Expanding Distillery to Boost Ethanol Production

A Report
ON
EXPANSION OF EXISTING MOLASSES/ GRAIN BASED

DISTILLERY FROM 300 KLPD TO 700 KLPD USING
GRAIN /CANE SYRUP FOR ETHANOL PRODUCTION
ALONG WITH 17 MW ELECTRICITY GENERATION
BY
Hermes Distillery Pvt. Ltd. (HDPL),

A/P: Yadrav, Tal.: Raibag, Dist.: Belgaum, Karnataka State
Prepared by
CONTENTS
CHAPTER 1 – PROJECT DESCRIPTION 01-34
1.1 Type of Project 1

1.2 Need of the Project 1
1.2.1 Employment Generation Potential 1
1.2.2 Potential of the Products 1
1.3 Project Location 2
1.3.1 Site History 3
1.4 Details Of Land Requirement 4
1.5 Project Operations, Approvals & Implementation 8
1.5.1 Plan for Approval and Implementation Schedule 8
1.6 Technology and Process Description 8
1.6.1 Products 8
1.6.2 Raw Materials for Integrated Project 9
1.6.3 Raw Material and Product Transportation Details 9
1.6.4 Manufacturing Process 10
1.6.4.1 Distillery Manufacturing Process 10
1.6.4.2 Manufacturing Process using Cane Syrup as Raw Material 11
1.6.4.3 Manufacturing Process using Grain Based Operations 11
1.6.4.4 Manufacturing Process for Co-generation Plant 17
1.7 Sources of pollution and their Control 17
1.7.1 Water Pollution (WP) 17
1.7.1.1 Fresh Water Adequacy 19
1.7.1.2 Effluent Generation 19
1.7.1.3 Domestic Effluent 20
1.7.1.4 Industrial effluent 20
1.7.2 Air Pollution 25
1.7.2.1 Fugitive Emission 27
1.7.2.2 Process Emissions 27
1.7.3 Solid Waste 27
1.7.4 Hazardous Wastes 28
1.7.5 Noise Pollution 28
1.7.5.1 Sources of Noise Pollution 28
1.7.6 Odour Pollution 29
1.7.7 Land Pollution 29
1.7.8 Budgetary Allocation by Industry towards Environment Protection 29
1.8 Green belt development plan 30
1.8.1 Area Calculation for Green Belt Plan 30
1.8.2 Existing Tree Plantation 31
1.8.3 Proposed Tree Plantation 31
1.8.4 Criteria for Green Belt Development 31
1.9 Rain water harvesting 32
LIST OF TABLES
Table No. Table Page No.

1.1 Details of Manpower 1
1.2 Project site & Environmental Settings 2
1.3 ECs Granted To HDPL 3
1.4 Area Statement of HDPL 4
1.5 Project Investment Details 8
1.6 Working Pattern 8
1.7 Product & By- Products in the Distillery Complex 8
1.8 List of Raw Materials in the Distillery Complex 9
1.9 Raw Material Transportation Details (Traffic Density) 9
1.10 Product & By-product Transportation Details 9
1.11 Raw Material Storage Details 10
1.12 Product Storage Details 10
1.13 Electricity Requirement Details 17
1.14 Distribution of Electricity Generated from Co-gen Plant 17
1.15 Water Consumption of Existing Molasses & Grain Distillery Operations 18
1.16 Water Consumption for Expansion w.r.t. Grain & Cane Syrup Distillery 18
1.17 Effluent Generation from existing 100 KLPD Molasses & Grain based Distillery 19
1.18 Effluent Generation from Proposed Grain & Cane Syrup based Distillery Unit 20
1.19 Spent wash Characteristics 24
1.20 DDGS Specifications 24
1.21 Details of MEE 24
1.22 Details of Boiler and Stack in HDPL 25
1.23 Characteristics of Fuels 26
1.24 Fuel Storage Details 26
1.25 Details of ESPs for Boilers 26
1.26 Solid Waste Generation & Disposal 28
1.27 Details of Hazardous Waste 28
1.28 Capital as well as O & M cost (Existing & Proposed) 30
1.29 Area Details 30
1.30 Area Taken for RWH 32
LIST OF FIGURES
Figure No. Figure Page No.

1.1 Project Location 5
1.2 Image Showing Site History 6
1.3 Industrial Complex 7
1.4 Grain Distillery Operations 11
1.5 Mass Balance and Process Flow Chart for Existing 100 KLPD Molasses Distillery 15
1.6 Mass Balance and Process Flow Chart for Existing 100 KLPD Grain Distillery 15
1.7 Mass Balance and Process Flow Chart for Proposed 400 KLPD Grain Distillery 16
1.8 Mass Balance and Process Flow Chart for 700 KLPD Cane Syrup Distillery 16
1.9 Flow Chart of Existing Distillery CPU (Cap.: 1260 M3/Day) 21
1.10 Flow Chart of Proposed Distillery CPU (Cap.: 3500 M3/Day) 22
1.11 Flow Chart of STP (Capacity 25 KLD) 22
1.12 Process Technology of STP 23
1.13 Existing Distillery CPU 23
1.14 MEE Installed At HDPL Site 25
1.15 Existing Stack & ESP of Boilers 26
1.16 Existing CO2 Bottling Plant 27
1.17 Existing Green Belt 33
1.18 Compliance done at HDPL w.r.t. Existing Unit 34
APPENDICES
No. Description Page No.

