Pre Feasibility Report

For
Molasses Based Fuel Ethanol Plant
of 60 KLD
Along with 25 TPH
Incineration Boiler
At
Village – Pondar, Post - Salichouka
Tehsil- Gadarwada
Distt – Narsinghpur (MP)

Proposed By
M/S Narmada Sugar Pvt Limited
Village- Vill.- Thaini , Post – Bankhedi,
Dist .- Hoshangabad, MP- 461990
 1. Identification of project and project proponent
M/s Narmada Sugar Pvt Limited (NSPL) is as partnership firm registered
with State Govt and located at Village- Pondar Tehsil- Gadarwada Dist
Narsinghpur (MP)
M/s. Narmada Sugar Private Limited (NSPL) is one of the pioneering sugar
factories of Madhya Pradesh and is in its 10th year of operation. NSPL
received its memorandum for manufacturing of vacuum pan sugar and
molasses along with other sugarcane by products from the Ministry of
Commerce & Industry in April 2005. The factory started its crushing
operations in the year of 2006-07. The licensed crushing capacity of the
plant is 4500 tonnes per day.

Brief Description of Nature of the Project

The present proposal is for setting up a 60 KLD fuel ethanol plant (Molasses
based) with 25 TPH Incineration Boiler at Village- Pondar Tehsil- Gadarwada
Dist Narsinghpur (MP) in the State of Madhya Pradesh at an estimated cost
Rs. 6358 Lacs. The proposed project will be set up within in premises of
existing sugar unit (4500 TCD & 30 MW power plant) of M/s NSPL.
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 60
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
 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
Sr. No. Particulate Description
1. Name of the proponent M/s Narmada Sugar Pvt. Limited (NSPL)
2. Project capacity 60 KLPD Molasses Based Fuel Ethanol Plant with
25 TPH Incineration Boiler
3. Khasara No. & Location of the Khasra No. 132/1³
project
132/4 2.150 Acre
 6/3 -2.100 Acre

Total-4.250 Acre
Village- Pondar Tehsil- Gadarwada Dist Narsinghpur (MP)
4. Geographic Location 1. 22°51'12.60"N- 78°39'2.67"E
2. 22°51'16.24"N- 78°38'58.12"E
3. 22°51'22.80"N- 78°39'5.94"E
4. 22°51'18.52"N- 78°39'12.07"E
348 m MSL
5. Land requirement 4.25 acres for proposed Distillery Unit
2.59 acre built up area of plant
1.66 acre for green belt area
6. Product Product:
Fuel Ethanol:60 KLPD With 25 TPH Incineration
Boiler.
7. Operation days 270 days
8. Molasses required Molasses 220 TPD ( Fermentable sugar 42% w/w)
9. Total water 466 KLD (After recycling)
10. Source of water Borewell
11. Electricity Operational: 1050 kWh
Connected load: 1360 kWh
12. Turbine generator 1.5 MW
13. Steam 13.20 TPH
14. Fuel Total Spent wash : 600 M3 TPD
Concentrated spent wash: 156 M3 TPD
Bagasse – 180 TPD
15. Source Captive & sister concern
16. Boiler 25 TPH Incineration Boiler
17. DG Sets Existing DG sets of 63 KVA, 160 KVA and 400 KVA
shall be used as standby arrangement
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 90 skilled and unskilled
20. Total project cost 6358 Lakhs
21 Land acquired 35.298 acres inclusive of sugar unit
22 Land earmarked for 4.250 acres
proposed distillery unit
23 Proposed area for plantation
1.66 acres
wrt distillery unit
24 Existing area of plantation 2 acres
25 Capital Cost for
Environmental measures 1200 Lacs
(proposed )
26 Recurring cost for
environmental monitoring etc 110 Lacs ( May be changed during EIA study)
(Proposed)
 Existing Sugar And Cogeneration Plant Details
Sr. No Description Quantity Unit

1. Crushing capacity, TPD 4500 TCD

2. Number of crushing days/year 120
(expected)
3. Boiler used 150 TPH
4. Power generation capacity 30 MW
5. Power consumption Season Offseason. MW
For sugar plant and cogen 5.68 0.10
Other In-house consumption 2.80 2.95
Power export 21.52 26.95
6. Bagasse generation 56.25 TPD @30 %
7. Molasses generation 40851 Tonne
8. Fresh water requirement for Season Offseason. CuM/D
Sugar and cogeneration after
recycling. 280 40
9. Water storage capacity 5000 CuM/D
10. Effluent generation form 358 CuM/D
sugar and cogeneration
plant
11. Final disposal of treated Within the premises for green -
effluent belt development, dust
12. Ash generation from existing 18.93
suppression etc. TPD
plant
13. Press mud 135 TPD
14. ETP Sludge 0.04 TPD
15. Lime sludge 0.07 TPD
16. WTP Sludge 0.01 TPD
17. Final disposal of Ash Given to farmer as manure. -
18. Storage capacity of Bagasse’s Kept at ground in bails form 6500 ft area
yard
19. Storage capacity of Molasses 9300 MT
20. Existing manpower 160 No.
requirement for
Sugar/Cogeneration (skilled
and unskilled)
Proposed manpower 90 No.
requirement for Distillery
(skilled and unskilled)
21. 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.

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.
4. Demand –Supply Gap
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 blending with
petrol mandatory across the country.
Year Ethanol production Ethanol utilization Ethanol Petrol
Blending Demand
Molasses Cane Total Industry Potable Balance
2001-02 1775 0 1175 600 648 527 5% 448 8960
10% 896
20% 1792
2006-07 2300 1485 3785 711 765 2309 5% 638 12672
10% 1276
20% 2552
2011-12 2300 1485 3785 844 887 2054 5% 814 16286
10% 162
20% 3257
2016-17 2300 1485 3785 1003 1028 1754 5% 1039 20785
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.

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.

7 Domestic/Export Markets
As above

8 Employment generation (direct and indirect) due to the project

Existing employment at sugar & co gen unit : 100+ 60 no.
Proposed Employment : 90 Nos. ( skilled and Direct )
Apart from that indirect employment generation is envisaged from the
project.
Total manpower requirement
Sr. No Staff Nos.
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 48
14. Total 90

9 Project Description

i. Type of the project including interlinked and interdependent project, if any

As submitted, the Ethanol Plant is proposed with the existing sugar unit of 4500
TCD. Incineration Boiler of 25 TPH is also proposed for implementation of zero
discharge concept. CO2 will also generated as by product from the fermentation
process which is turn can be utilized after further treatment at CO2plant in
industrial or food grade application. It is also proposed Evaporation plant of
effluent to provide better environment conservation and pollution control
arrangement in the unit as well as for the surrounding area.

ii. Location (map showing general location, specific location, and project
boundary & project site layout) with Coordinates:
The unit is spreaded over 23.5+11.7968=35.2968 acres of land in village
Pondar Tehsil, Gardarwada Dist. – Narsinghpur of MP. The latitude and
longitude of the site is as below :
1. 22°51'12.60"N- 78°39'2.67"E
2. 22°51'16.24"N- 78°38'58.12"E
3. 22°51'22.80"N- 78°39'5.94"E
4. 22°51'18.52"N- 78°39'12.07"E
Satellite Image of the Project area

