GGHGLGLLG

Proposed 160 KLPD Molasses based Distillery along with 7.
0 MW cogeneration power plant

At Village Bhatiyura Prathipur, Tehsil Tilhar, District Shahjahanpur, Uttar Pradesh
Detailed Project Report
DETAILED PROJECT REPORT
1.1 TYPE OF THE PROJECT

The project mainly consists of installation of all the manufacturing and EMP equipment and necessary
infrastructure development required for operations of distillery unit and co-generation power plant. The
proposed project falls in category “A” under Activity 5 (g) [Molasses based Distilleries ≥ 100 KLPD] as per EIA
Notification, dated 14th September, 2006 & as amended on 13th June 2019.
1.2 LOCATION (Maps showing general location, specific location, project boundary & project site layout)
The project site is located in village Bhatiyura Prathipur, Tehsil Tilhar, District Shahjahanpur, Uttar Pradesh
General Location Map
The map showing location of the project site is given in the figure below.
Figure 1.1: Location Map of the project site
Malbros International Pvt. Ltd.

Proposed 160 KLPD Molasses based Distillery along with 7.0 MW cogeneration power plant
Specific Location Map

The map showing specific location of the project site along with boundary coordinates marked on a Google image is given below:
Figure 1.2: Google image showing the specific location of the project site

1.3 Plant Layout

The total plant area is 12.328 ha (30.462 acres). Total land has been purchased, registered and land
conversion is under process. After expansion, about 33% (10 acres or 4.07 Ha) of the total project area will be
covered under greenbelt & plantation.
Area details are given in below table.
1.3.1 Site history
As per the information obtained from secondary sources, the proposed site was agricultural land and
industry has purchased, registered the land and land use conversion is under process. The land as seen from
photographs is plain and levelled. The area is categorized as open land which will be converted to industrial
land after installation of distillery.
[Source: Google Earth]
Area details are given in below table:
Table - 1.1
Area break-up
S. No. Particulars Area in Acres
1. Main plant, machinery & utilities 9.20
2. Raw material & product storages 1.94
3. Roads & other 2.13
4. Open area 6.812
5. Admin offices & excise office 0.38
6. Total greenbelt development and plantation 10.0
Total 30.462 acres (12.328 ha)
Layout map indicating the proposed unit indicating storage area, plant area, green belt area, utilities etc. has been
given in Figure below:

Figure 1.3: Plant Layout

1.4 Photographs of the proposed project site

The photographs showing the proposed project site are given below. The land is levelled and plain. The
existing vegetation will be a part of greenbelt after installation of distillery.
1.5 SIZE OR MAGNITUDE OF THE OPERATION

Size or magnitude of operation for the proposed project is given below:
Table: 1.2
Details of the proposed project
S. Units Capacity Products
No.
1. Molasses based distillery 160 KLPD Ethanol/Extra Neutral Alcohol (ENA)/
Rectified Spirit (RS)/ /Impure Alcohol
2. Co-generation power plant 7.0 MW Power
3. No. of working days 350 days/ annum
Source: Pre-feasibility Report

