Professional Documents
Culture Documents
For
Molasses Based Fuel Ethanol Plant of
45 KLD
Along with 14 TPH Incineration
Boiler
At
Village – Mendrana
Tehsil- Pansemal
Distt – Badwani (MP)
Proposed By
M/S Shree Durga Khandsari Sugar Mills
(SDKSM)
Village- Mendrana, Tehsil- Pansemal, Dist.
Barwani, MP
1
1. Identification of project and project proponent
M/s Shree Durga Khansari Sugar Mill (SDKSM) is as partnership firm registered
with State Govt and located at Village- Mendrana, Tehsil- Pansemal Dist
Barwani (MP)
The factory was established originally as Khandsari Sugar unit of 300 TCD in
1974. Initially factory was following traditional khandsari process which was
associated with number of disadvantages such as low sugar recovery, higher
sugar loss in bagasse and final molasses, high fuel consumption. In year 2004,
the unit upgraded the crushing capacity to 800 TCD and received permission for
conversion of khandsari unit to sugar plant. Presently SDKSM is operating plant
with expanded capacity of 2500 TCD.
Brief Description of Nature of the Project
The present proposal is for setting up a 45 KLD fuel ethanol plant (Molasses
based) with 14 TPH Incineration Boiler at Village Mendrana, Tehsil- Pansemal
Dist Barwani (MP) in the State of Madhya Pradesh at an estimated cost Rs. 4682
Lacs. The proposed project will be set up adjacent to the existing sugar unit
(2500 TCD & 11 MW power plant) of M/s SDKSM.
Most of the infrastructure facility is already available with the industry as
present sugar manufacturing operation is being continued from several years.
The Company proposes to set up an integrated pollution free (Zero discharge)
fuel ethanol plant in the State with an installed capacity of 45 KLD in the State
of Madhya Pradesh. The proposed Industrial Complex shall process molasses as
its raw material to produce RS & Dehydration:
Silent feature of the project
• Provided with most efficient Fed batch Fermentation technology
Distillation operating on Multi-Pressure Technology -a efficiently heat
integrated system, operating on fully automated PLC control system
On line cleaning system is provided for distillation equipment's to
minimize plant shut down period.
Process equipment's are designed as per TEMA/ ASME standards
Imported Buhler makes Mill and efficient Grain handling system is
considered.
Closed water recycles system and plant process is designed to minimize
fresh water requirement by recycling various effluents.
Zero Effluent Discharge norms is applied while designing the plant
2
Sr. No. Particulate Description
1. Name of the proponent M/s Shree Durga Khandsari Surgar Mills
2. Project capacity 45 KLPD Molasses Based Ethanol Plant with 14
TPH Incineration Boiler.
3. Khasara No. & Location of the Khasara No. 76/1 & 76/2, Village- Mendrana,
project Tahsil Pansemal, Dist. Barwani, MP.
4. Geographic Location 21°39'24.56" N and 74°39'14.41" E
217 m MSL
5. Land requirement Total land 8.0048 acres for proposed Distillery Unit
1.989 acre built up area
2.64 acre green belt area
6. Product Product:
Fuel Ethanol :45 KLPD With 14 TPH Incineration
Boiler.
7. Operation days 270 days
8. Molasses required Molasses 158 TPD ( Fermentable sugar 42% w/w)
9. Total water 351 KLD (After recycling)
10. Source of water Borewell
11. Electricity Operational: 847 kWh
Connected load: 1185 kWh
12. Turbine generator 1.20 MW
13. Steam 9.92 TPH
14. Fuel Concentrated spent wash: 117 TPD
Bagasse – 115 TPD
15. Source Captive & Nearby Market
16. Boiler 14 TPH Incineration Boiler
17. DG Two DG sets of capacity 250 kVA
18. Effluent treatment Condensate Polishing Unit (CPU) will treat spent
System lees, cooling tower blow down, boiler blow down
and process condensate. Spent wash will be
treated by multi effect evaporator followed by
slope fired boiler.
19. Man-power 70 skilled and unskilled
20. Total project cost 4682 Lakhs
21 Land acquired 24.19 acres
22 Land required for proposed 1.989 acres
plant
23 Proposed area for plantation 2.64 acres
24 Existing area of plantation 2 acres
25 Capital Cost for
1050 Lacs 100 Lacs ( May be changed during EIA
Environmental measures
study)
(proposed )
26 Recurring cost for
environmental monitoring etc 100 Lacs ( May be changed during EIA study)
(Proposed)
3
Existing Sugar And Cogeneration Plant Details
Sr. No Description Quantity Unit
4
22. Existing manpower 100 No.
requirement for
Sugar/Cogeneration (skilled
and unskilled)
23. Layout plan of existing sugar factory and cogeneration unit & proposed
Distillery unit with existing green belt, parking area, storage area etc -
Attached
3. Need for the project and its importance to the country and or region
Utilization of molasses for the production of ethanol in India will not only provide
value addition to the by-product, it also ensures better price stability and price
realization of molasses for the sugar mills. This will improve the viability of the sugar
mills, which will in turn benefit to cane growers.