Topographical Base Map

iii. Details of Alternate Site:

The site is proposed on the piece of land where sugar unit ( 4500 TCD) with
cogen plant of 30 MW is already in operation. The entire land is about 35.298
acres and out of that proposed unit will require 4.25 of land. Most of the
infrastructure is already available. Therefore proposed site suitable for the
project configuration.

iv. Size or magnitude of Operation:

It is proposed to produce 60 KLD of fuel ethanol from molasses based operation

along with 25 TPH Incineration Boiler. The unit shall adopt zero discharge
technology for the effluent disposal. .

v. Project Description With Process Details:

The overall process is shown on the attached Block Flow Diagram, and Process
Flow Diagrams. The following describes the production of ENA and co-products
from grain. The process envisages use of own molasses, as well as procured
molasses from nearby sugar factories, for manufacture of ethanol during sugar
mill season and during off- season days.
 Cane crushing system
 Fermentation system
 Distillation & Fuel Ethanol
 Effluent treatment system
Following is a brief description of the process:
Detail Process Description & Process Flow Charts
 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.
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
Blackstrap molasses usually contains enough yeast nutrients to give a fast,
efficient fermentation. In some cases, however, it is desirable to add small
quantities of ammonium salts, such as ammonium sulphate, to the mash to
increase the rate and efficiency of the fermentation. In such cases, the amount
of ammonium sulphate added varies between 0.5 liters and 3 liters per 10,000
liters of mash, depending on the molasses used, the optimum amount being
determined by laboratory in a blackstrap molasses fermentation.

Fermentation Temperatures
Fermenters are usually set at a temperature between 27º F and 30º C and are
held a 32º C by the use of water sprays on the rank internal cooling coils, or by
circulation of the mash through external coolers. It is desirable to maintain the
temperature of the mash below 35º 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
40º 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 & 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.
• 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

Multi-pressure vacuum distillation system for production of Rectified Spirit

/ ENA consists of following distillation columns namely
1. Degasifying cum analyzer column – Operation under vacuum
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

Benefits of Pressure Vacuum Distillation: -

Following are the advantages of pressure vacuum distillation.
• Since the analyzer column operates under vacuum, the formation of byproducts
such as acetal may minimize there by improvement in quality of alcohol.
• Pre-rectification column ensure removal of sulfur compounds/mercaptans and
also reduces load of lower boiling volatile compounds passing on to Rectifier cum
exhaust column.
• The chances of scaling due to invert solubility of certain precipitating inorganic
 salts are minimized in vacuum distillation.
• Vacuum distillation requires low steam consumption with re-boiler
Integrated Multi-products Concept: -
It is now possible to install a distillation system, which can produce different
products. In the proposed scheme; the production of rectified spirit have been
considered. This allows flexibility of operation and various products can be
manufactured depending on the market demand. This integrated multi-product
system involves less capital investment as compared to independent system.
In this type of system, switching over from one product to another is quite easy
and there is no chance of contamination of one product with another. The
system can work under multi-pressure principle with few columns operating
under vacuum and few under pressure/atmospheric.
3. Dehydration of Alcohol: Molecular Sieve:
The process drives the rectified feed though a bed of desiccant beds. To allow for
bed regeneration in continuous operation, twin beds are provided of which one
is in dehydration mode while the other is regenerating. Depending on feed
and product specifications, the dehydration-regeneration process releases the
adsorbed water together with contained ethanol, it is recycled back to
regeneration column for reprocessing.
The feed is pumped to regeneration column after preheating in feed
preheater. The overhead vapor of regeneration column is superheated to the
required operating temperature and circulated to sieve bed 1 assumed in the
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 60 KLPD distillery plant nearly about 600 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.

5. Spent wash Incineration Technology:

After spent wash evaporation, concentrated spent wash with desired
concentration is obtained is feed to incineration type of boiler. The
concentrated spent wash generated after entire process of evaporation is then
sprayed in a furnace with auxiliary fuel such as coal and is then burnt in a
boiler.
6. Process Condensate Treatment and Recycle:
The condensate polishing unit is also envisaged to take care of spent lees, cooling
tower blow down, washing and process condensate from evaporation plant. After
treatment all the stream at CPU, treated condensate can be recycled to process
for dilution and as cooling tower make up and will achieve zero liquid discharge
(ZLD) Due to recycle of process condensate back to process, fresh water demand
can be reduced at large extent.
Quantity of Raw Materials Required;

Raw Material Requirement

Sr. No. Name of raw Quantity Storage Transportation
material
Distillery
1. Molasses 220 TPD Tank Tanker
2. Sulfuric Acid 0.25kg/KL FRP Tank Tanker
3. Anti-foam reagent 0.25 kg/KL Drum Truck
Sugar Unit
1. Sugarcane 4500TCD Open Area Truck & Tractor
2. Lime 540 MT/Year Bags Truck
3. Caustic soda 20 MT/Year Bags Truck

NSPL will generate about 40851 MT of molasses from expected / sustained cane
crushing of 54 Lacs MT / year, with minimum 4.7% molasses recovery. M olasses
will be sourced from parent sugar unit and group sugar factories. The fuel ethanol
yield from cane molasses will be at 270 lit/ton. The per day requirement of
molasses will be about 220 MT per day for 60 KLPD ethanol production per
day. The total requirement of molasses for the 270 days operation of the
 proposed ethanol plant will be about 59400 MT (at maximum 95% utilization
level from 4th year onwards).

vii. Resource optimization/ recycling and reuse

 Multi Pressure Distillation system has lower steam consumption as it is designed
for maximum heat integration to conserve energy.
 Energy efficient Multi-Pressure Distillation system with a Steam Consumption
13.20 TPH of Total Spirit (depending on mode of operation).
 Vacuum operation nearly eliminates scaling problem in Analyzer Column and
ensures better separation of impurities, which results into better quality product.
 Well-engineered Plants with high efficiency trays to ensure elaborate separation
and removal of impurities ensuring superior quality of Extra Neutral Alcohol.
 Analyzer Column with Hyper-stat Rh-Grid trays ensure high turbulence on tray,
this minimizes chances of scaling. Also, this special construction of trays and
access to each tray helps in easier cleaning column internals.
 Condensers are designed with multiple passes to ensure high velocity and to
minimize scaling inside tubes.
Alcohol is well known as an industrial raw material for manufacture of a variety
of organic chemicals including pharmaceuticals, cosmetics, polymers etc. A large
demand is anticipated for alcohol as a fuel. Alcohol is an eco-friendly product and
is a substitute to the imported petroleum. Indeed fuel ethanol production has
been promoted for a variety of reasons as mentioned below,
 It has less severe impact on the environment than conventional gasoline and
less dangerous to health. As oxygenates are compounds such as alcohols or
ethers which contain oxygen in their molecular structure. Oxygenated fuels tend
to give a more complete combustion of its carbon to carbon dioxide (rather than
monoxide) which leads to reduced air pollution from exhaust emissions. It
reduces the dependence on oil imports.
 It helps to maintain rural economy.
 Factory proposes zero liquid discharge method for waste water treatment.
Maximum waste water will be recycled back into the system.
 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 466 KL per day
 Source : Borewells
Water Balance
. Water inputs (In KLD)
1. Process water for fermentation section and CO2 scrubber 552
2. DM water for RS dilution 65
3. Water for vacuum pump, pump sealing, air blower & 8
others
4. Soft water makeup for cooling towers 453
5. Other domestic usage, laboratory uses, cleaning 5
6. Boiler 20
7. Total water input at start-up 1103
Water Out Put (In KLD)
1. Spent Lees (PR & Rect.) 160
2. Process condensate 525
3. CT Evaporation & Drift Losses 362
4. Water losses from vacuum pump, pump sealing, Air blower 0.2
5. Cooling tower and boiler blow down 89
6. Total Water Output 1136
Recycled water (In KLD)
1. Lees recycle for cooling tower make up 160
2. Process condensate fermentation 160
3. Process condensate to cooling tower, CIP, Fermentation 310
4. Pumps Sealing Water Recycle cooling tower 6
5. CO2 scrubber beer well to process water for fermentation 1
6. Total Recycling water per day 637
Daily fresh water input 466