• Enclosures
Enclosures-I EC dt. 31.01.2017 35-42
Enclosures-II EC dt. 26.02.2019 43-49
Enclosures-III Amended EC dt. 19.05.2021 50-53
Enclosures-IV EC dt. 27.06.2022 54-56
• Annexures
Appendix- I KIDAB Letter (NA) & 7/12 Extracts of HDPL 57-94
Appendix- II Letter of Intent From Shivshakti Sugars Ltd. (SSL) w.r.t. Sale of Land to 95-223
HDPL, 7/12 Extracts & Land NA Documents
Appendix- III Valid CTO of HDPL 224-228
Appendix- IV Plot Layout 229
Appendix- V Water lifting permission & application 230-237
Appendix- VI ZLD Plan 238-241
Appendix- VII Stack height calculations for proposed boiler 242-244
Appendix- VIII GB Plan 245-247
Appendix- IX AQ Report 249-256
• Certificate of Incorporation 257-258
Chapter 1
Project Description
1.1 TYPE OF PROJECT
Hermes Distillery Pvt. Ltd. (HDPL) has planned to go for expansion of existing Molasses/
Grain based Distillery from 300 KLPD to 700 KLPD using Grain /cane Syrup for Ethanol
Production along with 17 MW electricity generation. Now, in light of HDPL’s participation in
National Biofuel Policy 2018, the management has planned to further expand distillery from
300 to 700 KLPD. Only Ethanol will be produced under expansion i.e. 400 KLPD and same
will be solely used for EB Program.
1.2 NEED OF PROJECT
Production of alcohol is gaining more importance with regards to production, usage and easy
availability of raw materials namely sugarcane & molasses which in fact are renewable sources.
With the increase in business, it has a considerable share in national income. Alcohol industry
is the secondary largest source of revenue of the state. Industry is probably only one in which
the inputs are de-controlled, but selling prices are determined by local state level and excise
duties. Moreover, there is a good export potential, for the alcohol, out of the contour. The
profits earned by conversion of molasses into alcohol are much higher than that of sale of
molasses alone. Apart from these, following also are the important aspects towards establishing
and expanding distilleries.
1.2.1 Employment Generation Potential
Activities under expansion project of HDPL will improve socio-economic status of people in
the study area in terms of local employment and contract basis jobs. Proposed expansion
activity could provide employment opportunities to the skilled and semi-skilled local populace,
especially in small-scale business and other related services. Table 1.1 gives details about the
number of workers employed in the existing as well as those to be employed under expansion
activities.
Table 1.1 Details of Manpower
No. Manpower Existing Plant Proposed Plant Total

