PRE-FEASIBILITY REPORT FOR BHAIRAVNATH SUGAR WORKS LTD, SONARI Highlights of Process

Fermentation: We have incorporated mechanical educator in place of an air sparger, which results in increased Dissolved Oxygen (D/O) level, facilitates better contact between yeast and Fermentable Sugars, avoids hydraulically-dead zones, increases active yeast cell mass for high efficiency of conversion and therefore a better yield. We have used Genetically Marked high osmo-tolerant yeast strain. We have optimized the Cooling System to maintain fermenting broth temperature to 30C, which results in improved activity of the yeast cell mass. This is done by splitting the recirculation pumps to half of the fullload. During most of the sugar season the wet-bulb temperature will be far lower than the max wet-bulb of the area and this will require a far lower recirculation rates of Fermenting Wash. Splitting the Fermenting Wash Recirculation Pumps achieves lower electrical consumption (energy conservation).

Distillation and Reboiler:

We have incorporated axial-flow pump to maintain high velocities in the tubes of the Reboiler but with low consumption of electrical power. The high velocities are important to avoid the soft and hard scaling in Stripper Reboiler.

Dehydration Plant
Offer three-bottle pressure swing adsorption, for smoother energy efficient operation and longer sieve life. Lowest Utility consumption per lit of anhydrous alcohol. Maximum alcohol yield. Component design and selection to guarantee extensive service life. Fully automated with PLC based system.

Annexure I
PRODUCT SPECIFICATION
1.1 Rectified Spirit (RS) Requirement of Alcohol (IS 323 1959) Ethanol Content (Minimum), % V/V at 15.6C 96.0 v/v Degrees over proof 67.2 Specific Gravity @ 15.6 C 0.81 Alkalinity Nil Fusel oil max. 200 ppm Aldehydes as acetaldehyde, mg/100 ml (Max.) 5 Esters as ethyl acetate, mg/100 ml (Max.) 10 Methanol, mg/100 ml (Max.) 5 Butanol 1 Nil Butanol 2 Nil Isobutanol mg/100 ml. (Max.) 5 Isopentanol mg/100 ml. (Max.) 1 Acidity as acetic acid mg/100 ml (Max.) 2 Residue on evaporation, mg/100 ml (Max.) 2 N-Propanol & Isopropanol, mg/100 ml. (Max.) 10 Copper as Cu, mg/100 ml (Max.) 0.3 Leas as Pb, mg/100 ml (Max.) 0.05 Potassium permanganate reaction, time, minutes (min.) 20 Characteristic

1.2 Extra Neutral Alcohol (ENA) :

The material shall comply with the requirements prescribed in the following table. S/N 1 2 3 4 5 6 7 8 Characteristic Ethanol content (min), % V/V at 15.6C Miscibility with water Alkalinity Acidity (as CH2COOH), mg/100 ml (max.) Residue on evaporation, mg/100 ml (max.) Aldehydes mg/100 ml [max.] Esters (CH3COO2H5), mg/100 ml (max.) Lead as Pb mg / 100 ml (max.) Requirement of Alcohol (IS 6613 1972) 96% Miscible Nil 1.25 2 0.5 2 Nil

9 10 11 12 13

Methyl alcohol content, max. ppm Furfural Potassium permanganate reaction time, minutes avg.(Min.) Copper as Cu, mg / 100 ml (max.) Fusel oil content, mg / 100 ml (max.)

5 To pass the test 30 0.2 1.5

1.3 Anhydrous Alcohol (Ethanol):

Sr. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Characteristic Requirement of Absolute Alcohol(IS : 321 : 1964)

Ethanol content (min.), % V/V 99.8% Miscibility with water Miscible Alkalinity Nil Acidity [as CH3 COOH], percent by weight, max. 0.006 Residue on evaporation, percent by weight, max. 0.005 Aldehydes content [as CH3 CHO] mg/100 ml (max.) 0.1 Ester content [as CH3COOC2H5], mg/100 ml (max.) 0.02 Copper as Cu, gm/100 ml. [max.] 0.0008 Lead [as Pb], gm/100 ml., max. 0.0001 Methyl alcohol content To satisfy the requirement of the test Fusel oil content To satisfy the requirement of the test Ketones, isopropyl alcohol and tertiary butyl alcohol To satisfy the requirement of the test Total sulfur and compounds of sulfur [as S] percent by weight, max. 0.001 Sulphur dioxide [as SO2] percent by weight, max. 0.00005

Annexure II
1. The Basis of design:
1.1 Raw Material A. Distillery Plant a. Fermentable Sugar in Molasses b. Density of Molasses c. F/NF Ratio d. Volatile Fatty Acid : Sugarcane Molasses : 42% : 85 Brix min : 1.1 or Higher : < 5000 ppm

1.2 Product. 1.2.1 Rectified Spirit + Impure Spirit : 28,500 LPD (RS) + 1,500 LPD (IS) 1.2.2 Extra Neutral Alcohol + Impure Spirit : 28,500 LPD (ENA) + 1,500 LPD (IS) 1.2.3 Fuel Alcohol : 30,000 LPD 1.3. Efficiency 1.3.1 Fermentation : 89% (VFA < 5,000 ppm, for every Increase of 1000 ppm Efficiency decrease by 1%) 98.5% 99.6% 8.0% v/v < 100 m Above Sea Level Min. 20 C Max. 40 C 80% RH at 30 C Indoor Fermentation Non Flameproof Distillation Flameproof Dehydration Flameproof Evaporator - Flameproof

1.3.2 Distillation 1.3.3 Dehydration 1.4 Alcohol % in Fermented Wash 1.5 Site Conditions Altitude Ambient Temperature Humidity Installation Area

: : : : : : : :

Annexure III
PERFORMANCE PARAMETERS
A] Performance Parameters Feed Molasses for 60 KLPD (Total spirit) : 5,063 Kg/hr at 42% FS