Wastewater generation from sugar unit and cogeneration

Sr. Source Process KLD Treatment Final Disposal
No.
1. Sugar Sugar 266 ETP Treatment Units: Bar screen For ferti
Plant manufacturi and grit chamber, oil and grease irrigation.
ng Process traps, reaction tank, equalization
tank, anaerobic tank, aeration
Tank I, aeration Tank II,
secondary clarifier, sludge drying
bed and polishing pond.
2. Co Cooling 20 For polishing pond for For Ferti-
generation Tower dilution with other effluent Irrigation
11 MW Boiler Blow 6 For polishing pond for For Ferti-
down dilution with other effluent Irrigation
 D.M. 66 Neutralization followed For Ferti-
Regeneration bydisposal to polishing pond for Irrigation
dilution with other waste water
stream.
Total - 358 - -

Summary of effluent generation from proposed distillery, existing sugar and

cogeneration unit
Source Effluent Quantity Disposal
Proposed Distiller Spent wash Raw spent wash Conc. Spent Wash
Generation : 600 KLD Feed in Incineration
Concentrated spent Boiler.
Wash : 156 KLD
Sugar Molasses 220 TPD
Effluent 266 KLD
Co generation Blow down from the 92 KLD
cooling tower &
boilers
Domestic Waste water Sewage generation 20 KLD

ix. Power Requirement:

Construction Phase – 30 kw
Electricity consumption bifurcation
Sr. No Section Operating load
Connected load (kWh) (kWh)
1. Fermentation
2. Distillation
3. MSDH
4. Integrated RSW
evaporation 1050 KWH 1360 KWH
5. Process condensate
treatment plant
6. Alcohol storage
7. Utility (Cooling tower)
8. Instrument air compressor

9. Total 1050 KWH 1360 KWH

During operation phase , the required power will be taken from cogeneration
power plant. Existing DG sets of 63 KVA, 160 KVA and 400 KVA shall be
used as standby arrangement.
Fuel consumption
Sr. No Fuel Quantity
1. Concentrated spent wash 156 TPD
 2. Spent wash concentrate, GCV 1600 kcal/kg
3. Bagasse 56.25 TPD
4 Bagasse GCV 2250 kcal/kg

Steam Requirement
Sr. No. Section Quantity (TPH)
Steam utilization for Distillery
1. Steam for Distillation (Wash to ENA mode) NA
Or Steam for Distillation (Wash to EQRS) 6.42 TPH
2. Steam for Integrated Evaporation 5.32 TPH
3. Steam for MSDH 1.46 TPH
4. Total 13.20 TPH
Steam utilization for sugar factory
5. Crushing rate 4500 TCD
6. Steam Generation 3300 MTD
7. Steam Requirement 1800 MTD
8. Steam Condensate 1500 MTD

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
For Liquid Waste

The total water requirement at the startup will be around 1103 m3/day, and after
recycling daily fresh water requirement will be 466 KL per day. Source of water
will be Bore well. Water storage facility is available with the sugar factory. Detail
water breakup is given in Table
Water Requirement For Existing Sugar Unit
Sr. No Particulars For sugar During Off Season
1. Total water requirement 460 M3 3 M3
2. Water recovered 180 M3 NA
3. Total daily fresh water 280 M3 NA
required after recycling
 Wastewater Generation Of Sugar And Cogeneration
Sr. Source Process KLD Treatment Final Disposal
No.
1. Sugar Plant Sugar 266 ETP Treatment Units: Bar screen For ferti
manufactur 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 20 For polishing pond for For Ferti-
Plant Tower dilution with other effluent Irrigation
Boiler Blow 6 For polishing pond for For Ferti-
down dilution with other effluent Irrigation

D.M. 66 Neutralization followed For Ferti-

Regeneration bydisposal to polishing pond for Irrigation
dilution with other waste water
stream.
Total - 358 - -

Summary Of Effluent Generation From Proposed Distillery, Existing Sugar And

Cogeneration Unit
Source Effluent Quantity Disposal
Proposed Distillery Spent wast Raw spent wash Conc. Spent Wash
generation : 600 KLD Feed in Incineration
concentrated spent Boiler.
wash : 156 KLD
Sugar Molasses 220 TPD ETP
Effluent 266 KLD
Co generation Blow down from the 92 KLD
cooling tower &
boilers
Domestic Waste Sewage generation 20 KLD Septic tank and
water soak pit

Solid And Hazardous Waste Management

 Yeast sludge mixed with spent wash and incinerated in the boiler or used as
manure.
 Ash generated will be given to brick manufacturers.
 Sludge from ETP will be used as manure.
Solid Waste Details
Sn Type of waste Quantity Disposal
From existing sugar &- Proposed
cogeneration plant Distillery
Yeast Sludge NA 0.25 Kg/day Fertilizer
Lime Sludge 0.07 MT/day NA Fertilizer
 WTP Sludge 0.01 MT/day NA Fertilizer
ETP Sludge 0.04 MT/day - Fertilizer
Ash Bagasse ash: Coal Ash : NA
18.93 TPD Spent wash Ash ; 2.3 MT/day
Domestic waste 0.01 MT/day NA
Waste Oil 0.0001 Ltr/day NA