1 Skilled & 310 280 590
Unskilled Workers
1.2.2 Potential of the Products
Under proposed project product Ethanol will be manufactured. Ethanol produced from
proposed expansion project has demand for blending in petrol/diesel after making anhydrous
alcohol from the conventional rectified spirit. In 2014, less than 1% ethanol was being blended
with petrol against the target of 5%. Now, this ratio has reached 8.5% and next year it is going
to be 10%. The government have set a target of reaching 10% ethanol-blending by 2022 (10%
of ethanol mixed with 90% of petrol) and 20% by 2030. The electricity produced from existing
co-gen plant shall be used for industrial operations.
1
1.3 PROJECT LOCATION
The proposed expansion activities will be carried out in existing premises of HDPL. Present
set up of the factory is located at Survey No. 96/5A, 96/5B, 96/5C, 96/3A/2, 98/1B/3, 98/1B/4,
98/1B/5 & 98/1C, 95/2, 95/3, 99/2, 99/3, 99/4, 98/1B/1, 99/1, A/P: Yadrav, Tal.: Raibag, Dist.:
Belgaum, Karnataka State. Geographical location of the site is Latitude 16°31'27.42"N,
Longitude 74°43'17.49"E, while making selection of site for existing activities of HDPL certain
aspects were taken in to consideration prominently. The Same were - (1) Availability of all
basic facilities like water, electricity, man power, raw material etc., (2) Rail and road links to
prominent market places so that procurement of raw material as well as marketing of finished
product was easier and economical, (3) Availability of good communication facilities and (4)
No rehabilitation and resettlement required. (5) No national park or wildlife habitats were
located in immediate vicinity of the project site. Total plot area of existing 300 KLPD distillery
unit is 8.12 Ha under Survey No. 96/5A, 96/5B, 96/5C, 96/3A/2, 98/1B/3, 98/1B/4 & 98/1B/5
& 98/1/C. Now, management has planned for expansion of Grain based Distillery from 300
KLPD to 700 KLPD using Grain /Sugarcane syrup for Ethanol Production with 17 MW
electricity generation. Copies of 7/12 extracts & land NA documents are enclosed at
Annexure-I. For this expansion, HDPL needs additional land for which the industry has a plan
to purchase the land from one nearby Industry - Shivshakti Sugars Ltd.; which is a sister
concern of HDPL. Accordingly, 7.49 Ha of land belonging to S. Nos. 95/2, 95/3, 99/1, 99/2,
99/3, 98/1B/1 & 99/4 will be acquired. For the same, Shivshakti Sugars Ltd. has given a Letter
of Intent (LOI) which is enclosed at Annexure-II. The process w.r.t. ‘Sale Deed’ is already
under way. Thus, now the total plot area of HDPL is 1,56,164 Sq. M. (15.61 Ha) including then
new land parcel under sale deed. Further, in order to meet the green belt development criteria,
additional 4.04 Ha land (S. No. 1/1, 1/6, 2/2A & 2/2B) has been taken on lease from one
adjacent farmer - Shri Annasaheb Patil. On this land of 4.04 Ha; only parking & green belt will
be implemented. Land lease document is enclosed at Annexure-II.
Table 1.2 Project Siting & Environmental Settings
No Particulars Details
1 Name and Address of Industry Hermes Distillery Pvt. Ltd., (HDPL), A/P: Yadrav, Tal.: Raibag,
Dist.: Belgaum, Karnataka State.
2 Survey No. 96/5A, 96/5B, 96/5C, 96/3A/2, 98/1B/3, 98/1B/4 & 98/1B/5,
98/1C, 95/2, 95/3, 99/2, 99/3, 99/4, 98/1B/1, 99/1
3 Land acquired by the Industry Total Land : 15.61 Ha (8.12 Ha. already acquired + 7.49 Ha now
under purchase for expansion).
Additional Land taken on Lease for GB & Parking : 4.04 Ha
4 Elevation 560 M above MSL
5 Nearest habitation Yadrav (0.65 Km, SE), Soundattivadi (0.76 Km, N)
6 Nearest city Raibag (6.6 Km, SE)
7 Nearest Highway SH-73 (6.6 Km, SE), SH- 72 (6.8 Km, W) & NH – 160 (6 Km, W),
Village Road- Yadrav to Naslapur (0.35, S)
8 Nearest railway station Raibag (9.5 Km, SE)
9 Nearest airport Kolhapur Airport (50 Km; NW), Belgaum Airport (74 Km; S)
10 Nearest tourist place(s) Raibag Rajwada (8 Km; SE), Gokak Falls (37 Km; SSE)
11 Defense installations Nil within 10 Km radius
12 Archaeological important No notified archaeological important sites are present in 10 Km
radius area
13 Critically / Severely polluted areas Nil within 10 Km radius area
declared by CPCB/MoEFCC
14 Ecological sensitive zones Nil within 10 Km radius area
2
No Particulars Details
15 Reserved forest/Protected forest/ Reserve forest (0.65 Km, W)
National Parks/WLS
16 Nearest streams / Rivers / water Krishna River (4.5 Km, NW)
bodies (from Project Site)
17 Nearest Industrial Area / Ind. Shivshakti Sugar Ltd. (0.35 Km, NE)
18 Interstate Boundary Maharashtra-Karnataka State Boundary (11 Km, NW)
19 Site Co-ordinates (all corners) Latitude -16°31'16.64"N, Longitude - 74°43'7.16"E
Latitude-16°31'36.48"N, Longitude- 74°43'7.11"E
Latitude-16°31'35.65"N, Longitude-74°43'28.71"E
Latitude - 16°31'16.42"N, Longitude-74°43'28.31"E
1.3.1 Site History
Hermes Distillery Pvt. Ltd. (HDPL) is located at Yadrav, Tal.: Raibag, Dist.: Belgaum, Karnataka
State. HDPL was first granted EC dated 31.01.2017 for establishment of a standalone 100
KLPD Molasses based Distillery. This distillery was established and commissioned in year
2018 which is presently operational on site. Thereafter, the management planned to go for
expansion. Accordingly, EC dated 26.02.2019 was procured from MoEFCC for expansion of
Distillery from 100 to 300 KLPD. Under expansion, it was planned to implement additional
Molasses 100 KLPD and Grain 100 KLPD distillery setups in the premises of existing 100
KLPD Molasses distillery premises. Subsequently, the management planned to participate in
National Biofuel Program (NBP). Accordingly, in light of availability of Grains (as raw
materials) in the command area; management decided to implement the 100 KLPD grain
distillery under expansion. As such, amendment in earlier EC dated 26.02.2019 was requested
from the Ministry. The same was w.r.t. splitting of a combined 75 TPH boiler capacity in the
EC dated 26.02.2019 as 39 TPH for Molasses and 36 TPH for Grain based operations thereby
having two separate boilers. In line with request by the Industry; MoEFCC awarded EC
amendment vide order dated 19.05.2021. Further, Consent for Operation was obtained for 100
KLPD grain plant and the distillery is operational on site. Ethanol manufactured under existing
100 KLPD Molasses and 100 KLPD Grains is being supplied to Petroleum Dept, Central Govt.
under Ethanol Blending Programme. As per EC dated 26.02.2019, 100 KLPD Molasses plant
is yet to be established on site. HDPL management has planned to implement this 100 KLPD
by using Grain as an alternative to Molasses. For this reason HDPL sought EC amendment and
accordingly MoEFCC granted the amendment in EC vide order dated 27.06.2022.
Table 1.3 ECs Granted To HDPL
No. Description EC Dates Total Capacity Status On Site