Feed Molasses for 60 KLPD (Fuel Alcohol) : 5,370 Kg/hr at 42% FS Alcohol Percentage in Wash Spent wash generated after distillation After Spent Wash Recycle to Fermentation : Approx. 8.0% v/v : 240 m3/day [approx.@15.7% w/w Dissolved Solids] 8.00 lit/lit

Spent wash generated after Integrated : 153 m3/day [approx.@ 24% w/w Evaporator (Spent Wash Recycle Option) Dissolved Solids] 5.11 lit/lit (ENA) Spent wash generated after Integrated Evaporator (Spent Wash Recycle Option) (RS) : 177 m3/day [approx.@ 21% w/w Dissolved Solids] 5.90 lit/lit

Annexure IV UTILITIES REQUIRED

a. Steam:
1. Rectified Spirit (RS) (Multi Pressure Distillation) Saturated steam at 3.5 kg/cm2 (g), 148C at steam header in the plant. Variation in pressure: 0.1 kg/cm2 In saturated. Required Steam 2.750 MT/hr (2.2 kg per lit of Total Spirit, at full capacity operation & the plant is insulated) 2. Extra Neutral Alcohol (ENA) (Multi Pressure Distillation) Saturated steam at 3.5 kg/cm2 (g), 148C at steam header in the plant. Variation in pressure: 0.1 kg/cm2 In saturated. Required Steam 4.375 MT/hr (3.5 kg per lit of Total Spirit, at full capacity operation & the plant is insulated) 3. Integrated Evaporator Alcohol Water Vapours from Distillation are to be use as heat source for concentrating the Spent Wash. 4. Dehydration Plant Saturated steam at 6 kg/cm2 (g), 165C at steam header in the plant. Variation in pressure: 0.1 kg/cm2 in saturated. Required Steam 0.690 MT/hr (0.55 kg per lit of Total Spirit, at full capacity operation & the plant is insulated).

b. Cooling Water:
1. Fermentation Recirculation water shall be filtered, soft water, free from algae,suspended solids, and hardness shall be less than 5 PPM.

310 m3/ hour (Re-circulation Rate) at pressure of 2.5 kg/cm 2 (g) at the header in the plant. At temperature of 30 C maximum. It will be returned with temperature rise of 2C maximum. Requirement of make up water will be approx 149 m3/ day 2. Multi Pressure Distillation, Integrated Evaporator, Dehydration, Week Beer Recycle Recirculation water shall be filtered, soft water, free from algae, suspended solids, and hardness shall be less than 5 PPM. 375 m3/ hour (Re-circulation Rate) At pressure of 2.5 kg/cm 2 (g) at the header in the plant. At temperature of 30 C maximum. It will be returned with temperature rise of 8C maximum. Requirement of make up water will be approx 180 m3/ day

c. Process Water for Fermentation

Process water shall be Filtered, Chlorinated free from algae, suspended solids, Process Water requirement for dilution will be 230 m3 / day

d. DM Water for Distillation ENA Option

DM Water requirement for dilution for Extraction Column will be 188 m3 / day Spent Lesse Recycle from Rectifier Column then D.M.Water Requirement for Dilution for Extraction Column thus reducing, the DM requirement will be 28 m3 / day

e. Compressed Air:
40 Nm3/hour at 6 bar (g) with dew point of 40C dew point dryness. Free from particulate matter, suitable for instruments.

f. Electricity:
415 V/4 Wire/3 Phase Frequency 1. Fermentation 2. Yeast Recycle 3. Multi Pressure Distillation 4. Integrated Evaporator 5. Fuel Alcohol 6. Cooling Tower Total Connected Load Without Stand By Motor : 50 Hz : 70 kW : 50 kW : 75 kW : 50 kW : 18 kW : 97 kW : 360 kW

g. Variation in Utility

: 10 %.

RETURN STREAMS
a. Steam condensate: 1. 2. Multi Pressure Distillation RS Option, Integrated Evaporator & Dehydration 2.75 MT / hour considering losses (Equivalent to steam utilized in the plant) Multi Pressure Distillation ENA Option, Integrated Evaporator & dehydration 4.05 MT / hour considering losses (Equivalent to steam utilized in the plant)

WASTE STREAMS
a. Spent Leese: 1. Multi Pressure Distillation ENA Option & Dehydration Plant 25 - 30 m3/day, depending on composition of feed. Other high boiling substances and nonvolatile matter from rectified spirit will get carried into lees.

CHEMICAL REQUIRED
1. Nutrient 2. Biocide 3. TRO* (TFM Min 60) 4. Sulphuric Acid 5. Tolerance : 30 Kg/day : 25 ppm : 70 Kg/day : 25 Kg/day : +10%

Annexure V PROCESS DESCRIPTION

The process of converting molasses to RS/ENA can be divided into following sub sections: 1] Feed Preparation and weighing 2] Yeast Propagation and Continuous Fermentation 3] Multi-pressure Distillation with Integrated spent wash evaporator 1] FEED PREPARATION AND WEIGHING 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 dilutor in fermentation section where it is diluted with water and fed to the fermenter. 2] YEAST PROPAGATION AND FERMENTATION The Yeast from Slant is transferred to Shaker Flasks and grown to the required volume. This genetically marked yeast strain is then further propagated, under aseptic conditions, in yeast culture vessel. These vessels are equipped with eductors which are designed to achieve enhanced efficiencies through better sugar / yeast contact by shearing and mixing, efficient oxygen transfer etc. The ready yeast seed is then transferred from culture vessel to fermenter. The molasses is diluted by recycled weak beer (partially exhausted spentwash or vinasse) before fermentation. This recycle conserves corresponding amount of Dilution Water. The glucose in the Feed media gets converted to ethanol, in each of the 3 fermenters operating in Continuous Cascade mode. A plate heat exchanger and a circulation pump is provided to each fermenter, which will continuously recirculate the Fermenting Wash through PHE for maintaining the Fermenters at 30 deg C. The nutrients, biocide, acid and anti-foam agents are fed to the fermenters as per process requirement. The CO 2 liberated during fermentation is sent to CO 2 Scrubber for recovery of ethanol otherwise being lost in vent.