Industry overview
Molasses is one of byproducts of sugar industry which is used to produce rectified
spirit/alcohol for making liquor and fuel. Traditionally, molasses has been used in
India to produce rectified spirit and alcohol of higher than 95% purity for producing
liquor for human consumption and for producing various chemicals. However, with
technological developments in the recent past, molasses has been effectively used to
produce bioethanol for blending with petrol as a fuel
Global scenario
Brazil is the second largest producer of ethanol globally after U.S. While U.S.
produces ethanol from corn, Brazil manufactures ethanol from sugarcane. Brazil
has mandatory blending ratio of ethanol in gasoline ranging from 18% to 25%. The
blend rate was as high as 25% before September 2011 and was reduced to 20% due
to drop in cane output hence affecting the ethanol production. Currently, flex-fuel
cars, which can use either ethanol or blended gasoline, in Brazil account for about
53% of the total car fleet and around 90% of the new vehicles sales. The proportion of
the flex-fuel cars are expected to cross 80% by 2020. Currently, the Brazilian light
vehicle fleet has been increasing by 6.7% y-o-y since 2003 with currently 90% of
the new vehicles being flex-fuel cars. Thus, there exists an increasing demand
in Brazil for ethanol which is encouraging for the sugarcane industry.
5
Indian scenario
India has about 330 distilleries, which produce over 4 billion liters of rectified spirit
(alcohol) a year. Beyond total distilleries, about 120 distilleries have the capacity to
distillate 1.8 billion liters (an additional annual ethanol production capacity of 365
million liters was built up in the last three years) of conventional ethanol per year
which is sufficient to meet requirement for 5% ethanol blending with petrol.
Government policy
In 2006, GOI mandated 5% ethanol blending with petrol, EBP programme to directly
benefit the sugarcane farmers by assuring the sugar industry a stable and reasonable
return for the molasses and then passing a significant part of the same to the
farmers. But since then the programme has been struggling to take off despite the
fact that the Cabinet Committee on Economic Affairs (CCEA) in November 2009
directed that a financial penalty be imposed on oil marketing companies for their
failure to reach targets. In November 2012, the CCEA has made it mandatory for Oil
Marketing Companies (OMCs) - Bharat Petroleum, Hindustan Petroleum and Indian
Oil Corporation - to blend 5% ethanol with petrol. This is likely to reduce the fuel
import bill and lower India's dependence on fossil fuel as the ethanol prices are lower
than petrol. The OMCs have been blending ethanol with petrol for the past two years
but the policy was partially implemented in absence of any clear directive. The
committee, headed by the Prime Minister, has also approved market-based
pricing of the biofuel, opening the
market for ethanol producers - mostly sugar companies. This shall result in an
increased demand for ethanol by OMCs.
The national bio-fuel policy, approved by the Government of India, has plans for a
20% ethanol blending programme by 2017 from the current mandated 5% blending &
recently increased to 10%, to reduce India’s dependence on fossil fuel imports.
The gap between the availability of alcohol and the requirement by the industry has
been widening. The existing requirement of alcohol by the industries is around 450
crore liters annually at 10% fuel ethanol blending, industrial alcohol and potable
alcohol and the production is around 285 crore liters. The trend is increasing as the
blending increases.
The Ministry of Petroleum recently issued gazette notification dated 11th Januray
2013 making 5% ethanol belnding with petrol mandatory across th country.
6
Year Ethanol production Ethanol utilization Ethanol Petrol
Blending Demand
Molasses Cane Total Industry Potable Balance
2001- 1775 0 1175 600 648 527 5% 448 8960
02` 10% 896
20% 1792
2006- 2300 1485 3785 711 765 2309 5% 638 12672
07 10% 1276
20% 2552
2011- 2300 1485 3785 844 887 2054 5% 814 16286
12 10% 162
20% 3257
2016- 2300 1485 3785 1003 1028 1754 5% 1039 20785
17 10% 2078
20% 4157
From the above table it can be concluded that actual production of ethanol in
India has not kept pace with the demand. Also with robust growth for
chemical and potable industries it will mean greater shortage of ethanol in
the coming years ahead. The Government of India has set an indicative
target of 20% blending of ethanol with petrol and also for diesel with
biodiesel across the country by 2017.
5. Imports Vs. Indigenous Production
No import is proposed as demand in domestic market is enough to consume
the product.
World Alcohol Production and Consumption (Billion Litres)
World Regions Years
2010 2011 2012 2013 2014
Americas 23.23 27.81 30.02 33.35 37.30
Asia 6.02 6.54 6.44 6.61 7.15
European Union 2.54 2.50 2.50 2.71 3.13
Rest of Europe 1.45 1.48 1.47 1.46 1.36
Africa 0.51 0.54 0.57 0.59 0.62
Oceania 0.18 0.16 0.15 0.15 0.17
World Total 33.93 39.03 41.15 44.87 49.73
India 1.80 1.90 1.65 1.70 2.0
* Projected
Source: F. O. Lichfs World Ethanol and Biofuels Report, Vol.4, No.17,
09/05/2006. Ethyl alcohol is basically used for three purposes i.e. 1)
Industrial alcohol for production of downstream chemicals, 2) Pptable Alcohol
for mamifacture of alcoholic beverages (Country Liquor and IMFL) and 3)
Fuel ethanol or Anhydrous alcohol, which can be blended with petrol or
diesel.
