach road from Khurja City is connected with village Sabitgarh.

Khurja railway station (of central railway) is approx. 16.92 km and Dhanwar railway station is approx.

13.4 km away from the project site. The international airport IGI New Delhi is approx. 92.08 km.

4.2 Land form, land use and ownership

The factory is holding 12.14 Hectare of land. The land is flat, open and already under the possession of

theTriveni Engineering and Industries Ltd, Unit - Distillery. So out of available land, a provision of

approx. 4.0Hectare is for green belt and rest 8.14 Hectare for the proposed distillery and ancillary units

thereof such as boiler house, turbine, storage etc.

4.3 Topography

The terrain is almost flat. The geographical coordinates of the area are 28˚11’47.25” N and

78˚00’03.01” E. The proposed site is 199.0 meter above the mean sea level. General slope in the is

from North east to south west toward Kaali nadi.

4.4 Land use pattern

The proposed project requires no additional land, existing land is under the ownership ofTriveni

Engineering and Industries Ltd, Unit - Distillery. Therefore, no social issues are involved. There

won’t be change in the land use pattern since the land is under the possession of the industry. There is

no sanctuary, bio-sphere reserve or national park in the 10km radius area. The land surrounding the

project site is used for agricultural purpose. There are more than 40.0 villages within 10 km of the

study area. River Kaali Nadi is approx. 3.94 km away from the project site in NE direction.

Table 4.1,

Salient features of the project location

Nearest City/ Town Khurja Tehsil : - 13.29 Km in North west from the project site

Railway Station Khurja railway station (of Central railway) is approx. 16.92 km from

the site

Airport The international airport IGI New Delhi is approx. 92.08 km.

River River – Kaali Nadi is approx. 3.94 km away from the project site in

north east direction.

Schools Government school in Pahasu, Sabitgarh and Karora village for

primary education. New English medium school and Junior college,




Khurja is approx16.92km from the project site.

Colleges Bharat Vikas Parishad Kanya Inter College (Khurja) is approx. 14.32

km from project site.

Manbard Public School (Khurja) approx. 4.3 km from the site.

Medical and health

care centers

Government Hospital &Private Hospital is within approx. 15.0 km

from the project site.

Banks Punjab National Bank &Kotak Mahindra Bank is. 3.0 km from the

project site

Market places Pahasuis a nearest market place at approx. 6.84 km from the project

site.

Protected Area/

Sanctuaries/NP

None within 15.0 km radius

CRZ applicability Not applicable

Seismicity Seismic Zone- IV (High)

4.5 Existing Infrastructure

Proposed project is new project. There are no existing infrastructures within the project site. The

nearest residential area to the factory is at a distance of 500.0 km towards east. There is an agricultural

and cultivated land in the surrounding area of the site. Within 10 km Influence Zone, there is no

Tropical Forest, Biosphere Reserve, National Park, Wild Life sanctuary. Bulandshahar district is

24.98 km from site towards north west.

4.6 Soil Classification

The soil of the district level is plain but in khadar area of Ganga-Yamuna and Kali Nadi the soil level

is uneven. The soil is entirely alluvium with the kankarembeded in abundance and surface

occasionally bears saline efforescence. Domat or loam, sandy loam, matiar or clay, blur or sand are the

different varieties of soil in the district. Domat is fertile loam which is soft, matiar is stiff clay in which

rice is grown.

4.7 Climatic data from secondary sources

The climate of the district is characterized by a cold winter, a hot summer and general dryness except

during monsoon season. Like other parts of northern India this district also has three major seasons –

summer, winter and rainy season. The cold winter season starts about the middle of November and

continues upto February. The period from March to the third week of June is the summer season. This

is followed by the monsoon season. The rainy season goes on till mid October. About 86 percent of

the annual rainfall in the district is received during June to September, July and August being the

http://khurja.wikimapia.org/

http://khurja.wikimapia.org/




rainiest months. The normal annual rainfall in the district. During year the maximum temperature of

the district was 40-45º C and minimum temperature was 4-5ºC. January is the coldest month. June is

the hottest month with mercury shooting to maximum. The hot, dry and dust laden western winds add

to the intensity of hot summer. Some rains also occur in winter season from north-westerly cyclones

which proves very useful to the standing rabi crops.

4.8 Social Infrastructure available

Infrastructure such as school, colleges, market, banks, hospitals, public transport, road, drinking water,

electricity, post, telecommunication, radio, etc are easily available to the local people within 15.0 km

radius of project site.

The present project is proposed by one of the leading and progressive sugar industry from western

Uttar Pradesh.

The sugar factory has already initiated several activities for the development of the region. Some of

the prime activities are as follows.

❖ The factory is providing medical aid to the employees and their dependents

❖ It provides primary school educational facilities to the children of workers

❖ It helps member farmers by supplying organic and chemical fertilizers, press-mud and

thedeveloped cane seeds approved by Government agency like NSI Kanpur. The factory also

arranges field demonstration to educate the farmers in sugarcane cultivation through application

of scientific methods

❖ Regular tree plantation with development being done every year through the separate tree

plantation cell in their campus and surrounding area. For nearby schools, hospitals free of cost

plants are provided.