The Fermented Wash is then sent to the Clarification Tank equipped with Lamella Separator. The settled sludge is sent to Sludge Washing Tank for recovery of alcohol. 3] MULTIPRESSURE DISTILLATION WITHOUT EVAPORATOR ( RS) The fermented wash is fed to CO 2 stripper column to remove CO2 gas present in wash. Alcohol is stripped off water in stripper column. The top vapors [alcohol + water] are fed to Beer Heater as heat source for preheat the Fermented Wash. Non Condensed vapour from Beer Heater fed to Principle Condenser & Vent Condenser Distillate from Beer Heater & Principle Condenser is fed to rectifier column as feed. In rectifier column RS is taken out from top tray. The impure spirit from top of CO 2 stripper column, rectifier column are fed to fusel oil column. The final impure spirit cut is taken out from the fusel oil column and partly alcohol is recycled to rectifier column. The alcohol containing fusel oil from rectifier column is fed to fusel oil column. Rectification column works under pressure. The CO 2 stripper and stripping column works under vacuum and fusel oil column works under atmospheric condition. The top vapours from rectifier column are condensed in Stripper Reboiler. The alcohol water vapours from stripping column are partly sent to CO 2 stripper bottom for heating. The Rectifier column and fusel oil column gets heat from steam. The Distillation process is operated through PLC. 4] MULTIPRESSURE DISTILLATION WITH EVAPORATOR ( RS) The fermented wash is fed to CO 2 stripper column to remove CO2 gas present inwash. Alcohol is stripped off water in stripper column. The top vapors [alcohol + water] are fed to Calendria 1 as heat source for concentrating spent wash. Distillate from Calendria is fed to rectifier cum exhaust column as feed. In rectifier column RS is taken out from top tray. The impure spirit from top of CO2 stripper column, rectifier column are fed to fusel oil column. The final impure spirit cut is taken out from the fusel oil column and partly alcohol is recycled to rectifier column. The alcohol containing fusel oil from rectifier column is fed to fusel oil column. Rectification column works under pressure. The CO 2 stripper and stripping column works under vacuum and fusel oil column works under atmospheric condition. The top vapours from rectifier column are condensed in Stripper Reboiler. The alcohol water vapours from stripping column are partly sent to CO2 stripper bottom for heating. The Rectifier column and fusel oil column gets heat from steam. The Distillation process is operated through PLC.

5]

MULTIPRESSURE DISTILLATION with Integrated Evaporator (ENA) The fermentation mash 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 premium quality extra neutral alcohol. The system details are as below: The system consists of 7 main columns, namely, CO 2 Stripper, Stripper Column, Prerectifier Column, Extraction Column, Rectification Column, Refining Column, Fusel Oil Column Cum HCC. Wash is fed to CO2 stripper column to remove CO 2 gas present in wash. Alcohol is stripped off in stripper column. The top vapours from stripper column are fed to Calendria 1. Distillate from Calendria 1 is feed to prerectifier column. Pre-rectifier remove most of the fusel oils. The distillate from pre-rectifier column is fed to extraction column after dilution where DM Water & Recycle Spent Lesse from Rectifier Bottom is used. In extraction column most of the high boiling impurities separate from ethanol in presence of water. The Alcohol Water Vapour from top of column is feed to Calendria 2. The bottom ethanol water mixture is pre-heated by steam condensate and spent Leese before being fed to rectifier column. In rectifier column product rectified spirit is taken out from top tray and fed to refining column where mainly methanol impurities are separated. Pure ENA is obtained at bottom, which is cooled and stored. The impure spirit from top of extraction column, rectifier column and refining column are fed to heads column. The final impure spirit cut is taken out from heads column top and balance alcohol is recycled to pre-rectifier column. The top Vapour is feed to Calendria 2. The alcohol containing fusel oil from prerectifier and rectifier column is fed to fusel oil column. The rectifier column, fusel oil column and pre-rectifier column get heat from steam at 3.5 bar (g). Rectification column and pre-rectifier column works under positive pressure. The top vapours from rectifier column are condensed in stripper column for giving heat to stripper re-boiler. Most of the other columns work under vacuum. The Distillation process is operated through PLC

6]

MULTIPRESSURE DISTILLATION EVAPORAOTR (ENA)

WITHOUT

INTEGRATED

The fermentation mash 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 premium quality extra neutral alcohol. The system details are as below: The system consists of 7 main columns, namely, CO 2 Stripper, Stripper Column, Prerectifier Column, Extraction Column, Rectification Column, Refining Column, Fusel Oil Column Cum HCC. Wash is fed to CO2 stripper column to remove CO2 gas present in wash. Alcohol is stripped off in stripper column. The top vapours from stripper column are fed to Beer Heater, Principle & Vent Condenser. Distillate from Condensers is feed to pre-rectifier column. Pre-rectifier remove most of the fusel oils. The distillate from pre-rectifier column is fed to extraction column after dilution where DM Water & Recycle Spent Lesse from Rectifier Bottom is used. In extraction column most of the high boiling impurities separate from ethanol in presence of water. The bottom ethanol water mixture is pre-heated by steam condensate and spent Leese before being fed to rectifier column. In rectifier column product rectified spirit is taken out from top tray and fed to refining column where mainly methanol impurities are separated. Pure ENA is obtained at bottom, which is cooled and stored. The impure spirit from top of extraction column, rectifier column and refining column are fed to heads column. The final impure spirit cut is taken out from heads column top and balance alcohol is recycled to pre-rectifier column. The alcohol containing fusel oil from prerectifier and rectifier column is fed to fusel oil column. The rectifier column, fusel oil column and pre-rectifier column get heat from steam at 3.5 bar (g). Rectification column and pre-rectifier column works under positive pressure. The top vapours from rectifier column are condensed in stripper column for giving heat to stripper re-boiler. Most of the other columns work under vacuum. The Distillation process is operated through PLC 7] PROCESS DESCRIPTION FOR FA Rectified Spirit at Azeotropic concentration is pumped by Feed Pump. This pump takes care of the entire backpressure of the system. The pump is in Stainless Steel material of construction for wetted parts complete with flameproof motor and mechanical seal. The rectified spirit will first pass through feed Preheater (E-401), which will pass through vaporizer cum super heater (E-402) which will convert the Rectified Spirit feed to superheated Alcohol vapour stream ready to feed