7
Sr. No. Ethanol Consumption for (%)
1 Industrial 21
2 Potable 11
3 Fuel 68
Industrial Alcohol: -
Ethyl Alcohol is an Important feedstock for the manufacture of chemicals.
World ethyl alcohol consumption for the production of chemicals is
around 1%. These chemicals are primarily the basic carbon based products
like Acetic acid, Butanol, Butadiene, Acetic Anhydride, Vinyl Acetate, PVC
etc. The existing plants such as synthetic rubber requiring large
quantities of alcohol will certainly grow to a large capacity. Acetic acid &
Butanol, which are needed in pharmaceuticals, paints & in many other
areas are important industries as they are value added products. Ethylene,
Ethylene oxide & Mono-ethylene glycol are also produced from
petrochemical route. However latest technological development & taking
into account the increasing cost of petrochemical raw material, it is now
possible toproduce Ethylene oxide, Mono-ethylene glycol etc. starting from
ethanol.
During the last 5-6 years, a number of alcohol-based industries have come up&
the existing has marginally expanded. The raw material needs of the
alcohol based chemical industry have to be niet to facilitate maximum
capacity utilization of these units in order to meet the domestic demands
for the end products. These units are starving for want of raw materials. The
shortage is wide spread & it has hit a most of chemical drug & other
industries. The drug industry is also bedeviled by scarcity of industrial alcohol.
Producers of insulin, antibiotics, tonics & several other essential bulk drugs &
finished formulations are unable to obtain their quota of industrial
alcohol, which is a vital raw material for them. Thus, even in
Maharashtra, which should be a State with surplus production of
alcohol, drug & chemical units are in the group of acute shortage of
industrial alcohol. 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.
6 Export Possibility
The company is setting up fuel ethanol plant, to supply the finish goods in the
country, at present is no export possibility at this capacity is envisaged.
8
7 Domestic/Export Markets
As above
1. Distillery manager 1
2. Production manager 1
3. ETP in-charge 1
4. Lab chemist 4
5. Operators 8
6. Project Engineer / Shift Engineer 8
7. Electrician 4
8. Mechanical fitters 4
9. Office Peon 3
10. Office assistant 3
11. Excise officer 1
12. Waterman/ Pump man 4
13. Other Contractual staff 28
14. Total 70
9 Project Description
ii. Location (map showing general location, specific location, and project
boundary & project site layout) with Coordinates:
9
The unit is spreaded over 24.19 acres of land in village Mendrana Tehsil,
Pansemal Dist. - Barwani of MP. The latitude and longitude of the site is as
below : 21°39'24.56"N - 74°39'14.41"E
10
iii. Details of Alternate Site:
The site is proposed on the piece of land where sugar unit ( 2500 TCD) with
cogen plant of 11 MW is already in operation. The entire land is about 24.19
acres and out of that proposed unit will require 32392 sq mt of land. Most of
the infrastructure is already available. Therefore proposed site suitable for the
project configuration.
FERMENTATION
Molasses, diluted with water to the desired concentration is metered
continuously into a single tank fermenter. Additives likes urea (in the form of
pellets or prills) and defoaming oil are also introduced in the fermenter as
required. There is an automatic foam level sensing and dosing system for
defoaming oil.
Every Kilogram of alcohol produced, generates about 290 Kcal of heat. This
excess heat is removed by continuous circulation of fermenting wash through
an external plate heat exchanger called the Fermenter Cooler. The
fermenter temperature is always maintained between 32 and 35 deg. C, the
range optimum for efficient fermentation.
11
The yeast for the fermentation is initially (i.e. during start-up of the plant)
developed in the Propagation Section described further on. Once propagated, a
viable cell population of about 500 million cells/ml is maintained by yeast
recycling and continuous aeration of the fermenter. Fluctuations in the yeast
count of +/- 20% have little effect on the overall fermenter productivity. Yeast
cell vitality which is usually above 70% may, in times of stress (such as
prolonged shut-downs) drop to 50% without affecting the fermentation.
Fermented wash passes through a series of hydro cyclones (one to three or
move in number depending on plant capacity), which remove grit, iron filings
and similar heavy particulate matter. This rejected material along with some
wash, is taken to the bottom portion of the wash column for alcohol recovery.
The overflow from the first hydro cyclone is taken a wash tank, also provided
with an arrangement to facilitate removal of heavy settable particulate matter.
Overflow from the wash tank is taken to the yeast separator, which clarifies
the wash. The hydro cyclone and the wash tank protect the separator from
erosion damage by removing grit and similar hard particles.
Wash Preparation
For the plant mash, molasses is diluted with water to give a sugar
concentration of 14 to 18% and pumped directly into the fermenter. This mash
is usually not sterilized, although in certain cases it has been pasteurised with
a resultant slight increase in efficiency. The fermenter is issued when it is one
eighth to one fourth full with a large volume of active yeast. 2 to 4% of the
final volume to allow development of the yeast during the entire filling period,
which may amount to 8 hours and to avoid growth of contaminating
organisms during this period.
Nutrients
12
by circulation of the mash through external coolers. It is desirable to
maintain the temperature of the mash below 350 C. The amount of heat
liberated during the fermentation agrees with the theoretical value.
C2H12O 2C2H5OH + 2CO2+26.0 Calories
The heat produced from a fermentation involving 100 kg of sugar is 260
cal. If the fermenters are not cooled the temperature of the mash will rise as
much as 400 C.