4.0 Site Analysis:

S. Particulars Details
No.
1. Locations
A. Village Pondar
B. Tehsil Gadarwara
C. District Narsinghpur
D. State Madhya Pradesh
Toposheet No. 55J/9
2. Latitude 22°51'12.60"N
Longitude 78°39'2.67"E
3. Co-ordinate of four  22°51'12.60"N- 78°39'2.67"E
corners  22°51'16.24"N- 78°38'58.12"E
 22°51'22.80"N- 78°39'5.94"E
 22°51'18.52"N- 78°39'12.07"E
4. General ground level 348 above MSL
5. Nearest National/ State Pipariya- Gadarwara - SH-22 – 350 mt -
Highway N
6. Nearest Railway Station Salichouka Road – 3.50km - SE
7. Nearest Airport Jabalpur - 148km
8. Nearest Tourist Place None within 10km radius
9. Archaeological Important None within 10km radius
Place
10. Ecological Sensitive Areas None within 10km radius
(Wild Life Sanctuaries)
11. Reserved / Protected None within 10km radius
Forest within 10km
radius
12. Nearest Town / City None
13. Surrounding village Pondar – 0.80km – NWN
within 1 km area of the Salichouka - 1.0 km – ENE
project.
14. Nearest village Pondar – 0.80km – NWN
15. Nearest River Dudhi River - 4.50km - SW
Umar (Shkhi) Nadi - 3.50km - NE
 16. Nearest Lake/ Ponds Bagha nalla - Along the eastern
boundary
Ulgana Nalla - 3.75km - SW
Gahra Nalla - 5.0km - E
17. Nearest Hill Ranges None within 10 km radius
18. Other major industries in None within 10 km radius
10 km radius
19. Surrounding Features North : Sugar plant & SH-22
South : Agricultural Land
East : Agricultural Land
West : Agricultural Land

i. Land Form, Land use and Land Ownership

Project Proponent is having around 35.298 acres of land which is possession
and diverted for industrial purposes.

ii. Topography
Topography of the area is almost plain. Map is given in point No. 3.2

iii. Existing Land use pattern

The land use of the project area is pertaining to industrial activity only. Out of
project area is predominantly being used or agricultural purposes.

Land use Break-Up for Existing and proposed unit

Area in Sq Mt
Particular Existing Sugar Unit Proposed Distillery
unit
Built up Area of main plant and The unit is having total 10517
machineries around 35.298 acres of
Road area land. Existing sugar and 1200
Raw Material storage area cogen unit covers over 150
Fuel Storage Area 23.5 acres of land. Out 1000
Parking area of that green belt have Common
Green Belt been developed over 5500
Open Land about 2 acres of land. 986
Total area ( 4.250 acres)

Land Bifurcation Of Proposed Distillery Unit

No. Units Area (sq. m.)
1. Molasses Storage Tanks 1800
2. Fermentation Section 200
3. Distillation Section 312
 4. Evaporation Section 600
5. Product Storage & Receiver Section 2800
6. Cooling Tower for Fermentation 40
7. Cooling Tower for Disti. + Int. Evaporation 40
8. Cooling Tower for MSDH Section 40
9. PCTP Section 400
10. WTP & Raw Water Storage Tank 450
11. Weigh Bridge 150
12. Administration Office 400
13. Excise Office 240
14. Security Cabin 25
15. Time Office 120
16. Boiler House 1800
17. Coal Yard NIL
18. Lagoon & Settling Pit 900
19. Fire Water Pump House 200
Total area of Plant & Machineries 10517
In Acres 2.59 acres
Total area earmarked for proposed project 4.250

iv. Existing Infrastructure

The required infrastructure is already in place as proposed site is in
operation. State Highway is passing at 200 mtrs from the proposed project .

v. Soil Classification

The soils in the area are generally of sedimentary type soil .

vi. Climate data from Secondary Source:

Meteorological data month of 1 st Feb to 31 st April 2016

Meteorological Data Month of 1st Feb., 16 to 29th Feb., 2016

Relative Humidity Evening Cloudiness Rain

Temperature OC Morning (8.00)
% (17.00) Octas fall in
Wind Wind mm
Date Wind Wind
Max Avg Min Max Avg Min Speed Speed Mor Eve.
Dir. Dir.
km/h km/h
1 30 22 13 80 52 18 0 0 0
NNE 6 WNW 4
2 27 20 14 79 56 30 NE 7 WNW 6 0 0 0
3 24 18 12 72 50 27 NE 8 NNE 5 0 0 0
4 24 16 9 73 43 15 0 0 0
ENE 4 NNE 6
5 26 17 8 69 48 18 ENE 6 NE 7 0 0 0
6 30 20 10 59 42 14 0 0 0
ESE 8 E 2
7 28 22 15 60 38 24 0 0 0
SSE 5 WNW 9
8 24 18 12 71 45 22 NNE 6 WNW 3 0 0 0
9 25 17 9 72 46 17 ESE 4 NW 4 0 0 0
10 29 20 11 77 47 23 0 0 0
ESE 5 WNW 7
11 29 22 14 64 41 11 WNW 3 W 9 0 0 0
12 28 20 11 63 40 14 ESE 1 NW 8 0 0 0
13 29 21 13 66 42 17 NNE 1 WNW 7 0 0 0

14 28 21 14 71 43 15 0 0 0
WNW 3 WNW 7
15 27 21 15 70 53 45 NE 8 WSW 2 0 0 0.2
16 29 23 17 75 54 32 E 6 NNE 14 0 0 1.4
17 32 24 15 71 54 19 ENE 5 NE 8 0 0 0
18 32 25 18 81 54 27 ESE 9 NE 6 0 0 0

19 34 26 17 75 44 19 0 0 0
ESE 5 N 5
20 33 26 18 65 37 14 WSW 5 W 6 0 0 0
21 29 24 20 69 57 37 NE 1 WNW 8 0 0 0
22 29 22 15 76 40 17 NE 5 WNW 5 0 0 0

23 29 21 13 55 33 8 0 0 0
ENE 3 NW 5
24 30 21 12 59 32 7 E 5 N 8 0 0 0
25 30 22 13 51 33 16 ENE 8 N 10 0 0 0

26 28 23 18 69 43 34 0 0 0.2
ENE 7 ESE 5
27 29 22 16 88 57 18 NE 5 NNE 7 0 0 0
28 31 22 13 74 45 16 ENE 5 NNE 7 0 0 0
29 30 23 16 70 54 30 ENE 5 NNW 6 0 0 0

Table
Meteorological data for month of 1 st March to 31 st March, 16
Relative Humidity Evening Cloudiness Rain
Temperature OC Morning (8.00)
% (17.00) Octas fall
Wind Wind in
Date Wind Wind
Max Avg Min Max Avg Min Speed Speed Mor Eve. mm
Dir. Dir.
km/h km/h
1 32 24 15 76 43 11 0 0 0
E 3 NNE 6
2 33 24 14 58 33 9 SE 7 NE 5 0 0 0
3 34 26 17 65 39 20 SE 5 NW 3 0 0 0.2

4 34 26 18 53 35 17 0 0 0.4
W 8 WNW 8
5 34 27 20 70 37 17 SW 6 SSW 7 0 0 0
6 29 24 20 86 60 31 E 4 SW 14 0 0 1.1

7 31 24 16 87 64 28 0 0 0.1
S 16 SSW 8
8 31 24 18 89 63 39 W 2 W 8 0 0 0
9 32 25 18 86 60 27 NE 6 WNW 8 0 0 0
 10 32 25 18 80 51 27 0 0 0
ENE 2 W 7
11 34 26 18 76 42 21 SE 3 W 7 0 0 0
12 34 26 19 65 47 23 S 10 SW 1 0 0 0.7
13 26 22 19 69 62 49 S 4 SSE 18 0 0 0.5