to the Molecular Sieve bottles. The degree of superheat is control via a temperature control loop and the flow rate to the plant is control via flow control loop. The superheated vapours will pass through a Sieve bottle, which is already regenerated, and pressurize to working pressure via. a bleed flow from an operating sieve bottle. After the drying cycle the flow will be shifted to the next Sieve bottle, which is ready after duly regenerated and pressurize. This sequence minimizes the rate of rise and fall of pressure through the molecular sieve. Thus minimizing the attrition of the sieve beads. The sieve column after completion of drying cycle is evacuated to remove the adsorb water through an evacuation system via a condenser. The mixture of Alcohol and water is preheat by Anhydrous Alcohol Vapour in Plate Heat Exchanger (E-405) before being feed to Recovery Column, which enriches the stream back to azeotropic composition. The bottom of recovery column get heat from partly by condensing Anhydrous Alcohol Vapour in Shell & Tube Heat Exchanger (E-407) & by steam in Shell & Tube Heat Exchanger (E-408) The Anhydrous Alcohol vapours condensed in product cooler. A flow indicator indicates the rate of Anhydrous Alcohol going to the Anhydrous Alcohol receivers

Annexure VI ADVANTAGES OF THREE BED SYSTEM

Rate of change of pressure from Atmospheric to Vacuum is less as the Regeneration is carried out in more time. Because of additional bed available for Regeneration, this enables almost complete Regeneration of bed and requires less sweep (Reversing movement of Anhydrous Alcohol Vapour, Dried Alcohol Vapour). This means the amount of Alcohol in recycle is less. Also, the amount of product fluctuation in vapor flow is minimum. Thus the system acts as continuous steady state system. Since the movement of bed is lower due to lower rate of change of pressure, the life of Sieve is better (due to less attrition). Theoretically, in more number of beds, (even more than three) which works individually for individual functioning, like drying, depressurization, regeneration and sweep will always be better than when these functions are done by smaller number of beds. For e.g. if you use only one bed, then there will be disruption of product vapour flow completely when bed is under depressurization and regeneration.

Annexure VII
1. CONTINUOUS CASCADE FERMENTATION SECTION 1.1 Molasses Handling Section
Sr.No. Description 1. Day Molasses Tank (T-101) a. Capacity b. Material of Construction c. Thickness d. Quantity Technical Specification 75 m3 MS 6 mm 1 No.

2. Automatic Molasses Weighing System with check Weighment and tank (T-102) a. Accessories Load cell c. Quantity 1 No. 3. Weighed Molasses Receiving Tank (T-103) a. Capacity b. Material c. Thickness - Shell/Bottom/Top d. Quantity 4 m3 MS 6 mm 1 No.

1.2 Yeast Propagation Section

1. Jacketed Yeast Vessel (YV 101) a. Capacity b. Material of Construction shell / jacket c. Accessories 150 lit SS 304/Mild steel Nozzles for SG,LG Pressure indicator, Temperature indicator, Safety valve, Air spurges etc. 1 No. 1500 lit SS 304 / Mild steel Nozzles for SG, LG, Pressure indicator,

d. Quantity 2. Jacketed Yeast Vessel (YV 102) a. Capacity b. Material of Construction shell / jacket c. Accessories

d. Quantity 3. Yeast Vessel (YV 103) a. Capacity b. Material of Construction c. Accessories

Temperature indicator, LG, Safety valve, Air spurges etc. 1 No. 15 m3 Mild Steel Nozzles for SG, LG, Pressure indicator, Temperature indicator, LG, Safety valve, Air spurges, Diffuser etc 1 No. SS 304 3 Nos.

d. Quantity 4. Molasses Diluter a. Material of Construction b. Quantity

1.3 Fermented Wash Preparation Section

1. Fermenters a. Capacity b. Material of Construction c. Thickness d. Accessories e. Quantity 2 Fermenter Cooler a. Type b. Material of Construction c. Quantity 180 m3 Geometric volume MS PU coated 6 mm Nozzles for Fermented Wash In, Out, CO2 Outlet, H2SO4, TRO, Biocide, Nutrient, Manhole 3 Nos.

Plate Heat Exchanger SS 316 Plate / MS Frame 3 Nos.

1.4 Fermented Wash Post Clarification Section

1. Wash Settling Tank a. Capacity b. Material of Construction c. Accessories 20 m3 MS with PU coating Lamellar Assembly

c. Quantity

1 No.

2.

Sludge Tank a. Capacity b. Material of Construction c. Quantity Clarified wash tank a. Capacity b. Material of Construction c. Quantity Sludge Settling tank a. Capacity b. Material of Construction c. Quantity Decanter for sludge separation a. Type b. Material of Construction c. Quantity

1 m3 Mild Steel 1 No. 30 m3 MS with PU coating 1 No. (For option without Yeast Recycle) 5 m3 MS with PU coating 1 No. (Optional) Centrifugal SS 304 [contact parts] 1 No.

3.

4.

5.

1.5
1.

Yeast Recycle System

Yeast Separator a. Capacity b. Material of Construction c. Accessories d. Quantity 25 m3/hr SS 316 Base Frame with motor, Yeast Trough, etc 1 No.(Working) + 1 No. (standby)

2.