• Yeast Recycling:
The yeast in the fermented wash is removed as a 45 to 55 v/v slurry, and is
returned to the fermenter. This feature ensures that a high yeast cell
concentration is achieved and maintained in the fermenter. By recirculating
grown, active yeast, sugar that would have otherwise been consumed in yeast
growth, is made available for alcohol production, ensuring high process
efficiency.
• Propagation:
The propagation section is a feeder unit to the fermenter. Yeast, either
Saccharomyees cereviseae or Schizosaccharomyees (the choice being
determined by other process parameters, mainly the downstream effluent
treatment system) is grown in 3 stages. The first two stages are designed for
aseptic growth. Propagation vessel III develops the inoculum using pasteurized
molasses solution as the medium. This vessel has a dual function. During
propagation, it serves for inoculum build-up. When the fermenter enters
the continuous production mode, Propagation Vessel III is used as an
intermediate wash tank. Propagation is carried out only to start up the
process initially or after very long shut-downs during which the fermenter is
emptied.
• CO2 Scrubbing and Recovery:
The carbon-di-oxide produced during fermentation is scrubbed with water in
packed- bed scrubber, to recover alcohol. The water from the scrubber is
returned to the fermenter. About 1.0% of the total alcohol production is
saved by scrubbing the fermenter off gas. In plants where it is desired to
recover carbon-di-oxide, a part of the wash is drawn into a separate vessel
and is aerated there. This external aeration allows the recovery of CO2
uncontaminated with air. More details of this system can be supplied on
request.
• Fermentation Parameters (Typical):
The pH of the fermenter is maintained between 4.0 & 4.8 usually without
addition of any acid. The alcohol concentration is maintained between 7.0 &
13
7.5 % v/v, unless a highly concentrate effluent is to be produced. To reduce
the effluent volume, the fermenter is operated at a very high dissolved solids
level by increasing the proportion of weak wash recycle. Under these
conditions, alcohol concentration is reduced to between 5.5 to 6.0% v/v.
Conversion of sugar to alcohol is instantaneous, and the residual sugar
concentration is maintained below 0.2 % w/w as glucose. This usually
corresponds to a residual reducing substances concentration of 2.0 to 2.5 %
w/w in wash.
All the nutrient elements necessary for yeast growth exist in adequate
quantities as impurities in molasses. Occasionally, Nitrogen may have to be
supplemented. Defoaming oil (DFO), say Turkey Red Oil is added to the
fermenter by an automated DFO dosing system, to control foaming. Usually no
other additives are required.
• Flexibility:
This process accords tremendous flexibility to the operator. Process conditions
and plant design can be varied to suit individual requirements of alcohol
quality, effluent concentration and characteristics. This unit can give spent
wash suitable for use in any effluent treatment process.
2. Distillation:
Clarified or de-yeasted wash flows by gravity to the propagation vessel No. III,
which during continuous production, operates as an intermediate wash tank.
From here, fermented wash is pumped to the wash preheater, which uses
vapors from the rectifying column to preheat wash. Further heating is done in
an exchange of heat with weak wash and spent wash (see flow sheet for
primary distillation). Preheated wash then enters the degasifying column of the
distillation section.
• Primary Distillation: The CO2 and the degasifying section help remove the
CO2 and other non-condensable entrained in the wash. The wash column is
first column in the distillation section. It is also called the analyzer. Wash is
boiled in this column with steam either supplied as live steam from the
boiler (after pressure reduction and desuperheating) or from a reboiler which
generates steam by evaporating effluent wash.
Alcohol in wash vapourises and is carried, along with water vapor, to the top of
the wash column from where it goes to the rectification column. As wash
travels down the analyzer, it is progressively ‘stripped’ of its alcohol content.
At a point in the column, where the alcohol concentration is 0.5 to 1.0% v/v,
a portion of the wash is drawn off. This is called weak wash.
14
• Weak Wash Recycling :
Weak wash recycling of weak wash helps maintain the desired level of
dissolved solids in the fermenter, so that an adequately high osmotic
pressure is achieved. Osmotic pressure and the concentration of alcohol in the
fermenter, together keep off infection and minimize sugar losses. Weak wash
recycling also reduces the quantity of effluent spent wash and reduces the
process water requirement of the plant.
Spent wash is the wash from which all alcohol has been removed, this emerges
from the bottom of the wash column at about 105 deg C. Some of the heat is
recovered to preheat fermented wash entering the degasifying column.
Spent wash may also be passed through a forced circulation reboiler to
generate vapors. This concentrates the effluent and reduces the volume
further.
Multi Pressure Vacuum Distillation:
After fermentation the next stage in the manufacture of alcohol is to separate
alcohol from fermented wash and to concentrate it to 95% alcohol called as
rectified spirit. For this purpose, distillation process is employed.
Distillation step consumes a considerable amount of energy and is also a
deciding factor in the quality of ENA produced. Hence, in line with the demand
of the industry, efforts have always been to minimize requirement of energy and
to improve the basic quality of alcohol produced. Ease of operation,
reliability, lower down time and flexibility of operations are other parameters
considered during the design.