1 EC Granted by MoEFCC for establishment 31.01.2017 100 KLPD 100 KLPD Molasses
of 100 KLPD Molasses Distillery Plant established.
2 EC Granted by MoEFCC for Expansion of 26.02.2019 200 KLPD Distillery 100 KLPD Grain Plant
Molasses Distillery from 100 KLPD to 300 (100 KLPD established (as per
KLPD (100 KLPD Molasses & 100 KLPD Molasses + 100 expansion EC of 2019).
Grain). KLPD Grain 100 KLPD Molasses
Distillery) Plant not established
3 EC Amendment Granted for Splitting of 75 19.05.2021 300 KLPD --
TPH Boiler into 36 TPH Boiler & 39 TPH
Incineration Boiler & additional land on
lease
3
No. Description EC Dates Total Capacity Status On Site
4 EC Amendment recommended for using 27.06.2022 300 KLPD (100 --
raw material Grain as an alternative to Molasses + 100
Molasses in existing approved 100 Grain +100
KLPD Molasses Distillery unit Grain/Molasses)
HDPL EC letters are enclosed at Enclosure – I to IV. Valid CFO copy is at Annexure- III.
1.4 DETAILS OF LAND REQUIREMENT
Total land area acquired by the HDPL is 15.61 Ha. Out of this; total built up area after
expansion will be 7.55 Ha. Detailed area statement is presented at Table 1.4, from which it
could be seen that sufficient land is available with HDPL for various activities under existing
and proposed projects. Refer Annexure - IV for plot layout plan of project site.
Table 1.4 Area Statement of HDPL
No Description Existing Area Expansion Total

(Sq.M.) (Sq.M.) (Sq.M.)
1 Total Plot Area 1,56,164
2 Built up Area of
Distillery, Cogen & 44,496 31,045 75,541
Bottling Unit
Total built up Area
3 Parking Area 13,023 10,500 23,523
(on lease land)
4 Area Under Road 13,338 7,000 20,338
5 Green Belt Area 27,036 24,498 51,534
(on lease land)
17% 16% 33%
Total Open Area 58,271 -- 20,226
Total plot area of the industry is 15.61 Ha. As per MoEFCC norms, green belt should be
developed on 33% of the total plot area of industry. Under existing set up 2.7 Ha area is under
green belt which is 17% of total plot area. To develop additional 2.44 Ha (16%) land area under
green belt; industry has taken land on lease.
4
Figure 1.1 Project Location
Note: The Maps are purely graphical and not to scale, Latitude 16°31'27.42"N, Longitude
74°43'17.49"E.
5
Figure 1.2 Images Showing Site History
Land use Status of HDPL – Year 2008 Land use Status of HDPL – Year 2021
6
Figure 1.3 Industrial Complex
7
1.5 PROJECT OPERATIONS, APPROVALS & IMPLEMENTATION
Proposed expansion project will be implemented only after obtaining requisite approvals,
permissions, consents from concerned authorities namely MoEFCC and KSPCB. Project will
be formulated in such a fashion and manner so that the utmost care of safety norms and
environment protection measures shall be taken.
Details on capital investment of existing distillery & bottling unit as well as days of distillery
operation is given in Table 1.5 & 1.6.
Table 1.5 Project Investment Details

No. Industrial Unit Capital Investment (Rs. Cr.)
Existing Proposed Total
1 Distillery & Bottling Unit Rs. 165 Rs. 450 Rs. 615
Table 1.6 Working Pattern

No. Type of Activity Days of Operation (No.)
1 Distillery Unit
On Molasses 330
On Grains 330
On Cane Syrup 180
1.5.1 Plan for Approval and Implementation Schedule

Project will be implemented after grant of Environmental Clearance (EC) from MoEFCC;
New Delhi & plant will be commissioned after getting Consent for Operation (CFO) from
KSPCB.
1.6 TECHNOLOGY & PROCESS DESCRIPTION