Table 1.3
Other details of the Project
A. Cost Details
1 Total Cost for the Project 225.0 Crores
2 Cost for Environmental Management Plan Capital Cost: 45 Crores
Recurring Cost: 4.5 Crores/ annum
1.6 Requirements for the project
The project requirement such as area, raw material, fuel, water, steam, power, manpower with source of
supply is described in the section below:
1.6.1 Raw Material Requirement
Details regarding quantity of raw materials required, their source, storage and mode of transportation for
proposed project are given in the table below:
Table- 1.4
Raw Material Requirement, Source and Transportation
S. Particulars Total Storage facility and Distance from Source & mode of
No. Requirement Capacity Project Site transportation
1 Molasses 730 TPD 3 x 10000 Ton Upto 150 km From nearby sugar mills
Molasses Tanks by road
2 Chemicals
Caustic soda 200 kg/ day Packed in 50 kg Bags & 200-500 km Near-by Markets by road
Nutrients 150 kg/ day stored in Godown
Antifoam 200 kg/ day Packed in Cans & stored in
Agent Godowns
Yeast Own Propagation or 50 kg/day (dry yeast)
1.6.2 List of nearby Sugar mills for procurement of Molasses
Table 1.5
List of nearby sugar mills
s. Name of Sugar factory Crushing Mode of Estimated Molasses
No. Capacity Sugar Produced
(In TCD) Factory (In MT/annum)
1 Dwarikesh Sugar Industries Ltd, Bareilly 7500 Private 66500
2 DSM Sugar Mill, Meerganj (Bareilly) 5000 Private 41250
3 Kesar Enterprises Ltd, Baheri (Bareilly) 7200 Private 52950
4 Kisan Sahakari Chini Mills Ltd, Semikhera (Bareilly) 7200 Co-operative 0
5 Oswal Overseas Ltd, Sainthal (Bareilly) 3500 Private 12500
6 Bajaj Hindusthan Sugars Ltd, Maqsoodapur (Shahjahanpur) 7000 Private 59450
7 Dalmia Chini Mills, Nigohi (Shahjahanpur) 10000 Private 90000
8 Kisan Sahakari Chini Mills Ltd, Tilhar (Shahjahanpur) 2500 Co-operative 19000
9 Kisan Sahakari Chini Mills Ltd, Powayan (Shahjahanpur) 2125 Co-operative 18750
10 Oudh Sugar Energy Ltd, Rosa (Shahjahanpur) 4200 Private 40500
11 Kisan Sahakari Chini Mills Ltd, Bisalpur (Pilibhit) 2750 Co-operative 20000
12 Bajaj Hindusthan Sugars Ltd, Barkhera (Pilibhit) 7500 Private 55700
13 LH Sugar factory, Pilibhit 11500 Private 103900
14 Kisan Sahakari Chini Mills Ltd, Puranpur (Pilibhit) 2500 Co-operative 16000
1.6.3 Fuel Requirement
The fuel required for incineration boiler to generate steam & power is concentrated spent wash, bagasse
/biomass/coal. Details for incineration boiler fuel required, their source, storage and mode of transportation
for proposed project are given in the table below:

Table- 1.6
Fuel Requirement
S. Name of Material Requirement Storage facility and Source & mode of transportation
No. (TPD) capacity
1 Concentrated spent wash 595 TPD - Own plant through pipelines
2 Bagasse 340-350 TPD Covered Sheds with Nearby Sugar Mills by road
or storage capacity of 20
Coal or 135-140 TPD days Through local vendors by road
or
Rice Husk Biomass 175-180TPD Open market
Note: - The usage of fuel mix will be as per availability & technology.
1.6.4 Water Requirement
Total water requirement for the proposed project will be 1120 KLPD (1100 KLPD for distillery and 20 KLPD for
others) which will be sourced from Groundwater.
Application has been submitted to CGWA vide application number 21-4/8290/UP/IND/2019 dated 20th
October, 2019. Ground water permission application has been approved from CGWB and forwarded to AO,
CGWA NR dated 2nd March, 2020. Break-up of the water requirement is given below:
Table – 1.7 (A)
Total water input
S. No. Section Water quantity (KLPD)
1. Process water in fermentation 1100
2. Boiler feed water 280
3. DM water for distillation 200
4. Soft water for vaccum pump & others 100
5. Soft water for CT make up 1300
6. Fermenter washing & floor washing 100
7. Domestic consumption 20
Total water input 3100
Table – 1.7 (B)

Recycling & utilizing stream
S. No. Section Water quantity (KLPD)
1. Spent lees from aldehyde 116
2. Spent lees from rectifier & PRC 454
3. Spent lees from MSDH plant 10
4. Vacuum pump sealing / purge 100
5. Process condensate 1100
6. Cooling tower blowdown 100
7. Fermenter washing & floor washing 100
TOTAL RECYCLING /RE-UTILIZATIONS OF WATER PER DAY 1980
Net fresh water requirement 3100-1980=1120 KLPD