Three basic types of plant are designed:
a) One is to produce primary quality of alcohol, usually referred to as 'Rectified
Spirit' (R.S.) from the fermented wash. Such plants are also referred to as
‘Primary distillation’ plants.
b) Second is to produce fine quality of spirit usually referred to as 'Extra Neutral
Alcohol' (ENA) starting from R.S. Such plants are also referred to as 'secondary
distillation' plants.
c) Third is to directly produce fine quality alcohol (ENA) from fermented wash.
Such plants are referred to as 'wash (mash) to ENA' plants, where the two
steps of primary and secondary distillation are combined. Such plants
usually have lower consumption of energy than two separate plants
15
2. Pre-rectification column – Operation under vacuum
3. Rectification cum Exhaust Column - Operated under pressure
4. Recovery column - Operated under atmospheric
5. Extractive distillation column – Operated under vacuum
6. Simmering column – Operated under atmospheric
16
description to be in dehydration mode. After passing though the desiccant,
the vapor is condensed, cooled and sent to storage.
A small portion of the product vapor is sent, under high vacuum, through
bed 2, in regeneration mode, to prepare the desiccant for cycle changeover when
bed 2 goes online. The regeneration operation forces the release of the moisture
from the desiccant, making the bed 2 ready for the next cycle. The recovered
low strength vapors are condensed and recycled back to the Regeneration
column.
4. Evaporation for Spent wash Treatment
As per recent Environmental Protection Norms from Ministry of
Environment and Forests (MoEF), it is Corporates Responsibility to achieve
Zero Discharge in Inland Surface Water. For 45 KLPD distillery plant nearly
about 117 M3/Day spent wash will produced. Considering the large volume of
spent and achieve Zero liquid discharge plant operation following three stage
process is proposed.
Multi pressure distillation – In this steam is utilized in direct way for heating.
Hence, spent wash quantity generated is less as compared to traditional
distillation technology. Integrated and Standalone Multi effect evaporation -
The spent wash evaporation technology is a multiple effect evaporator system in
which heat recovered from one effect is used to concentrate spent wash in
second effect evaporator with continuous recirculation of concentrated spent
wash within the system until desired concentration is obtained. This entire
concentration process is carried out under vacuum leading to less
consumption of steam and maximum concentration of spent wash with in less
period of time. This is the 3rd stage of effluent treatment wherein spent
wash after integrated evaporation is concentrated and used in incineration
boiler.
17
achieve zero liquid discharge (ZLD) Due to recycle of process condensate back
to process, fresh water demand can be reduced at large extent.
Sugar unit
2500TCD Open Area Truck & Tractor
1. Sugarcane
2. Lime 658 MT/Year Bags Truck
3. Sulphur 158 MT/Year Bags Truck
4. Caustic soda (50%) 5.45MT/year Bags Truck
5. Caustic soda 5.45 MT/Year Bags Truck
18
As the sugar plant is expected to crush about 3.125 lakh MT of sugarcane in
future, molasses of around 14,688 MT will be produced at 4.7 % molasses
generation on cane. The own molasses will be utilized by the fuel ethanol plant,
leaving 28,062 MT as other unit molasses, as the total molasses requirement is
42,750 MT for optimum level of operation.
The balance quantity of molasses will be sourced as procured molasses from
nearby sugar factories.
19
Factory proposes to install Multiple Effect evaporator followed by Incineration
boiler. Advantages are as follows
Production of steam and power generation
Reduction in air pollution as compared to coal based boiler.
Reduction in water pollution and achieve zero discharge in inland surface water.
viii.: Availability of Water its source, energy / power requirement and source:
Water requirement:
Construction Phase – 20 kld
Operational Phase – Net fresh water requirement will be 351 KL per day
Source : Borewells
Water Balance
. Water inputs (In KLD)
1. Process water for fermentation section and CO2 scrubber 414
2. DM water for RS dilution 50
3. Water for vacuum pump, pump sealing, air blower & 6
others
4. Soft water makeup for cooling towers 340
5. Other domestic usage, laboratory uses, cleaning 5
6. Boiler 15
7. Total water input at start-up 830
Water Out Put (In KLD)
1. Spent Lees (PR & Rect.) 120
2. Process condensate 395
3. CT Evaporation & Drift Losses 272
4. Water losses from vacuum pump, pump sealing, Air blower 0.2
5. Cooling tower and boiler blow down 67
6. Total Water Output 854.2
Recycled water (In KLD)
1. Lees recycle for cooling tower make up 120
2. Process condensate fermentation 120
3. Process condensate to cooling tower, CIP, Fermentation 233
4. Pumps Sealing Water Recycle cooling tower 5
5. CO2 scrubber beer well to process water for fermentation 1
20
Water requirement for existing sugar and cogeneration
Sr. Particulars For sugar in For During Off
No KLD Cogeneration Season
in KLD
1. Total water requirement 350 150 3 M3
2. Water recovered 135 25 -
3. Total daily fresh water 215 125 -
required after recycling
21
boilers
Domestic Waste Sewage generation 20 KLD
water
During operation phase , the required power will be taken from cogeneration
power plant. One DG set of 1010 KVA shall be kept as standby arrangement
Fuel consumption
Sr. No Fuel Quantity
1. Concentrated spent wash 117.84 TPD
2. Spent wash concentrate, GCV 1600 kcal/kg
3. Coal GCV NA
4 Bagasse 115.20 TPD
5 Bagasse GCV 2250 kcal/kg
22
Steam Requirement
Sr. No. Section Quantity (TPH)
Steam Requirement
S no Purpose Quantity
1 Ethanol Fuel 3.5 kg/lit
2 Evaporation 1.8 kg/lit
X. Quantity of wastes to be generated (liquid and solid) and Scheme for their
management/ disposal
23
Wastewater Generation Of Sugar And Cogeneration
Sr. Source Process KLD Treatment Final Disposal
No.