1.6.1 Products
Details of products that are being manufactured under existing Distillery as well as those to
be manufactured under expansion of distillery are represented in following table -
Table 1.7 Products & By-products in the Distillery Complex
Unit Products & By Products Capacity (KLPD) Status on Site
Existing Expansion Total
Existing Projects Molasses distillery 100 -- 100 Implemented & in
(RS/ENA/Ethanol/Alcohol) operation as per EC
Grain distillery 100 -- 100 Implemented & in
(RS/ENA/Ethanol/Alcohol) operation as per EC
Molasses/ Grain distillery 100 -- 100 Yet to be implemented
(RS/ENA/Ethanol/Alcohol) as per EC
Electricity Generation 13 MW -- 13 MW Implemented & in
operation as per EC
CO2 Gas (T/Day) 215 -- 215
DDGS (T/Day) 160 -- 160
Expansion Projects Grain (Ethanol) -- 400 400 To be implemented
Cane Syrup (Ethanol) -- 700 700 after Expansion EC
Electricity Generation -- 17 MW 17 MW
CO2 Gas (T/Day) -- 315 315
DDGS (T/Day) -- 320 320
8
1.6.2 Raw Materials
Basic raw materials required for Distillery unit along with their quantities and sources are
listed in the following table-
Table 1.8 List of Raw Materials Consumed in Distillery Complex
Quantity (T/Day)
Unit Raw Materials Source
Existing Expansion Total
Molasses (100 KLPD) 371 -- 371
Grains (100 KLPD) 255 1020 1275 Purchase from nearby
Grain (100 KLPD) / 255 / -- 255 / industries & farms
Distillery Molasses(100 KLPD) 371 -- 371
Sugarcane Syrup -- 2060 2060
Yeast 0.85 1.15 2.0
Urea 6.5 8.5 15
Purchase / Local
De-foaming Oil 12 16 28
Vendors
Co-gen Plant Coal/ 270 575 845
Bagasse 380 1200 1580
HDPL is a standalone distillery. Molasses & Cane Syrup will be purchased from outside
industries including adjacent 10,000 TCD sugar factory- Shivshakti Sugars Ltd. (SSL),
Yadrav. A LoI is procured for supply of cane syrup & molasses from SSL. A copy of LoI is
enclosed at Annexure-II. Bagasse will also be taken from nearby factories.
1.6.3 Raw Material and Product Transportation Details
Grains (Brocken Rice, Maize, Pearl Millet, Jowar, Wheat etc.)/ Molasses/ Cane Syrup which is
made available from local market or local farmers. Raw material is transported to site by
roads. Grains will be stored in silo on site.
Table 1.9 Raw Material Transportation Details (Traffic Density)
Avg. wt. (T) Daily No. of Vehicles

No. Type of Vehicle Raw Material (T)
/ Vehicle Existing After Expansion
A Grains
1 Tractor Trolleys 15 17 52 780
2 Trucks 18 14 42 756
Total 31 79 1536
B Molasses
Tanker 20 KL 38 -- 760
Table 1.10 Product & By-product Transportation Details
No Product / By Type of Daily No. of Vehicles Avg. Wt. Quantity of Final Product
- Product Vehicle Existing After Expansion (T)/ Vehicle Transported / Day
1 Alcohol Tankers 12-13 29 24 700 KL
2 DDGS Tractor 40 120 4 480 T
9
Table 1.11 Raw Material Storage Details
Details
No. Description Grain Molasses Cane Syrup
Existing Proposed Existing Proposed Proposed
1 Capacity 2,500 T 12,500 T 10,000 T 15,000 T 15,000 T
2 No. of Silos/ 2 5 4 2 2
Tanks
3 Type Covered Covered Covered Covered Covered
Table 1.12 Product Storage Details

No Description Details
Existing - Proposed- Fuel
RS/ENA/Ethanol Ethanol
1 Capacity 1500 KL (5) & 500 KL (3) 3000 KL
2 No. of Tanks 8 4
1.6.4 Manufacturing Process
1.6.4.1 Distillery Manufacturing Process