Yeast Cream cum Acidification Tank with agitator a. Capacity 1.5 m3 b. Material of Construction SS 304 c. Quantity 1 No. Yeast Activation Tank a. Capacity b. Material of Construction c. Quantity 2 m3 SS 304 1 No.

3.

1.6 Auxiliaries
1 Anti Foam Agent Tank

a. Capacity b. Material c. Quantity 2 Nutrient Mixing tank with Agitator a. Capacity b. Material c. Quantity CO2 Scrubber a. Overall dimensions b. Material of Construction c. Type of Plate d. Quantity

1 m3 MS 1 No.

1.0 m3 SS 304 1 No. Dia.425 mm x 3000 mm Height SS 304 Sieve 1 No.

1.7
1.

Utility
Cooling tower for Fermentation a. Operating UT b. Material of construction c. Quantity Liquid ring blower a. Capacity b. Accessories c. Quantity 2 C FRP 1 no. 360 m3/hr HEPA Filter, Motor, Base frame etc. 1 + 1 No.

2.

Note: All dimensions and specifications are indicative. The specifications may vary after detailed design and engineering.

Annexure VIII
2.
2.1 1.

MULTI PRESSURE DISTILLATION SECTION

Columns CO2 Stripping column (Under Vacuum) (RS/ENA) a. Diameter 900 mm b. Material of Construction SS 304 c. Type of Tray RH Grid d. No. of Trays 12 e. Thickness Shell / Tray 4 mm / 2.5 mm Stripping Column (Under Vacuum) (RS/ENA) a. Diameter 1,410 mm b. Material of Construction SS 304 c. Type of Tray RH Grid d. No. of Trays 22 e. Thickness Shell / Tray 4 / 2.5 mm Prerectifier Column (Under Pressure) (ENA) a. Diameter 1,150 mm b. Material of Construction SS 304 / SS304 / SS304 Shell / Tray / B.Cap c. Type of Tray Bubble cap d. No. Of Trays 55 e. Thickness [Shell / Tray / Cap] 4 / 2.5 / 1.6 mm Extraction Column (Under Vacuum) (ENA) Diameter Material of Construction Shell / Tray / B.Cap Type of Tray No. Of Trays Thickness [Shell / Tray / Cap] 1,150 mm SS 304 / SS304 / SS304 Bubble cap 44 4 / 2.5 / 1.6 mm

2.

3.

4.

5.

Rectifier Column (Under Pressure) (RS/ENA) Diameter 1,260 mm Material of Construction SS 304 / DOC Shell / Tray / B.Cap Type of Tray Bubble cap No. Of Trays 72 (37 DOC & 35 SS304)

Thickness [Shell / Tray / Cap]

4 / 2.5 / 1.6 mm

6.

Refining Column (ENA) Diameter Material of Construction Shell / Tray / B.Cap Type of Tray No. Of Trays Thickness [Shell / Tray / Cap] Fusel Oil Column Diameter Material of Construction Shell / Tray / B.Cap Type of Tray No. Of Trays Thickness [Shell / Tray / Cap]

700 mm DOC / DOC / DOC Bubble cap 55 4/ 2.5 / 1.6 mm 750 mm SS 304 / SS304 / SS304 Bubble cap 72 3 / 2.5 / 1.6 mm

7.

2.2
1.

Tanks
Cold water tank a. Capacity b. Material of Construction c. Quantity Hot water Header a. Material of Construction b. Quantity Prerectifier Reflux tank a. Capacity b. Material of Construction c. Quantity Rectifier Reflux tank a. Capacity b. Material of Construction c. Quantity Fusel Oil tank a. Capacity b. Material of Construction c. Quantity Steam Condensate tank 15 m3 Mild steel 1 No. Mild steel 1 No. 2 m3 SS 304 1 No. 2 m3 SS 304 1 No. 1 m3 SS 304 1 No.

2.

3.

4.

5.

6.

a. Capacity b. Material of Construction c. Quantity 7. Fusel Oil De-canter a. Capacity b. Material of Construction c. Quantity

2.5 m3 Mild Steel 1 No.

100 ltr. SS 304 1 No.

2.3
1.

Shell & Tube Heat Exchangers

Re-boiler for Stripping Column a. Heat transfer area b. Material of construction shell / tube / flange c. Tube (ERW) d. Quantity Re-boiler for Prerectifier Column a. Heat transfer area b. Material of Construction shell / tube / flange c. Tube (ERW) d. Quantity 115 m2 SS 304/ SS 304 / Mild steel 38.1mm OD x 1.6 mm thk 1Nos. 55 m2 Mild Steel / SS304 / Mild Steel 38.1mm OD x 1.6mm thk 1 No. 40 m2 SS304 / SS304 / Mild Steel 38.1mm OD x 1.6mm thk 1 No. 100 m2 Mild Steel / SS304 / Mild Steel 38.1mm OD x 1.6mm thk 1 No. 16 m2 SS304 / SS304 / Mild Steel 38.1mm OD x 1.6mm thk 1 No.

2.

3.

Re-boiler for Extraction Column a. Heat transfer area b. Material of Construction shell / tube / flange c. Tube (ERW) d. Quantity Re-boiler for Rectifier Column a. Heat transfer area b. Material of Construction shell / tube / flange c. Tube (ERW) d. Quantity

4.

5.

Re-boiler for Refining Column a. Heat transfer area b. Material of Construction shell / tube / flange c. Tube (ERW) d. Quantity

6.

Re-boiler for Fusel Oil Column a. Heat transfer area10 m2 b. Material of Construction shell / tube / flange c. Tube (ERW) d. Quantity

Mild Steel / SS304 / Mild Steel 38.1mm OD x 1.6mm thk 1 No. 7 m2 SS 304 / SS 304 / Mild steel 25.4mm OD x 1.6mm thk 1 No. 4 m2 SS 304 / SS 304 / Mild steel 25.4mm OD x 1.6mm thk 1 No.