Figure 1.4: Water Balance for 160 KLPD Molasses based distillery

Figure 1.5: Mass Balance for 160 KLPD Molasses based distillery
1.6.5 Steam Requirement
Steam generated from the boiler will be utilized in the generation of 7.0 MW Power which will be for the
own consumption and steam will be for boiler feed water heating and distillery process. Total steam
requirement for distillery is 55 TPH.
Source: 65 TPH Incineration Boiler.
The steam requirement for different purposes is given below:
Table – 1.8
Steam requirement
S. No. Purpose Steam Required (TPH)
1. Distillation Section 21.5
2. MEE Section 13.5
3. Molecular Sieve Dehydration unit 4.0
4. Steam Coil Air Pre-Heaters 6.0
5. De-aerator 5.0
6. Misc. 5.0
Total 55 TPH

1.6.6 Boiler details

A boiler of 65 TPH capacity with ESP as Air Pollution Control Equipment will be installed. Details regarding
proposed boiler are mentioned in the table given below:
Table – 1.9
Proposed boiler details
S. No. Details
1. Type of Fuel Concentrated Spent Wash & Bagasse /
Rice husk / coal
2. Capacity of Boiler 65 TPH
3. Stack Height 75 meters
4. Pollution Control Equipment Measure ESP
1.6.7 Power requirement
The power requirement is 4.5 MW, which will be sourced from proposed 7.0 MW Co-Generation Power Plant.
The D.G. Sets will be used for emergency backup purpose only. Details are given below.
Table 1.10
D.G Set details
S. No. Details
1. Type of Fuel HSD
2. Capacity 1X 1000 & 1X1500 KVA
3. Stack Height (above roof level) 6 meters
4. Pollution Control Equipment Measures Adequate stack height/ Acoustic
1.6.8 Manpower requirement
There will be direct & indirect jobs and business opportunities to the local people such as daily wage labour,
transporters and raw material suppliers. The direct total manpower required during operation phase for the
proposed project will be 200 persons. Indirectly due to visiting drivers/suppliers/others, there will be
generation of self-employment in the tune of 400+ people.
Source: Unskilled/ semi-skilled manpower from local area and skilled from outside/local.
Details regarding manpower requirement is given in the table below.
Table-1.11
Manpower Requirement
Temporary employment during construction 175
Permanent employment during construction 5
Total during construction 180
Temporary employment during operation 120
Permanent employment during operation 80
Total during operation 200
Total manpower required during construction and operation phase 380

1.7 PROPOSED SCHEDULE FOR APPROVAL AND IMPLEMENTATION

The project commissioning activities will start after getting Environmental Clearance (EC) from MoEFCC, New Delhi and relevant consents from UPPCB. Tentative
time for commissioning of the project will be within 3 to 4 years.
Activity Months
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Appointment of 3
consultant, basic
engineering and
issue of tender
enquiries and
main machinery
order placement
for units
Civil 9
construction
Fabrication and 11
mechanical work
Electrical and 3
instrumentation
erection
Refractory works 2
Trial runs and 2
commissioning

1.8 TECHNOLOGY AND PROCESS DESCRIPTION

1.8.1 Molasses Based Distillery Operation
i) Molasses unloading and storage

Molasses from tankers/pipe line will be unloaded at unloading point and transferred in to molasses storage
tank.
ii) Yeast propagation and fermentation:

Yeast activation:
Yeast seed material is prepared in water-cooled yeast Activation Vessel by inoculating sterilized mash with
Active Dry Yeast. Optimum temperature is maintained by cooling water. The contents of the yeast Activation
Vessel are then transferred to Pre- Fermenter.
Fermentation:
The Molasses from storage tank is pumped to Dilutor installed in fermentation section and diluted with
water. The diluted Molasses called wort is fed into pre Fermenter for activation of Yeast. The activated yeast
from the yeast activation vessel is transferred into pre-fermenter.
Once the yeast is activated in Pre-fermenters it will be transferred in to fermenters and diluted molasses is to
be add. The process of fermentation is to convert the fermentable substrate into alcohol. The pH of the wort
is adjusted by the addition of acid. Yeast is available in sufficient quantity to initiate fermentation rapidly and
complete it within cycle time.
Significant heat release takes place during fermentation. This is removed by passing cooling water through
the fermenter PHE’s to maintain an optimum temperature. The recirculating pumps also serve to empty the
fermenters into Beer Well. After the fermenters are emptied, they are cleaned with water and sterilized for
the next batch. The carbon dioxide evolved during the proceed is vented to atmosphere after recovery of
alcohol in a scrubber.
iii) Distillation: (Multi Pressure Distillation with Integrated Evaporation)

Fermented wash from holding tank / beer well is pumped by wash feed pump to the top of degassing
column after preheating the same in beer heater and spent wash heat exchanger. The vapors along with
non-condensable gases from the top of degassing column are rectified in Heads column, to expel the high
volatiles. Technically known as heads. Bottom liquid from bottom of analyzer column where alcohol is
stripped from liquid. The liquid from bottom of analyzer column is completely stripped of alcohol and is
pumped out by thick slop discharge pump through heat exchanger where is preheats the fermented wash
before in enters degassing column. The slop from the analyzer column will be feed in to MEE. The dilute
alcohol vapors from near the top of analyzer column are condenser. Degasser and analyzer operate under
vacuum. The condensate from beer heater and analyzer condenser is collected in Rectifier Feed Tank. The
vapors of stripping alcohol are generated from analyzer column bottom liquid in the analyzer column re-
boiler by using the rectified column top vapors, as discussed subsequently.
Vapors from the top of heads column are condensed in heads column condenser and then in head column
vent condenser. Part of the condensate is returned to column as reflux while a small portion is taken out as
an impure spirit cut. Liquid from bottom of heads column is also taken into Rectifier-feed tank.

Dilute alcohol water mixture from rectifier feed tank is pumped by rectifier feed pump through rectifier feed
pre-heater in to rectifying column. Rectifier and its associated equipment work under pressure so that these
vapors can supply the necessary heat for generating the vapors.
The condensate from analyzer column reboiler is then pumped as Reflux to rectifying column. Rich alcohol
vapors at a concentrating of 95.5 % v/v from top of rectifying column are condensed first in Analyzer reboiler
and then in Reflux vent condenser. The liquid is then collected in Rectifier Reflux Tank. Part of the liquid from
vent condenser may be drawn off as impure spirit. The impure spirit cut will be maintained as little as
possible to maintain aldehyde levels to meet the required limits in Absolute Alcohol.
Liquid from the rectifier reflux tank is pumped bye product pump partly as product and partly as reflux to the
top of the Rectifying column. The necessary rectifying vapors to rectifying column are generated by boiling
the bottom liquid in Rectifier column Re-boiler by using medium pressure steam, some side streams are
drawn from rectifier column as light and heavy fractions of higher alcohols called fusel oils and cooled in
fusel oil coolers. These are mixed with water and allowed to separate out in fusel oil separator. All vents from
condensers are connected to Vent Gas Absorber where the vent gases are scrubbed with water to recover
entrained alcohol. The scrubber water is used for washing the fusel oils in fusel oil separator to recover
alcohol from the fusel oil fractions. The absorber vent is connected to vacuum pump which is used to create
vacuum in the respective columns.
iv) Alcohol bulk storage:

Alcohol is first taken to daily receiver storage tank and is thereafter transferred to Bulk storage Tank after
taking the daily receiver Dip. This is transferred using flameproof pumps. Final dispatch of alcohol is again
carried out using special flameproof pumps.
v) Effluent handling section in the process

a) Evaporation section:
The spent wash coming from Distillation section will be fed in to first calandria of the evaporator section. The
multi effect evaporator (MEE) shall be designed to concentrate the dissolved solids. Suggested treatment
scheme is FF + Finisher Evaporation plant for spent wash Evaporation. The following points will elucidate the
basic working principle:
 Shell & tube type evaporators with highly efficient liquid distributor working on the principal of Falling
Film 7 Forced Evaporation have been used, with Pre-heaters for preheating FEED stream which serves
the purpose of energy conservation.
 Vapors generated in 1st effect VLS (Vapor Liquid Separator) are used as heat source in the 2nd effect
and from 2nd to third and so on.
 The product at the desired concentration of TS is obtained at the outlet from the final effect, shell &
tube type Multi-pass Surface condenser is employed for condensing the shell side vapors.
 The pure and the process condensate are collected in receiving vessels.
 Highly efficient operating pumps will be provided for pumping the required fluid.
 The operation of the plant will be under vacuum and it will be created with the help of water ring
vacuum pump.

 The plant will have high level of automation to get consistent output at required concentration.
 Cooling water from cooling water is used in the surface condensers for condensing the vapors.
b) Incineration boiler along with the turbine generator:
The concentrated spent wash will be mixed with bagasse/biomass/coal and fired into especially designed
incineration boiler to generate high pressure steam and power.
Figure 1.6: Process flow diagram of Molasses based Distillery

1.8.2 Co-generation power plant of 7.0 MW capacity
The unit proposes to set-up incineration boiler and power turbine. Incineration boiler of 65 TPH will be
installed based on Concentrated Spent Wash and Bagasse / Biomass/coal as available fuel options. The
Incineration Boiler will operate mainly to feed steam to Molasses based operations and 7.0 MW power
generations from turbine.
Proposed 7.0 MW Co-Generation power plant consists of a high-pressure water tube steam boiler extraction
cum condensing steam turbine. Fuel in the steam boiler will be burnt with the help of air in the Incineration
boiler furnace. Water will be circulated in the Incineration boiler drum and tubes thus getting heated by the
flame burning in the Incineration boiler furnace. Water comes out of the Incineration boiler drum located at
the top of the Incineration boiler as steam. Flue gases rise in the Incineration boiler furnace and come in
contact with the steam coming out of Incineration boiler drum. Steam after coming in contact with flue gases
gets heated up further thus getting superheated. Super heated steam leaves the incineration boiler in a pipe.
Flue gases after super heating the steam pass through economizer where they pre-heat the incineration
boiler feed water before it enters the incineration boiler drum. After economizer, flue gases pass through air
pre-heaters where they heat the air which is fed to the incineration boiler furnace for burning the fuel. After

air pre heaters flue gases pass through ESP where the dust particles are collected. The dust is collected in
closed system with dense phase technology for final disposal.
High pressure superheated steam from incineration boiler is passed through a steam turbine, which is used
for distillery process operations. While passing through the turbine, the high pressure and temperature
steam rotates the turbine rotor and an electric alternator mounted on the same shaft. Electric power is
generated by the alternator. This electric power generated is consumed in house i.e. for running the distillery
and utilities like incineration boiler’s auxiliaries etc.
Figure 1.7: Process Flow Chart for Co-Generation Power Plant
1.8.3 Distillery Effluent Treatment Scheme –RO based Process condensate Treatment Plant
Quantity of effluent generated (KLPD) ETP capacity (KLPD)