1. Sugar Plant Sugar 200 ETP Treatment Units: Bar screen For ferti
manufactur M3 and grit chamber, oil and grease irrigation.
ing Process traps, reaction tank, equalization
tank, anaerobic tank,
aeration Tank I, aeration Tank II,
secondary clarifier, sludge drying
bed and polishing pond.
2 CO Gen Cooling 15 For polishing pond for For Ferti-
Plant Tower dilution with other effluent Irrigation
24
Solid Waste Details
Sn Type of waste Quantity Disposal
From existing sugar &- Proposed Distillery
cogeneration plant
Yeast Sludge NA 0.2 Kg/day Fertilizer
Lime Sludge 0.008 MT/day NA Fertilizer
WTP Sludge 0.001 MT/day NA Fertilizer
ETP Sludge 0.001 MT/day - Fertilizer
Ash Bagasse ash: Coal Ash : NA
24 MT/day Spent wash Ash ; 1.73 MT/day
Domestic waste 0.01 MT/day NA
Waste Oil 0.0001 Ltr/day NA
S. Particulars Details
No.
1 Co-ordinate 1. 21°39'24.56"N - 74°39'14.41"E
2
3 Height above mean sea 217 m MSL
level
4 Nearest Town Pansemal – 4.50km
5 Nearest Railway Dondaicha – 37.25km
Station/Town
6 Nearest Airport Shirpur – 48.00km
7 Nearest Highway/Road Khetia- Sendhwa Road SH 36 - 0.17 km
- S
8 Hills/Valley Toramal Hill – NEE – 8.75km
9 Ecological Sensitive Zone None
10 Reserve Forest RF- NNE – 8.75km
RF- ENE – 9.75km
11 Nearest Village Mendrana – E – 0.90km
12 Nearest River/ Nalla Bandbhara Buzurg nadi – N- 0.09km
Gomai River – SE – 1.25km
Umri Nadi – W – 3.25km
14 Surrounding Features
25
ii. Land Form, Land use and Land Ownership
Project Proponent is having 24.19 acres of land which is possession and
diverted for industrial purposes.
iii. Topography
Topography of the area is almost plain. Map is given in point No. 3.2
26
14. Security Cabin 20
15. Time Office 20
16. Boiler House 900
17. Coal Yard NA
18. Lagoon & Settling Pit 1000
19. Fire Water Pump House 10
Total area of Plant & Machineries 8049 Sq. Meter
In Acres 1.98 Acres
Total area earmarked for project 8.0048 acres
v. Existing Infrastructure
The required infrastructure is already in place as proposed site is in operation.
State Highway is passing at 170 mtrs from the industry.
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24 37 21 29 47 11 25 NNW 14 WNW 15 1 0
25 38 19 29 49 11 26 NW 10 WNW 18 0 0
26 39 18 29 53 12 29 E 5 WNW 10 0 0
27 38 23 31 47 14 27 NE 10 NNE 11 0 0
28 40 20 30 35 12 24 NW 6 NW 6 0 0
29 41 23 32 36 12 21 N 15 NW 8 0 0
30 40 22 31 28 12 19 N 15 WNW 17 0 0
31 39 23 31 39 13 26 NW 10 W 15 0 0
28
27 38 19 29 39 4 17 NW 12 WSW 11 0 0
28 39 21 30 27 5 14 WNW 15 WSW 24 0 0
29 39 24 31 37 10 23 W 17 W 17 0 0
30 37 21 29 41 15 28 W 18 WSW 18 0 0
Table No. 3.2 (C)
Meteorological Data Month Of 1 st May To 31 st May 2017
29
29 37 25 31 65 27 47 W 18 WSW 25 0 0
30 36 22 29 78 26 55 W 16 W 13 1 5
31 40 25 32 69 26 51 WSW 12 SSW 9 0 2
Amenities / facilities
30
Sr. Equipment Technical Specification Qty. MOC
No.