7.

Degasser Condenser Heat transfer area Material of Construction shell / tube / flange, Bonnet , Dished End Tube (ERW) Quantity Vent Condenser for CO2 Stripper a. Heat transfer area b. Material of Construction shell / tube / flange, Bonnet , Dished End c. Tube (ERW) d. Quantity Beer Heater

8.

9.

(For option without integrated Evap.)

a. Heat transfer area 21 m2 b. Material of Construction shell / tube / SS 304 / SS 304 / Mild steel flange c. Tube (ERW) 25.4mm OD x 1.6mm thk d. Quantity 1 No. 10 Main Condenser for Stripper (For option without integrated Evap.) 34 m2 SS 304 / SS 304 / Mild steel 25.4mm OD x 1.6mm thk 1 No.

a. Heat transfer area b. Material of Construction shell/tube/ flange, Bonnet , Dished End c. Tube (ERW) d. Quantity 11 Vent Condenser for Stripper a. Heat transfer area b. Material of Construction shell/tube/ flange, Bonnet , Dished End c. Tube (ERW) d. Quantity 12 Main Condenser for Prerectifier a. Heat transfer area

5 m2 SS304 / SS304 / Mild steel 25.4mm OD x 1.6mm thk 1 No. 6 m2

b. Material of Construction shell/tube/ flange, Bonnet , Dished End c. Tube (ERW) d. Quantity 13 Vent Condenser for Prerectifier a. Heat transfer area b. Material of Construction shell/tube/ flange, Bonnet , Dished End c. Tube (ERW) d. Quantity

SS304 / SS304 / Mild steel 25.4mm OD x 1.6mm thk 1 No. 8 m2 SS304 / SS304 / Mild steel 25.4mm OD x 1.6mm thk 1 No.

14

Main Condenser for Extraction (For option without integrated Evap.) a. Heat transfer area b. Material of Construction shell/tube/ flange, Bonnet , Dished End c. Tube (ERW) d. Quantity 19 m2 SS304 / SS304 / Mild steel 25.4mm OD x 1.6mm thk 1 No. 6 m2 SS304 / SS304 / Mild steel 25.4mm OD x 1.6mm thk 1 No. 8 m2 SS304 / SS304 / Mild steel 25.4mm OD x 1.6mm thk 1 No.

15

Main Condenser for Extraction a. Heat transfer area b. Material of Construction shell/tube/ flange, Bonnet , Dished End c. Tube (ERW) d. Quantity

16

Vent Condenser for Rectifier a. Heat transfer area b. Material of Construction shell/tube/ flange, Bonnet , Dished End c. Tube (ERW) d. Quantity Main Condenser for Refining a. Heat transfer area b. Material of Construction shell/tube/ flange, Bonnet , Dished End c. Tube (ERW) d. Quantity Vent Condenser for Refining a. Heat transfer area b. Material of Construction shell/tube/ flange, Bonnet , Dished End c. Tube (ERW) d. Quantity

17

10 m2 DOC / DOC / Mild steel 25.4mm OD x 1.6mm thk 1 No. 5 m2 DOC / DOC / Mild steel 25.4mm OD x 1.6mm thk 1 No.

18

19

Main Condenser for Fusel Oil (For option without integrated Evap.) a. Heat transfer area 17 m2 b. Material of Construction shell/tube/ SS304 / SS304 / Mild steel flange, Bonnet , Dished End c. Tube (ERW) 25.4mm OD x 1.6mm thk d. Quantity 1 No. Vent Condenser for Fusel Oil a. Heat transfer area b. Material of Construction shell/tube/ flange, Bonnet , Dished End c. Tube (ERW) d. Quantity Vent Scrub Heat Exchanger a. Heat transfer area b. Material of Construction shell/tube/ flange, Bonnet , Dished End c. Tube (ERW) d. Quantity 5 m2 SS304 / SS304 / Mild steel 25.4mm OD x 1.6mm thk 1 No. Suitable SS 304 / SS 304 / Mild steel 25.4mm OD x 1.6mm thk 1 No. 12 m2 DOC / DOC / Mild steel 25.4mm OD x 1.6mm thk 1 No. 12 m2 SS 304 / SS 304 / Mild steel 25.4mm OD x 1.6mm thk 1 No. Suitable SS 304 / SS 304 / Mild steel 25.4mm OD x 1.6mm thk 1 No. Suitable SS 304 / SS 304 / Mild steel 25.4mm OD x 1.6mm thk

20

21

22

ENA Cooler a. Heat transfer area b. Material of Construction shell/tube/ flange, Bonnet , Dished End c. Tube (ERW) d. Quantity Rectified Spirit Cooler a. Heat transfer area b. Material of Construction shell/tube/ flange, Bonnet , Dished End c. Tube (ERW) d. Quantity

23

24 Impure Spirit Cooler a. Heat transfer area b. Material of Construction shell/tube/ flange, Bonnet , Dished End c. Tube (ERW) d. Quantity 25 Fusel Oil Cooler a. Heat transfer area b. Material of Construction shell/tube/ flange, Bonnet , Dished End c. Tube (ERW)

d. Quantity

1 No.

2.3.1 Plate Heat Exchangers

1. Plate Heat Exchangers for Preheating Prerectifier & Rectifier Feed a. Material of Construction Plate SS316, Frame MS with anticorrosive coating b. Quantity 4 Nos. Plate Heat Exchangers for preheating (Feed Pre Heating - Fermented Wash) a. Material of Construction Plate SS316, Frame MS with anticorrosive coating b. Quantity 1 No. (for option without Integrated Evaporator) & 2 Nos. (for option with Integrated Evaporator)

2.