5.0 PLANNING BRIEF

5.1 Planning concept

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

Planning/ Development authority classification.

The proposed project is molasses and grain based distillery. Facilities required for the proposed project

will be provided as per requirement. Transportation of raw material and final product will be done via

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

(ii) Population Projection

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

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

government.




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

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

proposed site and will be developed in under corporate social responsibilities programs.

(iv) Amenities/Facilities

The Company will develop the Amenities/Facilities in nearby area of the proposed project site as per

requirement of local people under corporate social responsibilities programs.

6.2 Proposed Infrastructure

The proposed project will be carried out in the area owned by the Triveni Engineering and Industries

Ltd, Unit - Distillery. The total allocated land for the proposed project is 12.14 Hectares.

5.2.1 Residential Area

The residential colony is in place (for existing sugar unit). It has capacity to accommodate additional

families of proposed distillery unit. Since, most of the employees of the sugar mill are local.

5.2.2 Greenbelt Area

The total greenbelt area provided is ~ 4.0 Hectare.

5.2.3 Social infrastructure

The physical infrastructures such as land, roads, power, water, transportation etc are easily available

for the proposed unit. Raw material and filler material are also available with factory adequately. Very

minor influx of population is anticipated due to the project. Available social infrastructure such as

schools, colleges, market, medical facilities, etc. is adequate to support the probable minor population

increase.

5.2.4 Connectivity

The site is well connected by road, railway. It is approx0.1 km and 9.5 km away from the state

highway no. 63 (Khurja City to Chhatari town) and State Highway no. 18 (Meerut - Badaun)

respectively. Approach road from Khurja City is connected with village Sabitgarh. Khurjarailway

station (of central railway) is approx. 16.92 km and Dhanwar railway station is approx. 13.4 km away

from the project site. The international airport IGI New Delhi is approx. 92.08 km.

5.2.5 Sewerage system

Estimated domestic effluent will be 16.0 m3/d, which will be treated separately in septic tank and soak

pit.




5.2.6 Drinking water management

Triveni Engineering and Industries Ltd, Unit Distillery draws water from well and supply the drinking

water to factory as well as the staff colony.

5.2.7 Industrial Waste management

The proposed Molasses and grain based distillery would be based on “ZERO EFFLUENT

DISCHARGE”.

5.2.8 Solid Waste Management

➢ Spent wash generated during molasses operation, would be concentrated in Multi-effect evaporator

and then used as fuel in incineration boiler.

➢ Spent wash generated during Grain based operation, would be centrifuged for solid separation,

permeate from centrifuge will be partly recycle to liquefaction and rest will be concentrated in

MEE and concentrate from MEE will be mixed with Wet cake from centrifuge. DWGS then finally

dried in dryer and dried DDGS will be used as cattle feed.

➢ Fly ash from the Boiler would be utilized as manure.

➢ Yeast sludge will be mixed with Press Mud for manufacturing Organic Manure.

5.2.9 Power requirement and source

The total power requirement for the proposed project will be 4.5 MW, which will be sourced fromCo

generation power plant of 7.0 MW and for emergency DG set will be installed.

6.0 Rehabilitation and Resettlement (R & R) Plan

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

oustees, land oustees and landless labourers (a brief outline to be given).

The proposed plant is adjacent to own Sugar Mill named Triveni Engineering and Industries Ltd, Unit

- Distillery. The land is already under the possession of TEIL. Therefore, there will not be any

displacement of people and hence, Rehabilitation & Resettlement is not applicable.

7.0 Project Schedule and Cost Estimates

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

project to be given).

The project will start only after obtaining Environmental Clearance and all other required clearance

and will complete within 1.5 years of commencement.

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

❖ Total cost of the Project: Rs. 200.00 Crores

❖ Cost for Environment Protection Measures:




• Capital Cost: Rs. 56.00 Crores

• Recurring Cost/annum: Rs. 3.20 Crores/annum

8.0 Analysis of Proposal

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

tribal population, if any, in the area.

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

and supporting infrastructure. Special emphasis on Financial and Social benefits will be given to the

local people including tribal population, if any, in the area.

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

and creation of self-help groups.

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

will be available like transport of raw material/product to market, fly ash transport to Brick

manufactures, maintenance & house-keeping contract work etc.

CONFIDENTIAL

16 15 14 1312

11 10 9 38 7 6 5 42

1

1615

14 13 12 11 10 9 38 7 65

4 2 1

EXISTING TUBEWELL NO.-3

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10.0 M WIDE ROAD

EXISTING TUBEWELL NO.-3

E. T

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AR

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SUGAR GODOWN90000X45000X12000

6

10.0 M WIDE ROAD

TEMP. GODOWN

6

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