1980 2150
(Cooling tower blow down, spent lees, vacuum pump sealing
water, process condensate and CIP of fermenter)
1) Feed Tank / Buffer Tank
The plant feed and the condensate will be sent to feed tank. The initial pH of the feed will be 3.5. Caustic
soda is added to increase the pH of feed to 9.5
2) Anaerobic digester
Waste water which will be transferred to digester and pH will be 7. Methane gas will be produced as the by-
product which will be stored in The Methane Gas Holder. The pump will draw the feed from the bottom of
the digester with the capacity of 35 m3. The feed rate will be 20-22 m3 and the Capacity of digester will be
4700 ton.
Digester overflow will pass to the next section.
3) De-classifier
It will be open from top and feed enters from bottom. Here the gas i.e. CO2 and NH3 will be removed.
4) Lamella Classifier
It removes the sludge or solid particles and recycle the sludge back to digester. Waste water will be sent for
further treatment.
Mechanism: It consist of vertical lines with small openings to pass it further. Sludge settles and waste water
through small opening passes further. The pump present at the bottom withdraws more feed.

5) Biofilter
Molder will be present at the bottom which helps the sludge and solid particles to settle and clear water
flows through the sparging pipe having holes to the top.
6) Tube Settler Clarifier
Media will be added to filter the waste water from the contaminants and then passed to AT-1 (Aeration tank-
1)
7) Conventional Aeration Tank-1
In this section aeration and agitation will be done. The purpose of aeration is
 To provide oxygen to bacteria so that it does not get deactivated.
 To increase the chemical oxygen demand, this will further help in aerobic degradation.
 Allow the biological matter to settle.
Biological treatment uses micro organisms which will be already present in waste water to degrade the
organic matter.
3 pumps will be present in AT-1:
i. 6 inches – tube settler pump.
ii. 2 inches – recycle from the clarifier
8) Clarifier -1
Sludge separator will be provided to separate waste water from solid particle. Water will be sent further to
AT-2 by gravity and sludge is passed to sludge tank and rest is sent back to AT-1.
pH is 8.2 and COD is 600 mg/l
9) Extended Aeration Tank-2
It withdraws feed from the clarifier-1. Two aerators will be provided for efficient aeration.
10) Clarifier-2
In this clarifier pH is 8.3 and COD level is 40 mg/l.
Water will be passed to Clarifier-3 and sludge back to AT-2. Poly-alum will be added after the sludge
separation which will be metered automatically. It clears the water.
11) Clarifier -3
Clear water from Clarifier-3 will be sent to R.O system by gravity.
COD is 0.1 mg/l
12) Sludge Tank / Bed
There will be 6 sludge tanks. Sludge will be filtered to remove the remaining water and then dried. It can be
further used as fuel.
During filter, 60% of the sand will be used as a filter media and 40% water will be added to increase
efficiency. After filtration the water will be passed to AT-1 and sludge to drier.
13) Multi Grade filter
Effluent will be passed through multi layers of filter media consisting of fine and coarse sand supported by
layers of pebbles and gravels with adequate pore size. This media will capture the small and large suspended

particles and undissolved impurities. The captured particles will be effectively removed by backwashing. The
filtered water will pass at the bottom of the tank from where it will be sent to Activated carbon filter.
14) Activated carbon filtration
Activated carbon filter uses a bed of activated carbon/charcoal that provides a larger surface area, allowing
maximum possible exposure to contaminants with the active sites in the filter media. It works on the basis of
adsorption whereby organic compounds in the water received from MGF are trapped inside the pore
structure of the carbon substrate. They effectively remove chlorine, sediment, volatile organic compounds,
taste and odour.
15) Multi membrane RO system
The reverse osmosis occurs when pressure, greater than the osmotic pressure, is applied to the water
recovered from ACF. Treated water is forced to flow from the concentrated to the diluted side, and solutes
are retained by the membrane. The membranes will allow the selective movement of solvent while rejecting
the solutes, such as salts or low molecular weight organic materials against its osmotic pressure difference. It
will effectively remove almost all the inorganic compounds, contaminant ions and most dissolved non-ions.
The permeate generated from the multi membrane RO system will be passed through the permeate RO
system for further removal of dissolve solid. The system comprises of two pressure vessels containing four
elements each configured in series. As the feed water will flow through the first membrane from feed to
reject end the pure water permeates through the membranes & will be collected in the permeate header.
The concentrated water will be collected in Reject header & then passes through the second pressure vessel.
The permeate generated from the system will be collected on the permeate RO product tank and recycled in
cooling tower whereas the final reject will be used as ash spray.
Table – 1.12
Characteristics of Untreated and treated effluent
S. Parameters Untreated Effluent Treated effluent
No. Evaporation process condensate Cooling tower blow down
1. pH 3.5-4 7.2 7.5
2. BOD <2500 mg/l 60 mg/l <30 mg/l
3. COD <4000 mg/l 200 mg/l <100 mg/l