Plate Heat Exchangers for Preheating (Week Bear Recycle Cooler) a. Material of Construction Plate SS316, Frame MS with anticorrosive coating b. Quantity 1 No.

2.4
1.

Utility
Cooling tower for distillation + Evaporation + Weak Bear Recycle + Dehydration Plant a. Operating T 8 C b. Material of construction FRP/Wood c. Quantity 1 no.

2.

Air Compressor a. Capacity 40 m3/hr b. Accessories Pressure Switch, Air Dryer etc. c. Quantity 1 no. Note: All dimensions and specifications are indicative. The specifications may vary after detailed design and engineering.

Annexure IX
3.0 3.1
1

SPENT WASH EVAPORATOR INTEGRATED DISTILLATION (for Concentration up to 24%) Equipments

Evaporator Calendria a. Type b. Material of Construction Shell Tubes c. Quantity Vapour Separator a. Material of Construction b. Quantity Barometric Condenser a. Material of Construction b. Type c. Quantity Multiple effect Falling Film SS 304/ mild steel SS 304 4 Nos. SS 304 4 Nos. SS304 Shell & Tube 1 No.

WITH

3.2
1

Auxiliary
Vapour Duct a. Material of Construction Piping for a. Condensate, non-condensate b. Product, etc. SS304

SS304 SS 304

Note: All dimensions and specifications are indicative. The specifications may vary after detailed design and engineering

Annexure X
4.0 TECHNICAL SPECIFICATION FOR PLANT AND MACHINERY FOR 30 KLPD ANHYDROUS ALCOHOL PLANT BASED ON MOLECULAR SIEVE TECHNOLOGY

5.1 Equipments
1. Adsorber bed with molecular sieve packing and internals a. Over all dimension 800 mm b. Material of Construction Mild Steel c. Thickness 6 mm d. Quantity 3 Nos. Recovery Column a. Over all dimension b. Material of Construction c. Thickness shell / tray / cap d. Quantity 508 AISI 304 3 / 2.5 / 1.6 mm 1 No.

2.

3.2
3.

Heat Exchanger
Feed Sieve Vaporizer cum Super Heater a. Type Shell and tube b. Heat transfer area Suitable c. Material of Construction shell/tube MS / AISI 304 d. Thickness shell / tube 6 / 1.6 mm e. Quantity 1 No. Recovery Column Re-boiler 1 Type Heat transfer area Material of Construction shell / tube Thickness shell / tube a. Quantity Recovery Column Re-boiler 2 Type Heat transfer area Material of Construction shell / tube Thickness shell / tube4 / 1.6 mm b. Quantity Shell and tube Suitable MS / AISI 304 6 / 1.6 mm 1 No. Shell and tube Suitable AISI 304 / AISI 304 1 No.

4.

5.

3.2.1 Plate Heat Exchanger

6. Feed Economizer a. Type b. Plate material c. Frame material PHE d. Plate thickness e. Quantity Plate heat exchanger SS 316 M. S duly painted 0.5 mm 1 No Plate heat exchanger SS 316 M S duly painted 0.5 mm 1 No. Plate heat exchanger SS 316 M S duly painted 0.5 mm 1 No. Plate heat exchanger SS 316 M S duly painted 0.5 mm 1 No. Plate heat exchanger SS 316 M S duly painted 0.5 mm 1 No.

7. Regeneration Cooler a. Type b. Plate material c. Frame material d. Plate thickness e. Quantity 8. Product Cooler a. Type b. Plate material c. Frame material d. Plate thickness e. Quantity Regenerating Condenser a. Type b. Plate material c. Frame material d. Plate thickness e. Quantity Proof Condenser a. Type b. Plate material c. Frame material d. Plate thickness e. Quantity

9.

10.

3.3
11.

Tanks
Regeneration Tank a. Capacity b. Material of construction c. Thickness 650 ltrs. AISI SS 304 2 mm

d. Quantity 12. Reflux Tank a. Capacity b. Material of construction c. Thickness d. Quantity

1 No. 50 ltrs. AISI SS 304 2 mm 1 No.

3.4
13.

Auxiliary
Vacuum Eductor Type Material of Construction Quantity Liquid Jet Eductor Bronze 1 No.

14.

Chilling plant with pump, motors / starters/ push buttons Material of construction Mild steel Make Premier / Equivalent Quantity 1 no.

Note: All dimensions and specifications are indicative. The specifications may vary after detailed design and engineering.

Annexure XI Pumps & Motors

1.1 Fermentation Section
Sr. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. Pump Raw Molasses Transfer Pump Fermenting Wash Circulation Pump Fermenting Wash Circulation Pump Fermenting Wash Circulation Pump Clarified Wash Transfer Pump Sludge Transfer Pump Nutrient Dosing Pump TRO Dosing Pump Cooling Water Qty 1 1 1 1 2 2 2 2 2 Type Gear Centrifugal Centrifugal Centrifugal Centrifugal Screw Metering Metering Centrifugal Flow Rate (m3/hr) 6 MT 120 80 60 20 1 0.5 0.5 310 Head (mWc) 30 15 15 15 45 15 15 15 18 Shaft Seal -Single Mech. Single Mech. Single Mech. Single Mech. Single Mech. Gland PTFE Gland PTFE Gland Packing MOC Contact Part CI Case-CI Contact Part-SS304 Case-SS304 Contact Part-SS304 Case-SS304 Contact Part-SS304 Case-SS304 Contact Part-SS304 Case-SS304 Contact Part-SS304 Case-SS304 Contact Part-SS304 Case-SS304 Contact Part-SS304 Case-SS304 Contact Part-SS304 Case-SS304

1.2 Yeast Recycle Section

Sr. No. 1. Pump Yeast Cream Pump Qty 2 Type Centrifugal Flow Rate (m3/hr) 10 Head (mWc) 25 Shaft Seal Single Mech. MOC Contact Part-SS304 Case-SS304

1.3 Multi Pressure Distillation (RS/ENA)

Sr. No. 1. 2. 3. 4. Pump CO2 Stripper Reflux Pump Stripper Bottom Pump (Spent Wash) Prerectifier Feed Pump Prerectifier Qty 2 2 2 2 Type Centrifugal Centrifugal Centrifugal Centrifugal Flow Rate (m3/hr) 1 15 3 4 Head (mWc) 30 35 55 25 Shaft Seal Single Mech. Single Mech. Single Mech. Single Mech. MOC Contact Part-SS304 Case-SS304 Contact Part-SS304 Case-SS304 Contact Part-SS304 Case-SS304 Contact Part-SS304

5. 6. 7. 8. 9. 10. 11.