14 31 24 18 86 53 21 0 0 1.6
SE 7 NNW 6
15 31 24 17 80 45 15 ENE 4 NE 14 0 0 0
16 31 24 16 65 33 16 ENE 8 NNW 4 0 0 0
17 33 24 16 47 31 14 SE 6 S 8 0 0 0

18 35 27 19 58 36 15 0 0 0
WSW 13 W 10
19 35 28 22 38 26 11 W 12 W 12 0 0 0
20 36 28 21 42 23 8 W 13 WNW 10 0 0 0
21 35 27 19 35 22 9 0 0 0
W 13 NW 7
22 37 27 17 42 25 10 NE 10 NW 6 0 0 0
23 34 25 16 38 20 4 NNE 5 N 4 0 0 0
24 36 26 16 34 19 5 ENE 4 NE 5 0 0 0

25 37 27 17 39 23 6 0 0 0
SE 8 NNE 5
26 39 29 19 55 23 5 SE 9 ENE 5 0 0 0
27 29 26 21 55 41 23 NW 5 S 4 0 0 0

28 35 26 18 77 47 16 0 0 0
SE 5 WNW 7
29 36 28 19 67 34 11 0 0 0
NE 7 W 6
30 37 28 19 52 26 6 0 0 0
NE 7 NW 5
31 37 28 19 45 25 8 0 0 0
SE 10 WNW 3
Table
Meteorological data for month of 1 st April, 16 to 30 th April, 16
Relative Humidity Cloudiness Rain
Temperature OC Morning (8.00) Evening (17.00)
% Octas fall
Wind Wind in
Date Wind Wind
Max Avg Min Max Avg Min Speed Speed Mor. Eve mm
Dir. Dir.
km/h km/h
1 38 30 21 36 21 6 0 0 0
W 9 SW 5
2 40 30 21 41 24 7 WNW 7 W 2 0 0 0
3 41 32 22 51 23 7 SW 3 WNW 5 0 0 0

4 41 32 23 43 24 10 0 0 0
NW 12 S 6
5 38 30 23 40 20 9 W 10 W 11 0 0 0
6 38 31 24 31 17 8 W 15 WSW 10 0 0 0

7 38 32 26 34 19 8 0 0 0
W 12 W 13
8 38 30 22 39 23 10 SSE 4 SSW 9 0 0 0
9 39 31 23 45 25 8 WNW 8 W 10 0 0 0
10 40 32 23 52 22 6 0 0 0
NW 9 W 12
11 39 32 26 28 16 6 WNW 10 WNW 17 0 0 0
12 38 30 22 32 21 8 N 12 WNW 18 0 0 0
13 38 30 21 38 18 6 NNE 9 WNW 15 0 0 0

14 40 31 22 30 15 6 0 0 0
W 10 W 9
15 41 32 22 42 15 4 W 12 WSW 10 0 0 0
16 42 33 24 22 12 4 W 9 W 14 0 0 0
17 40 34 27 23 13 7 W 15 W 15 0 0 0
18 40 32 23 30 18 7 WNW 12 W 15 0 0 0
19 41 33 25 31 18 6 W 8 W 15 0 0 0

20 42 34 26 25 16 7 0 0 0
W 9 WNW 11
21 41 33 25 30 15 5 WNW 3 WNW 12 0 0 0
22 41 34 27 18 10 5 W 13 W 12 0 0 0
23 39 32 26 26 15 8 WNW 13 WNW 11 0 0 0

24 39 30 22 40 15 4 0 0 0
W 10 WNW 11
25 40 32 23 29 16 5 WNW 6 W 8 0 0 0
26 41 32 23 40 18 4 WNW 6 W 8 0 0 0
27 41 33 25 31 17 6 0 0 0
WNW 6 W 10
28 41 34 26 27 14 5 W 4 W 9 0 0 0
29 41 33 25 30 17 5 WNW 6 W 10 0 0 0
30 42 33 24 36 15 4 WNW 7 W 8 0 0 0
Source: IMD, Climatological Normals, Office of the Additional Director General of Meteorology (Research), IMD, Pune
vii. Social Infrastructure available
Social infrastructure like community center, hospital and electricity is available in
Salichouka, Pondar, Gadarwara as well as in Narsingpur (MP)
Planning Brief:
i. Planning Concept :
The grain base unit shall be installed after receiving environment clearance and
consent under air and water act from the MPPCB. 14 Months has been considered
for the same.
ii. Population Projection:
The project is small in magnitude. No influx of population is expected as labour
shall be deployed from the local villages.

iii Land use planning

As above

Amenities / facilities

 First aid facility has already been provided at site.

 The area shall not being used at all by general public.
 A rest shelter is there for workers.
 Guards during day & night has already been deputed at site to prevent
unauthorized entry.
 In case of natural hazards such as earthquake we will take assistance from the
local competent authority of Govt.

5.0 Proposed Infrastructure

The major plant & machinery required for the proposed project is as given under.
Outline Technical Specifications For 60 Klpd Ethanol
Storage & Handling:
SN Equipment Technical Specification Qty. MOC
1 Raw Molasses Type- Screw/Gear type 1+1 CI
transfer pump Capacity- 25 MT/hr
2 Day Molasses Tank Capacity- 300 MT 1 MS
3 Molasses Transfer Pump Type- Screw/Gear type 1+1 CI
Capacity- 25MT/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

32
6 Molasses Weighing System Type- Load Cell Capacity 4 1 MS
MT Per Trip
7 Weighed Molasses Tank Type- Cyl/Vert. Shell with 1 MS
Conical Top & Sloping
Bottom, Capacity- 25 MT
8 Weighed Molasses Type- Screw/Gear type 1+1 CI
Transfer Pump with Motor Capacity- 15 MT/hr

9 Molasses Diluter For Type- Static Mixer 1 AISI304

Yeast Vessel

Fermentation Section:

Sr. Equipment Technical Specification Qty. MOC

No.
1 CO2 Scrubber Type: Sieve Trays Dia: 600 mm 1 AISI 304
2 Culture Vessel-I with Air Type - Cyl/Vert Shell, 1 AISI 304
Sparger Jacketed with Dished Ends.
3 Culture Vessel-II with Air Type - Cyl/Vert Shell, 1 AISI 304
Sparger Jacketed with Dished Ends.