Molasses is stored in mild steel storage tank. Proper care is taken to cool down molasses
before it goes to molasses tanks. Then the molasses is pumped from the MS storage tanks to
weighing scales. Here it is weighed on automatic weighing scales and then fed for further
processing. In the production of ethyl alcohol from molasses, two major steps are involved.
1) Fermentation of Molasses with the help of yeast strains of the species Saccharomyces
cerevisiae to produce 6% to 8% alcohol in the fermented wash; and
2) Distillation of the fermented wash for recovery and concentration of alcohol.
Fermentation
Molasses containing 40% to 50% of total sugar will be weighed and diluted with clean as
well as fresh water to the desired concentration. This will be achieved in a continuous diluter.
The molasses-water mixture will have a specific gravity to the tune of 1.06 for pre-
fermentation and specific gravity of to the tune of 1.096 to 1.1 for the main fermentation
process. Molasses with sp. gr. of 1.060 will be taken in to pre-fermenters and to it, ready
compressed yeast will be added for further activation. As soon as the yeast becomes active
in solution, the molasses-yeast slurry will be transferred to main fermenters for the process
of conversion of sugars into alcohol. It takes about 24 to 30 hours to complete the
fermentation reaction. Sugar in the molasses gets converted into ethyl alcohol and carbon
dioxide through metabolic activities of the yeast. Fermentation efficiency observed, in above
process, is generally to the tune of 85% and ethyl alcohol concentration to the tune of 6% to
8% of volume in the fermented wash is obtained. This depends on the quality of molasses &
its total sugar content.
Distillation
Fermented wash, then, will be taken to Distillation House. The distillation unit mainly
consists of wash boiling column and rectification column. Before feeding to the boiling
column the fermented wash will be passed through beer heater and heat exchangers where
the final temperature rises to about 850 C to 900 C. Fermented wash will be fed to the wash
boiling column from its top and open steam will be introduced from its bottom. While the
wash trickles from the top, alcohol vapours get recovered along with rising steam. Alcohol
vapours, analyzed from this wash boiling column, containing 40% to 45% of alcohol will
then be fed to rectification column at its bottom. Here, in this column, alcohol rectification
10
from 45% to 95% will take place. The product i.e. 95% alcohol will be drawn from the top
of rectification column where temperature will be @ 780C, which is boiling point of rectified
spirit. Thereafter, the alcohol will be cooled and stored in daily receiving tanks. Condensers
and refluxes will be provided to each column for proper concentration and condensation.
About one beer heater and one condenser are provided for the boiling column, whereas two
condensers and one beer heater are provided to the rectification column. Daily product
manufactured will be transferred to spirit storage warehouse.
1.6.4.2 Manufacturing Process using Cane Syrup as Raw Material
The freshly made sugar cane syrup is diluted & fermented in a fermentation vessel where
yeast are added to work on the juice. By the process of fermentation, the yeast digest the
sucrose and produce ethanol from the sugar cane syrup, as well as another byproduct, carbon
dioxide.
1.6.4.3 Manufacturing Process for Grain Based Operations
Incoming grains are inspected upon receipt. Inspection is carried out to deter-mine bushel
weight, moisture content, mold infestation and general appearance. Accepted grains are
unloaded into silos for storage before milling. Stored grains are weighed to determine
incoming quantity.
Figure 1.4 Grain Distillery Operations
A. Grain Milling Section

The purpose of milling is to break up the grains to the required particle size in order to
facilitate subsequent penetration of water in the cooking process. The milling section of the
plant has the necessary equipment’s for cleaning of the raw materials and screening the
milled floor so as to get the desired particle size. Selected hammer mill will be able to mill
the grains. Raw material is first milled to form flour in the milling section. Reduced particle
size makes the starch accessible to gelatinization during cooking. In this mill 20 to 30%
oversize particles will be recycled for second milling.
B. Liquefaction
Liquefaction initiates the conversion of starch into simple molecules of dextrin. It is divided
into three sub processes. i.e. Pre liquefaction, jet cooking and post liquefaction.
11
i. Pre- Liquefaction
This involves partial hydrolysis/liquefaction of starch, in presence of enzyme -amylase, at
a temperature much below the gelatinization temperature. Gelatinization results in reduction
in viscosity of the mash. Gelatinization temperature varies for the different grains (e.g. for
corn, it is 62-720C and for sorghum, it is 68-770C). Part of the enzyme is added in this step
after necessary adjustment of pH and Ca++ ion concentration
ii. Jet Cooking
This step involves the cooking of the starch slurry with live steam so as to instantaneously
raise its temperature. Mash is pumped continuously through a jet cooker, where temperature
is raised to 1200C. It then passes into the top of the vertical column. With plug flow the mash
moves down the column in about 20 minutes and passes into the flash chamber for post-
liquefaction at 80-900C. This gelatinizes and opens up starch molecule, thus allowing water
to penetrate and making it accessible to enzyme action. Jet cooking also sterilizes the slurry.
iii. Post- Liquefaction
Retention time in post-liquefaction/ flash chamber is 30 minutes Second part of -amylase
enzyme is added in post-liquefaction. Jet-cooked slurry is again held at high temperature in
presence of enzyme to complete the process of post-liquefaction. -amylase enzyme used
will be able to break down the starch molecule at higher temperature
C. Saccarification
Scarification is the formation of sugars. Here, it is done enzymatically by breakdown of
dextrin. Here the dextrin is acted upon by a second enzyme for further breakdown and release
of sugars.
D. Fermentation
The fermentation process employs a special yeast culture, which can withstand variations in
the grain slurry quality, temperature and other shock loads. Batch Fermentation plant consists
of 6 nos. fermenters connected in series with all the accessories like plate heat exchangers
for cooling, sparges, broth mixers and air blowers etc. The yeast is immobilized using special
media and it remains in the fermentation plant throughout and hence it gives tremendous
advantages in maintaining the yeast population and in combating the bacterial infection.
Grain slurry after weighing is also pre-treated to an appropriate sugar concentration while
pumping through Batch Broth Mixer into the fermenter. The fermenters are then inoculated
with culture developed in the culture vessels. This culturing with suitable yeast is carried out
only during the start-up of the plant. The culture thus developed maintains itself in fermenters
on a batch basis.
To help the fermentation sustain the assailable nitrogen are added in the medium in the form
of Urea and DAP as required. Temperature in the fermenters is maintained to an optimum
level as required for efficient reaction with the help of Plate Heat Exchanger and recirculation
pumping system. This recirculation also helps in proper mixing of fermented wash. The
retention time for the reaction is provided. Air blower is provided to supply the necessary
oxygen required for the yeast and also for agitation. After completion of reaction the
fermented wash is delivered to clarified wash tank. CO2, which is liberated, is scrubbed in
water, with the help of CO2 Scrubber. This CO2 contains ethanol, which is recovered by
collecting CO2 Scrubber water into Sludge Trough. The diluted sludge is pumped into Sludge
Settling clarifier.
The fermented mash collected in the Clarified Wash Tank is then pumped to Analyzer
column for distillation. A closed loop cooling tower system with an induced draft-cooling
12
tower with circulation pumps is also provided to ensure higher cooling efficiency and to
minimize water wastages.
E. Multi pressure Wash to ENA, RS Distillation