1 Raw Molasses Type- Screw/Gear 1+1 CI
transfer pump type Capacity- 20
2 Day Molasses Tank MT/hr
Capacity- 250 MT 1 MS
3 Molasses Transfer Pump Type- Screw/Gear 1+1 CI
type Capacity-
20MT/hr
4 Molasses Filter Type- Basket Strainer 1+1 MS
5 Molasses Receiving Tank Type- Cyl/Vert. Shell with 1 MS
Open Top & Conical
Bottom, Capacity- 3 MT
6 Molasses Type- Load Cell 1 MS
Weighing System Capacity 4 MT Per
Trip
7 Weighed Molasses Tank Type- Cyl/Vert. Shell with 1 MS
Conical Top & Sloping
Bottom, Capacity- 20 MT
8 Weighed Molasses Type- Screw/Gear 1+1 CI
Transfer Pump with Motor type Capacity- 15
MT/hr
9 Molasses Diluter For Type- Static Mixer 1 AISI304
Yeast Vessel
Fermentation Section:
31
8 Fermenter Type- 4+1 CF8
Recirculatio Centrifugal
n Pump with Motor Capacity-
9 Fermenter Wash Cooler Type- 3PHE 4 Plates
250m /hr AISI
10 Pre fermenter Type- Cyl/Vert. Shell with 2 316
AISI 304
/Yeast Activation Conical Top & Sloping
Vessel with SG,LG Bottom, Capacity- 40m3
11 Molasses Broth Mixer Type- Static Mixer 2 AISI 304
for Yeast
Activation Vessel
12 Yeast Activation Type- 1+1 CF8
Vessel Transfer Centrifugal
Pump with Motor Capacity- 30
3
m /hr
13 Yeast Activation Type- PHE 1 Plates
Vesse AISI 316
l Cooler Frame
14 Wash Holding Tank Type – Cyl/Vert. Shell 1 MS
MS Epoxy
with Conical Top &
Sloping Bottom, Capacity –
15 Wash Transfer Pump 200 m3
Type- Centrifugal Capacity- 1+1 CF8
3
25 m /hr (Wetted
Parts
16 Air Filter Type- HEPA 1+1 Only)
MS Frame
17 Air Blower with Motor Type- Watering Capacity- 1+1 CI
220 Am3/hr
18 Nutrient Dosing Tank Capacity- 1 m3 1 AISI 304
with Agitator
19 Nutrient Dosing Pump Type- Centrifugal 1+1 CI
3
Capacity- 1 m /hr
20 Acid Dosing Tank Type- Cylindrical, 1 MS
Vertical Capacity- 1 m3
21 Acid Dosing Pump Type- Centrifugal 1+1 Wetted
3
Capacity- 1 m /hr Parts
Alloy 20
22 Antifoam Dosing Tank Type- Cylindrical, 1 MS
Vertical Capacity- 1 m3
23 Antifoam Dosing Pump Type: Gear Capacity- 1 m3/hr 1+1 CI
24 CIP tank Type- Cylindrical, 1 AISI304
Vertical Capacity- 25
25 CIP Pump m3
Type- Centrifugal Capacity- 1+1 Wetted
Parts
12 m3/hr
Alloy 20
32
26 Piping, Valves As Per Standards Lot
Instrumentati
on
DISTILLATION SECTION:
Sr.
No. Description MOC Tech. Specs. Qty.
Re boilers
1 Analyzer Column Reboiler Shell & Tube Type AISI 304 1
2 ED Column Reboiler Shell & Tube Type AISI 304 1
3 Rectifier Cum Exhaust Column Reboiler Shell & Tube Type AISI 304 1
4 Pre Rectifier Column Reboiler Shell & Tube Type AISI 304 1
Co ndensers & Coolers
5 DG Condenser I Shell & Tube Type AISI 304 1
6 DG Condenser II Shell & Tube Type AISI 304 1
7 Analyser Condenser I & II Shell & Tube Type AISI 304 3
8 ED Condenser I & II Shell & Tube Type AISI 304 2
9 Recovery Condenser Shell & Tube Type AISI 304 1
10 Vent Condenser for Analyzer Shell & Tube Type AISI 304 2
33
13 Product (RS) Cooler Shell & Tube Type AISI 304 1
14 TA Cooler Shell & Tube Type AISI 304 1
15 FO Cooler Shell & Tube Type AISI 304 4
16 R/E Alcohol Cooler Shell & Tube Type AISI 304 1
17 ED Feed Cooler Shell & Tube Type AISI 304 1
OUTLINE TECHNICAL SPECIFICATIONS FOR 45 KLPD ETHANOL
PHE's, Pumps
19 DM Water Preheater PHE SS 316 Plates /MS 1
Frame
20 Rectifier Feed Preheater PHE SS 316 Plates /MS 1
Frame
21 PR Feed Preheater PHE SS 316 Plates /MS 1
Frame
22 Analyser Bottom Centrifugal Type CF8 (Wetted Parts Only) 1+1
Transfer Pump
23 Rectifier Lees Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1
24 PR Lees Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1
25 Pre Rectifier Feed Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1
26 PR Refux Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1
27 Rectifier Reflux Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1
28 FO Washing Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1
29 ED Bottom Transfer Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1
30 Alcohol Transfer Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1
31 Recovery Feed Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1
32 Steam Condensate Pump Centrifugal Type CI 1+1
Others
34
7 TA Mixing Bottle As Per Standard 1
8 Pipes & Fittings, Valves and As Per Standard Lot
Instrument
17 Filters CS 3
18 RS Feed Tank MS 1 Capacity : 50 m3
19 Instrumentation Standard Lot
20 Piping and Valves Standard Lot
21 Electricals Standard Lot
35
3 Ethanol Receiver Capacity: 50 m3 MS 3
4 RS Storage Tank with Vent Capacity: 900 m3 MS 2
Condenser & Flame
Arrestors
5 Ethanol Storage Tank with Capacity: 900 m3 MS 1
Vent Condenser & Flame
6 IS Bulk Storage Tank with Capacity: 400m3
Arrestors MS 1
Vent Condenser & Flame
7 Arrestors
FO Storage Capacity: 8 m3 MS 1
8 Alcohol Pumps with Centrifugal Wetted Parts Suitable
Flameproof Motor CF 8
9 Issue Measures PD Flowmeters Standard 3
10 Piping & Fittings Standard Standard 1 Lot
INTEGRATED EVAPORATOR:
INDEPENDENT EVAPORATOR:
36
2 Feed Pump & Spent 1 + 1 each Type - Centrifugal type SS 316
wash pump Suitable
3 Evaporators Suitable Type : Forced circulation SS304
4 Vapor Liquid Separators Suitable Type : Gas SS304
liquid separator
5 Evaporation Pump Suitable type
Recirculation pump SS 316
6 Surface Condenser 1 Type : shell & tube; SS 304
9 Vacuum Pump 1+1 Type - Water ring type SS 316
10 Condensate Tank 1 Capacity – Suitable SS 304
11 Condensate Pump 1+1 Type - Centrifugal type SS 316
12 Piping and Valve, Electrical and Instruments
37
Water Treatment Area Filtration Plant
Fire protection system to be offered based on site plan. The system is designed
as per International rules (NFPA) & equivalent standards.