4 Culture Vessel-III with Air Type - Cyl/Vert Shell, 1 AISI 304

Sparger Jacketed with Dished Ends.
Capacity- 15 m3
5 Cell Mass Transfer Pump Type- Centrifugal with Trolley 1
with Motor Capacity- 15 m3
6 Fermenter with Agitator, Type- Cyl/Vert. Shell with 4 AISI 304
SG, LG Conical Top & Sloping Bottom,
Capacity- 400 m3
7 Molasses Broth Mixer for Type- Static Mixer 3 SS 304
Fermenter
8 Fermenter Recirculation Type- Centrifugal Capacity- 340 4+1 CF8
Pump with Motor m3/hr

9 Fermenter Wash Cooler Type- PHE 4 Plates AISI

316
10 Pre fermenter Type- Cyl/Vert. Shell with 2 AISI 304
/Yeast Activation Conical Top & Sloping Bottom,
Vessel with SG,LG Capacity- 50 m3
11 Molasses Broth Mixer for Type- Static Mixer 2 AISI 304
Yeast Activation Vessel

33
 12 Yeast Activation Vessel Type- Centrifugal Capacity- 40 1+1 CF8
Transfer Pump with Motor m3/hr

13 Yeast Activation Vessel Type- PHE 1 Plates AISI

Cooler 316 Frame
MS
14 Wash Holding Tank Type – Cyl/Vert. Shell with 1 MS Epoxy
Conical Top & Sloping Bottom,
Capacity – 250 m3
15 Wash Transfer Pump Type- Centrifugal Capacity- 30 1+1 CF8
m3/hr (Wetted Parts
Only)
16 Air Filter Type- HEPA 1+1 MS Frame
17 Air Blower with Motor Type- Watering Capacity- 280 1+1 CI
Am3/hr
18 Nutrient Dosing Tank with Capacity- 2 m3 1 AISI 304
Agitator
19 Nutrient Dosing Pump Type- Centrifugal Capacity- 1 1+1 CI
m3/hr
20 Acid Dosing Tank Type- Cylindrical, Vertical 1 MS
Capacity- 1 m3
21 Acid Dosing Pump Type- Centrifugal Capacity- 2 1+1 Wetted Parts
m3/hr Alloy 20

22 Antifoam Dosing Tank Type- Cylindrical, Vertical 1 MS

Capacity- 2 m3
23 Antifoam Dosing Pump Type: Gear Capacity- 1 m3/hr 1+1 CI
24 CIP tank Type- Cylindrical, Vertical 1 AISI304
Capacity- 30 m 3

25 CIP Pump Type- Centrifugal Capacity- 15 1+1 Wetted Parts

m3/hr Alloy 20
26 Piping, Valves As Per Standards Lot
Instrumentation

DISTILLATION SECTION:

Sn .
Description MOC Tech. Specs. Qty.
1 Analyser Column (Rh Grid AISI 304 Dia: 1400 mm No. 1
Trays) of Trays : 19

34
 2 Degasifying Column (Seive AISI 304 Dia: 800mm No. of 1
Trays) Trays : 5

3 Pre-Rectifier Column (Bubble AISI 304 Dia: 1000 mm No. 1

Cap Trays) of Trays : 56
4 Extractive Column (Bubble AISI 304 Dia: 800 mm No. of 1
Cap Trays) Trays : 45
Rectifier Cum Exhaust Shell : AISI 304 Dia: 1100 mm No.
5 Column Trays AISI 304 of Trays : 72 1
(Bubble Cap Trays)
6 Simmering column ( Bubble Shell: DOW CU Dia : 800 mm No. of
Cap) Trays : DOW CU ( Trays 50
Bottom Segment in
SS 304
6 Recovery Column (Bubble AISI 304 Dia: 500 mm No. of
Cap) Trays : 50 1
7 Alcohol Scrubber AISI 304
1

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 Simmering Coloumn Reboiler Shell & Tube Type AISI 304 1
5 Pre Rectifier Column Reboiler Shell & Tube Type AISI 304 1
Co ndensers & Coolers
6 DG Condenser I Shell & Tube Type AISI 304 1
7 DG Condenser II Shell & Tube Type AISI 304 1
8 Analyser Condenser I & II Shell & Tube Type AISI 304 3
9 ED Condenser I & II Shell & Tube Type AISI 304 2
10 Recovery Condenser Shell & Tube Type AISI 304 1
11 Vent Condenser for Analyzer Shell & Tube Type AISI 304 2

12 PCV Condenser Shell & Tube Type AISI 304 2

13 Product Alcohol Cooler Shell & Tube Type DOW Cu 1
14 Product (RS) Cooler Shell & Tube Type AISI 304 1
15 TA Cooler Shell & Tube Type AISI 304 1
16 FO Cooler Shell & Tube Type AISI 304 4
17 R/E Alcohol Cooler Shell & Tube Type AISI 304 1
18 ED Feed Cooler Shell & Tube Type AISI 304 1

35
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

33 Vacuum Pump Water Ring Type CI 1+1

34 Emergency Water Supply Set Standard 1

Others

Sr. Description Tech. Specs. Qty.

No.
1 FO Decanters As Per Standard 2
2 Mixing Bottle (For ED/Purifier As Per Standard 1
3 Column)
Vapour Bottles As Per Standard Lot
4 Manometer Bottles As Per Standard 2
5 Seal Pot As Per Standard 1
6 Siphon For Recovery Column As Per Standard 1
7 TA Mixing Bottle As Per Standard 1
8 Pipes & Fittings, Valves and As Per Standard Lot
Instrument

36
ABSOLUTE ALCOHOL PLANT:

Sr. Description MOC Qty. Tech. Specs.

No.
1 Absorber Bed AISI 304 2 Diameter : 900 mm
2 Evaporator Column AISI 304 1 Diameter : 900
mm with Trays
3 Evaporator Column Re boiler AISI 304 1 Suitable
4 Feed Preheater AISI 304 1 Suitable

5 Regeneration Preheater AISI 304 1 Suitable

6 Product Condenser AISI 304 1 Suitable
7 Product Cooler AISI 304 1 Suitable
8 Regeneration Condenser AISI 304 1 Suitable

9 Regeneration Cooler Plates: 1 PHE

SS
10 Super heater 316
AISI 304 1 Suitable

11 Regeneration Receiver AISI 304 1 Suitable

12 Product Receiver AISI 304 1 Suitable

13 Vacuum Educator AISI 304 1 Suitable

14 Feed Pump with Motor AISI 304 1+1 Suitable
15 Regeneration Pump with Motor AISI 304 1+1 Suitable
16 Product Pump with Motor AISI 304 1+1 Suitable
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

Storage Section for RS, Ethanol Section-

Sr. Equipment Technical MOC Qty.

No. Specification
1 RS Receivers Capacity: 70 m3 MS 3
2 IS Receivers Capacity: 12 m3 MS 1
3 Ethanol Receiver Capacity: 70 m3 MS 3

37
 4 RS Storage Tank with Vent Capacity: 1200 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: 600m3
Arrestors MS 1
Vent Condenser & Flame
7 Arrestors
FO Storage Capacity: 10 m3 MS 1
8 Alcohol Pumps with Centrifugal W Wetted Parts CF Suita
Flameproof Motor 8 ble
9 Issue Measures PD Flowmeters Standard 3
10 Piping & Fittings Standard Standard 1 Lot

INTEGRATED EVAPORATOR:

Sr. Description Qty. Technical data M.O.C.

No.
1 Multiple effect Suitable Shell & Tube type, SS304
evaporator Falling Film
2 Vapor Separator Suitable Cylindrical SS304
3 Surface condenser 1 Sheet & Tube type SS304
4 Circulation pump Suitable Double Mech Shaft Contact Part SS 304
5 Process Condensate 1+1 Contact Part SS 304
pump
6 Concentrated Spent 1+1 Contact Part SS 304
wash transfer pump
7 Condensate Pump 1+1 Contact Part SS 304
8 Vacuum pump 1+1 Contact Part SS 304
9 Piping & Valves Lot Suitable
10 Electrical & Lot With Std.
Instrumentation Specification

INDEPENDENT EVAPORATOR:

Sr. Description Qty. Technical data M.O.C.