The vacuum distillation has many advantages over conventional distillation atmospheric
distillation plants like lower energy requirement, very good quality alcohol and less scaling
of the distillation trays due to sludge. The vacuum distillation produces ethanol of
international quality standards and there is a lot of demand of ethanol from the vacuum
distillation process.
“The Extra Neutral Alcohol produced from this latest technology will meet most of the
international quality standards for ethanol like US Pharmacopoeia, British Pharmacopoeia
and Japanese standards.
The vacuum distillation approximately requires 50% less steam as compared with the
conventional old distillation technologies. The vacuum distillation consists of distillation
columns with high efficiency column trays, condensers, Reboiler, vacuum pumps and reflux
pumps. A closed loop cooling tower system with an induced draft-cooling tower with
circulation pumps is also provided to ensure higher cooling efficiency and to minimize water
wastages.
In this vacuum distillation ethanol is separated and concentrated using principle of fractional
distillation. This is based on difference in boiling points of volatile compounds in mixture.
There are seven columns in the system Primary column also called Primary column, Pre-
Rectifier cum Exhaust column, Rectifier Column, Hydro extractive distillation column,
Refining column, De-aldehyde Column and Defusal Column.
The Primary or Mash column is operated under vacuum and it is heated using the vapours
from the Rectifier column, which is operated under a slightly higher pressure. The vacuum
operation of the Primary column will help in reducing the overall energy requirement and
also improve the product quality.
Due to vacuum operation of the Primary column the scaling of the column trays is minimized
and plant can be operated without stoppage for a longer duration as compared with
atmospheric plant. The fermented mash is preheated using a beer heater at the top of the Pre-
Rectifier / exhaust column and followed by a plate heat exchanger and finally delivered to
the top of Degasser column. The pre heating of mash in two stages recovers energy and saves
steam required for the distillation. The mash runs down the Primary column trays from tray
to tray, while vapour goes up in the column contacting the mash at each tray. As a result of
this contact and boiling, ethanol and other impurities along with some water are stripped in
the form of vapours and remaining mash in the form of vinasse (effluent) is disposed off
from the bottom of the Primary column for CPU.
When the vapours of ethanol and other volatile compounds reach the top, they are separated
out from the top of Primary column and are then fed to pre rectifier exhaust column. The
heat is supplied by the Rectifies vapours from the Reboiler provided at the bottom of the
Primary column. Two Reboilers are provided at the bottom of the Primary column to
facilitate the heat transfer from Rectifier column vapours to Primary column. The vapours
from Primary top are fed to Rectifier /exhaust column for purification. Alcohol from the top
of rectifier Columns are also diluted with soft water and are fed to Hydro extractive
distillation column. A Reboiler is installed at the bottom of the Hydro extractive distillation
column. Impurities such as Aldehydes and Fusel oil are removed from the top of the Hydro
extractive distillation Column. Impurities like ester which is removed from top section of
hydro extractive column are fed to Fusel oil concentration column, while dilute ethanol along
with fewer impurities, are fed to Rectifier column middle. Steam is fed to Hydro extractive
distillation column through Reboiler. A Reboiler is installed at the bottom of the Rectifier
13
column, which heats the process liquid i.e. alcohol and water received from the Hydro
extractive distillation column, indirectly with the help of steam. In the Rectifier column, the
ethanol is concentrated to 96 % by refluxing the Rectifier reflux liquid. Extra neutral ethanol
(ENA) is tapped from the top of Rectifier column, which is directly sent to refining column
for removal of other low boiling impurities. While the bottom product of the Rectifier column
called spent lees is drained off. The higher alcohols also called light and heavy fusel oils are
removed from the middle portion of the Rectifier column so that they are not mixed with
Extra Neutral Alcohol. Light and Heavy fusel oil from Rectifier column and top cut from
Hydro extractive distillation column is fed to fusel oil concentration column.
The steam is delivered from the bottom of the Defusal Column to allow the desired
separation. Fusel oil consisting of higher alcohols viz. Amyl alcohol, iso amyl alcohol, n-
propanol etc. are concentrated near middle portion of Fusel oil concentration column and can
be removed and separated in the Fusel Oil Decanter in sufficient higher concentration. While
the bottom product called spent lees is drained off. The top product from the De-aldehyde
Column is cooled in the cooler and sent to storage as Technical Alcohol . The Refining
column is fed with the ENA from the Rectifier column, which is boiled off in the Refining
column to remove the low boiling impurities like methanol and mercaptans. Extra Neutral