38
2 Raw molasses Transfer Gear type positive 2+2 C.S.
pumps. displacement pumps Nos.
3 Interconnecting piping. Carbon steel pipes. LOT MS
iii Greenbelt
Approx 2 acres area has been covered with the good green belt. Further it is
proposed to cover 2.64 acres in next 05 years of time.
iv Social Infrastructure
Company shall evaluate the need base program under CSR and shall execute as
per the given plan.
v Connectivity
Site is well connected with by State Highway Khetia- Sendhwa road. .
39
i. Likely date of start of construction and likely date of completion
After obtaining environmental clearance and water / air consent the company
shall start the project. Proposed date shall be July 2018 (subject to clearances)
ii. Estimated project cost along with analysis in terms of economic viability
of the project
a. Land & Site Development (Refer Annexure – 1)
SDKSM has already earmarked 8 acres of land for the proposed fuel ethanol plant.
The site development expenses is estimated at Rs. 49 lakh which include leveling,
fencing, gates, internal roads, green belt development, etc
Civil Works
The main civil works for the fuel ethanol plant and their estimated costs are
indicated in the following table.
Item Cost, Rs.
Lakh
Main plant building, admin building, lab, Excise Office, 450.00
stores Weigh bridge, storage, distillery machinery
foundations, Structural for evaporation, distillation &
fermentation, Pipe Racks, Cooling tower civil works (Basin
Only), Raw water tank, Treated Water storage tanks, Fire
water storage tank, Raw & Concentrated Spent wash holding
tank, Condensate Polishing Unit civil work, Boiler
foundations & Axillaries, Turbine foundations DG set
foundation, structural work for Boiler & Turbine, Ash & Fuel
Architect
handling fees
system foundations etc., staging structure and 9.00
Total
foundations 459.00
Based on the actual civil costs incurred for similar capacity fuel ethanol
plant and preliminary estimates from the project architect, the civil estimates
have been worked out at Rs. 459 lakh, including Architect’s fees. The
appointed architect for the project will work out detailed estimates and civil
drawings (based on the inputs received by the equipment suppliers and labour
/ material rates at the site location).
Equipment
The main items of equipment for the fuel ethanol plant and their estimated
erected costs are given in the following table:
Item and brief specifications Estimated
Erected
Cost, Rs.
lakh
40
1) 45 KLPD Capacity distillery plant, including incl.
Molasses storage & handling, Fermentation, Multi-Pressure
Distillation & Ethanol, Integrated & Independent
Evaporation for spent wash concentration, Utility Equipment 1525.00
- Cooling Towers, Condensate Polishing Unit, Blower, Alcohol
Storage & auxiliaries, interface piping, electrical &
instrumentation, Air compressor, structural work, Erection
& Commissioning etc.
Based on the budgetary offers received from reputed machinery suppliers &
possible negotiation margins, the estimated erected cost of plant and equipment
for the proposed fuel ethanol plant including Boiler & Turbine has been worked
out at Rs.3422.00 lakh
Item Year
1 2 3 4 5
Installed Capacity-KLPD 45 45 45 45 45
Number of shift/day 3 3 3 3 3
No. of days 180 270 270 270 270
No. of hrs. 24 24 24 24 24
Annual Installed Capacity 8100 12150 12150 12150 12150
Capacity utilization, % 80 90 95 95 100
Net Production Fuel Ethanol, 6480 10935 10935 11543 12150
KL
Cost Summary
Based on the capital cost break up worked out, the project cost summary for
the entire integrated project is given in the following table
Distillery Plant
Particulars
(Rs. Lakh)
Land and Site Development 49
41
Buildings 459
Indigenous Plant and Machinery 3422
Miscellaneous Fixed Assets 248
Prelim. & Preoperative Expenses 308
Contingencies 68
Working capital margin 128
Total 4682
Financial and social benefits with special emphasis on the benefit to the
local people including tribal population, if any, in the area.
From the foregoing analysis, it is observed that proposal is environmental
compatible and will helps to people improving their financial status,
performance and repayment capability. This also helps the company in
venturing into production of niche specialty products which will eventually
better their profits and also their ranking in the industry. CSR programme
shall be executed through the group discussion and need base programme will
be proposed for the area, by which people of the area will be benefitted.
42