Figure 1.8: Process Flow Chart for Distillery Effluent Treatment Scheme

1.9 DESCRIPTION OF MITIGATION MEASURES

The Company will implement mitigation measures for different environmental components (air, water, noise,
soil) in order to meet environmental standards. This Chapter will describe in detail the mitigation measures
the Company will follow in order to remain within prescribed limits of suggested pollutants.
1.9.1 Air pollution
 Proposed boiler will be provided with Electrostatic Precipitator to maintain PM emissions below
permissible limits. Boiler will be equipped with stack of suitable height (75 m) for discharge of
pollutants as per CPCB standards.
 CO2 (118 TPD) generated during fermentation process will be collected by scrubbers and sold to
authorized vendors.
 Continuous emission monitoring system will be installed at process stacks to monitor stack emissions.
 Calibration will be done time to time according to equipment supplier specifications.
 D.G. sets emission limits and stack height (6 m) will be as per CPCB guidelines.
 Internal roads will be concreted to control fugitive emissions.
 Adequate greenbelt will be provided to absorb pollutants and attenuate levels of dispersion in
ambient environment.
 Covered facilities will be provided for storage and transportation to prevent dispersion in open
environment.
1.9.2 Water pollution
 The proposed Molasses based distillery will be based on “Zero Effluent Discharge”
 The spent wash will be concentrated in MEE and the concentrated spent wash will be mixed with
auxiliary fuel and burnt in the incinerator boiler.
 RO technology will be installed for proper treatment of effluent so that EPA norms of treated effluent
are complied.
 Process condensate will be neutralized and polished in Condensate Polishing Unit (CPU) and recycled
in process and cooling tower makeup.
 Domestic waste water will be treated in Sewage Treatment Plant.
 Online Monitoring System for water quality monitoring will be installed within the premises.
 The company will practice rainwater harvesting after installation.
Major effluents generated during process and their mitigation plan:
 Spent Wash: Spent wash generated from the analyser column during the operation, will be
concentrated in integrated & standalone Multi – Effect Evaporator (MEE) from initial 16% solid to 55%
solid and transferred for complete incineration in a special boiler designed for slop. Hence, the complete
spent wash will be concentrated & incinerated & no spent wash will be discharged.
 Process Condensate: Process condensate from MEE will be treated & polished in CPU and recycled to
process and cooling tower makeup.
 Spent Lees: Spent lees & PR lees will be completely used in process.