No
1 Feed and Product Tank 2 Type:- Rectangular SS304

2 Feed Pump & Spent 1 + 1 each Type - Centrifugal type SS 316

wash pump Suitable
3 Evaporators Suitable Type : Forced circulation SS304

38
 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

UTILITIEs: COOLING TOWER:

Sr. Equipment Description Specifications Qty. (Nos)

No.
1 Cooling tower for Fermentation plant 1400 M Kcal/hr 1
2 Cooling tower for Distillation 4000 M Kcal/hr 1
3 Cooling tower for Ethanol 800 M Kcal/hr 1
4 Cooling tower for evaporation 4200 M Kcal/hr 1
5 CW Recirculation pump for Suitable. Centrifugal, 1+1
Fermentation
6 CW Recirculation pump for Distillation Suitable. Centrifugal, 1+1
7 CW Recirculation pump for evaporation Suitable. Centrifugal, 1+1
8 CW Recirculation pump for Ethanol Suitable. Centrifugal, 1+1
9 PRDS Suitable. 2
10 Instrument Air compressor & dryer Suitable capacity 1+1
11 Piping, Valves standard Lot
12 Instrumentation standard Lot

Slop Fired Incinerator Boiler & Turbine

Sr. Particulars Specification

No.
1 Slop fired incinerator boiler 25 TPH, 45 Kg/Cm2 (g) Pressure
with coal as supporting fuel
2 Turbine Suitable capacity of 1.5 MW back
pressure with exhaust pressure of
4.5 Kg/Cm2(g)

39
 Water Treatment Area Filtration Plant

1. Multi grade Sand Filter 1 No.

Pressure vessel internally painted with black 1 No.MS with epoxy coating
bituminous and externally with red oxide primer
:MOC
Piping works with valves 1 No.
Graded filtering sand specifically selected and 1 No.
graded
2. Activated Carbon Filter 1 No.
Pressure vessel internally painted with 1 black
No. MS with epoxy coating
bituminous and externally with red oxide primer
:MOC
Piping works with valves 1 No.
3. Softener 1 No.
Pressure with rubber lining from inside and 1 No.
externally with red oxide primer
Piping works with valves 1 set
Cation Exchange resign 1 set
Hardness test kit 1 set
Brine saturated tank of MS construction 1 No.
Brine distribution system 1 Lot
4. D.M. PLANT ( 1 No.)
1 Strong acid cation 1 No.
2 Degasser tower & pump 1 No.
3 Strong acid anion 1 No.
4 Mixed bed exchanger 1No.

Fire Fighting & Protection

Fire protection system to be offered based on site plan. The system is designed
as per International rules (NFPA) & equivalent standards.

Molasses Bulk Storage Section.

Sr. Equipment Technical Qty. M.O.C.

No. Specification
1 Molasses Storage Tank 4000 MT storage 2 Mild steel,
capacity. Nos. painted
2 Raw molasses Transfer Gear type positive 2+2 C.S.
pumps. displacement pumps Nos.

40
3 Interconnecting piping. Carbon steel pipes. LOT MS

Sr. Equipment Technical Specification Qty. MOC

No.
1 Raw Molasses Type- Screw/Gear 1+1 CI
transfer pump type Capacity- 20
MT/hr

2 Day Molasses Tank 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:

Sr. Equipment Technical Specification Qty. MOC

No.
1 CO2 Scrubber Type: Sieve 1 AISI 304
Trays Dia: 500
2 Culture Vessel-I with mm
Type - Cyl/Vert 1 AISI 304
Air Sparger Shell, Jacketed with
Dished Ends.

3 Culture Vessel-II with Type - Cyl/Vert 1 AISI 304

Air Sparger Shell, Jacketed with
Dished Ends.

41
4 Culture Vessel-III with Type - Cyl/Vert Shell, 1 AISI 304
Air Sparger Jacketed with Dished
Ends. Capacity- 12 m3
5 Cell Mass Transfer Pump Type- Centrifugal with 1
with Motor Trolley Capacity- 10 m 3
6 Fermenter with Agitator, Type- Cyl/Vert. Shell 4 AISI 304
SG, LG with Conical Top &
Sloping Bottom, Capacity-
7 Molasses Broth Mixer Type- 3
300 mStatic Mixer 3 SS 304
for Fermenter
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

42
 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
26 Piping, Valves As Per Standards Lot
Instrumentati
on

DISTILLATION SECTION:

Sr.
No. Description MOC Tech. Specs. Qty.

Analyser Column (Rh Dia: 1200 mm

1 Grid Trays) AISI 304 No. of Trays : 1
19
Degasifying Column Dia: 700mm
2 (Seive Trays) AISI 304 No. of Trays : 1
5
Pre-Rectifier Column Dia: 800 mm
3 (Bubble Cap Trays) AISI 304 No. of Trays : 1
56
Extractive Column Dia: 600 mm
4 (Bubble Cap Trays) AISI 304 No. of Trays : 1
45
Rectifier Cum
5 Exhaust Column Shell : AISI Dia: 1000 mm 1
(Bubble Cap Trays) 304 Trays No. of Trays :
AISI 304 72
Recovery Column Dia: 500 mm
6 AISI 304 No. of Trays :
(Bubble Cap) 1
50
7 Alcohol Scrubber AISI 304
1

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

43
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

11 PCV Condenser Shell & Tube Type AISI 304 2

12 Product Alcohol Cooler Shell & Tube Type DOW Cu 1
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

33 Vacuum Pump Water Ring Type CI 1+1

34 Emergency Water Supply Set Standard 1

Others

44
 Sr. Description Tech. Specs. Qty.
No.
1 FO Decanters As Per Standard 2
2 Mixing Bottle (For ED/Purifier As Per Standard 1
3 Column)
Vapour Bottles As Per Standard Lot
4 Manometer Bottles As Per Standard 2
5 Seal Pot As Per Standard 1
6 Siphon For Recovery Column As Per Standard 1
7 TA Mixing Bottle As Per Standard 1
8 Pipes & Fittings, Valves and As Per Standard Lot
Instrument

ABSOLUTE ALCOHOL PLANT:

Sr. Description MOC Qty. Tech. Specs.

No.
1 Absorber Bed AISI 304 2 Diameter : 900 mm
2 Evaporator Column AISI 304 1 Diameter : 900
mm with Trays
3 Evaporator Column Re boiler AISI 304 1 Suitable
4 Feed Preheater AISI 304 1 Suitable

5 Regeneration Preheater AISI 304 1 Suitable

6 Product Condenser AISI 304 1 Suitable
7 Product Cooler AISI 304 1 Suitable
8 Regeneration Condenser AISI 304 1 Suitable

9 Regeneration Cooler Plates: 1 PHE

SS
10 Super heater 316
AISI 304 1 Suitable

11 Regeneration Receiver AISI 304 1 Suitable

12 Product Receiver AISI 304 1 Suitable

13 Vacuum Educator AISI 304 1 Suitable

14 Feed Pump with Motor AISI 304 1+1 Suitable
15 Regeneration Pump with Motor AISI 304 1+1 Suitable
16 Product Pump with Motor AISI 304 1+1 Suitable

17 Filters CS 3
18 RS Feed Tank MS 1 Capacity : 50 m3
19 Instrumentation Standard Lot

45
 20 Piping and Valves Standard Lot
21 Electricals Standard Lot

Sr. Equipment Technical MOC Qty.