Reflux Pump Rectifier Feed Pump Rectifier Reflux Pump Fusel Oil Column Feed Pump Condensate Transfer Pump Axial Flow Pump Cooling Water Pump Vacuum Pump

2 2 2 2 1 2 2

Centrifugal Centrifugal Centrifugal Centrifugal -Centrifugal --

15 10 2 6
Suitable

50 45 35 15 6 25 --

Single Mech. Single Mech. Single Mech. Gland packing Double Mech. Gland Packing

375 20

Case-SS304 Contact Part-SS304 Case-SS304 Contact Part-SS304 Case-SS304 Contact Part-SS304 Case-SS304 Contact Part-MS Case-CI Contact Part-SS304 Case-SS304 Contact Part-CI Case-CI Body-CI Contact Part-SS304

1.4 Integrated Evaporation Section

Sr. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Pump Circulation Pump for Calendria I Circulation Pump for Calendria II Circulation Pump for Calendria III Circulation Pump for Calendria IV Condensate Transfer Pump Stripper Distillate Pump Extraction Distillate Pump FOC Reflux Pump Vacuum Pump Feed Pump Qty 1 1 1 1 2 2 2 2 2 2 Type Centrifugal Centrifugal Centrifugal Centrifugal Centrifugal Centrifugal Centrifugal Centrifugal -Centrifugal Flow Rate (m3/hr)
Suitable Suitable Suitable Suitable Suitable Suitable Suitable Suitable Suitable Suitable

Head (mWc) 15 15 15 15 15 25 25 25 -35

Shaft Seal Double Mech. Double Mech. Double Mech. Double Mech. Single Mech. Single Mech. Single Mech. Single Mech.

MOC Contact Part-SS304 Case-SS304 Contact Part-SS304 Case-SS304 Contact Part-SS304 Case-SS304 Contact Part-SS304 Case-SS304 Contact Part-SS304 Case-SS304 Contact Part-SS304 Case-SS304 Contact Part-SS304 Case-SS304 Contact Part-SS304 Case-SS304 Body-CI Contact Part-SS304 Contact Part-SS304 Case-SS304

Double Mech.

1.5 Dehydration Plant

Sr. No. 1. 2. 3. Pump R.S. Feed Pump Regeneration Pump Proof Pump Qty 2 2 2 Type Multi Stage Multi Stage Multi Stage Flow Rate (m3/hr)
4 22 2.5

Head (mWc) 65 85 20

Shaft Seal Single Mech. Single Mech. Single Mech.

MOC Contact Part-SS304 Case-SS304 Contact Part-SS304 Case-SS304 Contact Part-SS304 Case-SS304

Note: All specifications are indicative. The specifications may vary after detailed design and engineering.

Annexure XII INSTRUMENTATION, PIPING & VALVES

1.1 FERMENTATION 1 2 3 4 5 6 1.2 Magnetic Flow Meter Glass Tube Rota meter Metal Tube Rota meter Pressure Gauges Temp Element On / Off Valve 2 12 4 25 13 2

DISTILLATION (RS/ENA) 1 2 3 4 5 6 7 Temp Element Pressure Transmitter Pressure Gauges Level Transmitter Glass Tube Rota meter Metal Tube Rota meter Control Valve (Level, Pressure, Temp) 58 7 22 9 24 10 19

1.3 DEHYDRATION 1 2 3 4 5 6 7 1.4 Temp Element Pressure Transmitter Pressure Gauges Level Transmitter Glass Tube Rota meter Metal Tube Rota meter Control Valve (Level, Pressure, Temp) 23 4 22 9 24 9 6

INTEGRATED EVAPORATOR 1 2 3 4 Level Transmitter Control Valve Pressure Gauge RTD 3 3 12 4

Motor Control Centre for Fermentation, Multi Pressure Distillation, Integrated Evaporator, Dehydration Plant 1.5.1 a. Material of Construction MS CRCA b. Quantity 1 No. c. Accessories Electrical like Relay, Fuses, Starter, Pushbuttons, Indicating Lamps, etc. Evaporator,

1.5

1.6

PLC for Multi Pressure Distillation, Integrated Dehydration 1.6.1 PLC Modules and Rack, Software (SCADA) For Multipressure Distillation, Integrated 1 Set. Evaporator, Communication Cable 1 Lot PC with Monitor and Printer 1 No.

Piping
1. Molasses Acid Nutrient CO2 Yeast_ Sludge Fermented Wash Spent Wash Instrument Air Extra Neutral Alcohol Rectified Spirit Fuel Alcohol Fusel Oil Impure Spirit Steam Steam Condensate Spent Lesse Cooling Water Supply Cooling Water Return Vacuum MS B Class PP SS304 PVC/HDPE SS304 SS304 SS304 SS304 GI SS304 up to Cooler SS304 up to Cooler SS304 up to Cooler SS304 up to Decanter SS304 up to Cooler MS C Class MS C Class SS304 MS B Class MS B Class SS304

Valves
2. Above 50 NB Up to 50 NB MOC a. SS304 Piping Contact Part SS304, Non Contact Part CI Butterfly Valve Ball Valve

b. MS Piping

CI

Note: All specifications are indicative. The specifications may vary after detailed design and engineering.