 Blow down: Waste water generated from cooling tower blow down, boiler blow down, vacuum pump
and sealing will be recycled in the process itself after proper treatment in CPU.
 Domestic sewage- Will be treated in proposed sewage treatment plant and used for greenbelt
development.
1.9.3 Noise pollution
 Acoustic enclosure will be provided to DG sets for controlling noise pollution.
 Greenbelt will be developed around plant boundary to prevent noise problems outside plant
boundary.
 Noise generating equipment like pump, motors, compressors, blower, turbine/engines, power
generator sets/ engines etc. will be mounted on sturdy concrete foundations with proper & suitable
rubber padding to reduce vibrations & thereby noise generation. Pumps, fans, compressor, etc. will be
statically and dynamically balanced.
 The major noise producing equipment such as turbine will be provided with sound proof container,
where ever possible. Acoustic enclosure for DG set and similar provision like noise attenuator
wherever suitable/possible.
1.9.4 Solid and hazardous waste pollution
 The ash will be used as manure due to rich potash content (biomass ash) or supplied to brick
manufacturers (coal ash).
 Spent wash will be concentrated in Multi-effect evaporator and then used as fuel in boiler.
 Sludge generated will be used as manure.
 Used oil & grease generated from plant machinery/gear boxes as hazardous waste will be burnt
completely in incinerator boiler or sold to authorized vendors.
1.9.5 Soil pollution
 No discharge of effluent or solid waste outside or inside plant premises will be done.
 Strict disposal rules will be implemented inside and outside plant premises.
 Solid and hazardous waste will be handled as per MSIHC rules so no dumping on soil environment.
 Greenbelt will be developed and deforestation will be prevented.
 No construction waste will be dumped on soil and proper bins will be constructed at designated areas
where dump will be collected and disposed according to their type.
The mitigation measures which will be incorporated by the project proponent for maintaining the prescribed
standards as directed by EPA, 1986, MOEFCC guidelines and CPCB guidelines have been given above. The
Company will implement all the mitigation measures compulsorily after obtaining EC during construction as
well as operation phase.
1.10 ASSESSMENT OF NEW & UNTESTED TECHNOLOGY FOR THE RISK OF TECHNOLOGICAL FAILURE
For this proposed project using different grades of Molasses and Cane Juice Syrup, only proven technologies
will be selected. No new or untested technology will be used. The Process will be based on proven
technologies i.e. HIFERM-Fermentation, Multi Pressure Distillation with integrated/SA Evaporation followed
by Incineration.

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Proposed 160 KLPD Molasses based Distillery along with 7.

0 MW cogeneration power plant

DETAILED PROJECT REPORT

1.1 TYPE OF THE PROJECT

Figure 1.1: Location Map of the project site

Malbros International Pvt. Ltd.

Specific Location Map

Malbros International Pvt. Ltd.

1.3 Plant Layout

Malbros International Pvt. Ltd.

Figure 1.3: Plant Layout

Malbros International Pvt. Ltd.

1.4 Photographs of the proposed project site

1.5 SIZE OR MAGNITUDE OF THE OPERATION

Malbros International Pvt. Ltd.

Malbros International Pvt. Ltd.

Table – 1.7 (B)

Malbros International Pvt. Ltd.

Malbros International Pvt. Ltd.

Malbros International Pvt. Ltd.

1.6.6 Boiler details

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1.7 PROPOSED SCHEDULE FOR APPROVAL AND IMPLEMENTATION

time for commissioning of the project will be within 3 to 4 years.

Malbros International Pvt. Ltd.

1.8 TECHNOLOGY AND PROCESS DESCRIPTION

i) Molasses unloading and storage

ii) Yeast propagation and fermentation:

iii) Distillation: (Multi Pressure Distillation with Integrated Evaporation)

Malbros International Pvt. Ltd.

iv) Alcohol bulk storage:

v) Effluent handling section in the process

Malbros International Pvt. Ltd.

Figure 1.6: Process flow diagram of Molasses based Distillery

Malbros International Pvt. Ltd.

Figure 1.7: Process Flow Chart for Co-Generation Power Plant

Quantity of effluent generated (KLPD) ETP capacity (KLPD)

Malbros International Pvt. Ltd.

Malbros International Pvt. Ltd.

1. pH 3.5-4 7.2 7.5

2. BOD <2500 mg/l 60 mg/l <30 mg/l

3. COD <4000 mg/l 200 mg/l <100 mg/l

Malbros International Pvt. Ltd.

Malbros International Pvt. Ltd.

1.9 DESCRIPTION OF MITIGATION MEASURES

Malbros International Pvt. Ltd.

Malbros International Pvt. Ltd.

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