No. Specification
1 RS Receivers Capacity: 50 m3 MS 3
2 IS Receivers Capacity: 10 m3 MS 1
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:

Sr. Description Qty. Technical data M.O.C.

No.
1 Multiple effect Suitable Shell & Tube SS304
evaporator type, Falling
Film
2 Vapor Separator Suitable Cylindrical SS304
3 Surface condenser 1 Sheet & Tube type SS304
4 Circulation pump Suitable Double Mech Shaft Contact Part SS 304
5 Process 1+1 Contact Part SS 304
Condensate
6 pump
Concentrated Spent 1+1 Contact Part SS 304
wash transfer pump
7 Condensate Pump 1+1 Contact Part SS 304
8 Vacuum pump 1+1 Contact Part SS 304
9 Piping & Valves Lot Suitable
10 Electrical & Lot With Std.
Instrumentatio Specificatio
n n

46
 INDEPENDENT EVAPORATOR:

Sr. Description Qty. Technical data M.O.C.

No
1 Feed and Product Tank 2 Type:- Rectangular SS304

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

UTILITIEs: COOLING TOWER:

Sr. Equipment Description Specifications Qty. (Nos)

No.
1 Cooling tower for Fermentation plant 1000 M Kcal/hr 1
2 Cooling tower for Distillation 2000 M Kcal/hr 1
3 Cooling tower for Ethanol 600 M Kcal/hr 1
4 Cooling tower for evaporation 3000 M Kcal/hr 1
5 CW Recirculation pump for Suitable. Centrifugal, 1+1
Fermentation
6 CW Recirculation pump for Distillation Suitable. Centrifugal, 1+1
7 CW Recirculation pump for evaporation Suitable. Centrifugal, 1+1
8 CW Recirculation pump for Ethanol Suitable. Centrifugal, 1+1
9 PRDS Suitable. 2
10 Instrument Air compressor & dryer Suitable capacity 1+1
11 Piping, Valves standard Lot
12 Instrumentation standard Lot

Slop Fired Incinerator Boiler & Turbine

47
 Sr. Particulars Specification
No.
1 Slop fired incinerator boiler 14 TPH, 45 Kg/Cm2 (g) Pressure
with coal as supporting fuel
2 Turbine Suitable capacity of 1.2 MW back
pressure with exhaust pressure of
4.5 Kg/Cm2(g)

Water Treatment Area Filtration Plant

1. Multi grade Sand Filter 1 No.

Pressure vessel internally painted with black1 No.MS with epoxy coating
bituminous and externally with red oxide primer
:MOC
Piping works with valves 1 No.
Graded filtering sand specifically selected and 1 No.
graded
2. Activated Carbon Filter 1 No.
Pressure vessel internally painted with 1 black
No. MS with epoxy coating
bituminous and externally with red oxide primer
:MOC
Piping works with valves 1 No.
3. Softener 1 No.
Pressure with rubber lining from inside and 1 No.
externally with red oxide primer
Piping works with valves 1 set
Cation Exchange resign 1 set
Hardness test kit 1 set
Brine saturated tank of MS construction 1 No.
Brine distribution system 1 Lot
4. D.M. PLANT ( 1 No.)
1 Strong acid cation 1 No.
2 Degasser tower & pump 1 No.
3 Strong acid anion 1 No.
4 Mixed bed exchanger 1No.

Fire Fighting & Protection

Fire protection system to be offered based on site plan. The system is designed as
per International rules (NFPA) & equivalent standards.

48
 Molasses Bulk Storage Section.

Sr. Equipment Technical Qty. M.O.C.

No. Specification
1 Molasses Storage Tank 9300 MT storage 1 Mild steel,
capacity. Nos. painted
2 Raw molasses Transfer Gear type positive 2+2 C.S.
pumps. displacement pumps Nos.
3 Interconnecting piping. Carbon steel pipes. LOT MS

ii Residential area (Non Processing area)

As the local people from nearby villages shall be engaged in project activity.
Therefore no housing / building is proposed.

iii Greenbelt
 Approx 2 acres area has been covered with the good green belt. Further it is
proposed to cover 11 acres in next 05 years of time inclusive of sugar and
proposed distillery.

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 . .

vi Drinking water management

Drinking water will be supplied through bore well with proper RO system.

vii Sewerage System

The domestic waste shall be taken to soak pit and septic tank.

viii Industrial waste management

As described earlier.

ix Solid waste management

As described earlier.

49
x Power Requirement and supply / source
As described earlier.

7.0 Rehabilitation & Resettlement Plan

No R & R plan is required.

8.0 Project Schedule and Cost estimate

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)

NSPL has already earmarked 4.774 acres of land for the proposed fuel ethanol
plant. The site development expenses is estimated at Rs. 110.00 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, 600.00

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 12.00
Total
foundations 612.00

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. 612.00 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).

50
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
1) 60 KLPD Capacity distillery plant, including incl.
2200.00
Molasses storage & handling, Fermentation, Multi-Pressure
Distillation & Ethanol, Integrated & Independent
Evaporation for spent wash concentration, Utility
Equipment - Cooling Towers, Condensate Polishing Unit,
Blower, Alcohol Storage & auxiliaries, interface piping,
electrical & instrumentation, Air compressor, structural
work, Erection & Commissioning etc.

2) 25 TPH Capacity, 45 kg/cm2 pressure slop fired 1300.00

Boiler & auxiliaries
3) 1.5 MW Capacity matching back pressure TG set & 150.00
auxiliaries
4) Molasses Storage Tank & Weigh Bridge 200.00

4) Balance of Plant equipment incl. PRDS, DCS, etc. 500.00

Sub-total including erection & commissioning, packing 4350.00
forwarding, insurance, etc.
Avg. Taxes & Duties (18 %) 783.00
Total 5133.00

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.5133.00 lakh
Item Year
1 2 3 4 5
Installed Capacity-KLPD 60 60 60 60 60
Number of shift/day 3 3 3 3 3
 No. of days 270 270 270 270 270
 No. of hrs. 24 24 24 24 24
 Annual Installed Capacity 16200 16200 16200 16200 16200
Capacity utilization, % 85 85 90 95 95
Total Spirit, KL 13770 13770 14580 15390 15390
Net Production Fuel Ethanol, 13082 13082 13851 14621 14621
KL

51
 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 (Rs. Lakh)
Particulars
Land and Site Development 110
Buildings 612
Indigenous Plant and Machinery 5133
Miscellaneous Fixed Assets 124
Prelim. & Preoperative Expenses 254
Contingencies 125
Working capital margin 6358
Total

9.0 Analysis of Proposal (Final Recommendation)

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.

52