Alcohol (ENA) is tapped from the bottom of the Refining column, which is cooled up to
300C, by passing through ENA cooler. The impure ethanol, which contains many impurities,
is drawn from the top of the Refining column and cooled in the cooler and sent to storage as
Technical Alcohol. Both fermentation and distillation are operated with PLC computer
controls system. This will help in maintaining the parameters. Alcohol stripped whole
stillage is subjected to centrifugation to separate suspended fibrous mass and thin stillage.
This thin stillage is concentrated in multi-effect evaporation system, which is supplied with
steam. Part of thin stillage is recycled back to be used in the process as backset. Water
vapours coming out of evaporator is condensed and sent back to be used as recycle
condensate. Concentrated thin stillage in form of syrup is taken to the drying section where
it is mixed with the fibrous mass and subjected to drying in the decanter-dryer system to
produce DDGS. This also requires additional steam. The final moisture content of DDGS is
about 10%.
F. Molecular Sieve Technology for Ethanol Production
Molecular sieve technology works on the principle of pressure swing adsorption. Here water
is removed by adsorbing on surface of `molecular sieves' and then cyclically removing it
under different conditions (steaming). Molecular sieves are nothing but synthetic zeolites
typically 3Ao zeolites. Zeolites are synthetic crystalline alumino silicates. This material has
strong affinity for water. They adsorb water in cold condition and desorb water when heated.
This principle is used to dehydrate ethanol. The crystalline structure of zeolites is complex
and gives this material the ability to adsorb or reject material based on molecular sizes. Water
molecule can enter the sieve and be adsorbed, but larger alcohol molecule will not be retained
and will go through the bed. There can be two to three beds in parallel. Once a particular bed
is saturated with water, it is heated with steam so that adsorbed water is desorbed from the
bed. Till that time, other bed is used for dehydration.
G. DDGS Production
Alcohol stripped whole stillage is subjected to centrifugation to separate suspended fibrous
mass and thin stillage. This thin stillage is concentrated in multi-effect evaporation system,
which is supplied with steam. Part of thin stillage is recycled back to be used in the process
as backset. Water vapour’s coming out of evaporator is condensed and sent back to be used
as recycle condensate. Concentrated thin stillage in form of syrup is taken to the drying
section where it is mixed with the fibrous mass and subjected to drying in the decanter-dryer
14
system to produce DDGS. This also requires additional steam. The final moisture content of
DDGS is about 10 %. Quantity of DDGS produced has been envisaged under the proposed
project.
Figure 1.5 Mass Balance and Process Flow Chart for Existing 100 KLPD Molasses Distillery
Figure 1.6 Mass Balance and Process Flow Chart for Existing 100 KLPD Grain Distillery
15
Figure 1.7 Mass Balance and Process Flow Chart for Proposed 400 KLPD Grain Distillery
Figure 1.8 Mass Balance and Process Flow Chart for 700 KLPD Cane Syrup Distillery
16
1.6.4.4 Manufacturing Process for Co-generation Plant
Co-generation is broadly defined as the coincident generation of useful thermal energy and
electrical power from the same input fuel. Thus, cogeneration can allow the energy
consumers to lower their energy costs, through use of the energy normally wasted in
conventional systems as losses. Useful thermal energy could be in the form of hot gases, hot
liquids or steam; generally used for meeting the process and or heating requirements. When
the thermal energy is required in the form of steam, industries employ steam boilers for
raising the required steam at the required pressure and temperatures, suitable for the process.
Industry is having boilers of capacity 36, 35 & 39 TPH & working pressure 87 Kg/cm2 to
meet the requirement of steam for existing and proposed 110 TPH under expansion. A
portion of power generated in the turbo generators will meet the power requirements of the
co-generation plant auxiliary loads and sugar plant loads. After meeting the in-house
requirements, the plant can export a net power during cane crushing season and during off-
season, under normal operating conditions.
Table 1.13 Electricity Requirement Details
No. Description Existing (MW) Proposed (MW) Total (MW)
1 Distillery Unit 4.0 5.5 9.5
2 Co-gen Plant 3.0 4.0 7.0
Grant Total 7.0 9.5 16.5
Table 1.14 Distribution of Electricity Generated from Co-gen Plant

No. Description Existing (MW) After Expansion (MW)
1 In-house 7 16.5
2 Grid 6 13.5
Grant Total 13 30
1.7 SOURCES OF POLLUTION AND THEIR CONTROL

Sources of pollution from existing and proposed operations in the HDPL complex shall be
mainly manufacturing operations and processes in the industry, boiler and stand by D.G. etc.
Detailed identification and quantification of impacts, due to above sources, are separated
under various heads. They are – (1) Water Pollution, (2) Air Pollution, (3) Noise Pollution,
(4) Hazardous Wastes, (5) Solid Waste, and (6) Land Pollution.
1.7.1 Water Pollution (WP)
Requirement for fresh water on site will be met from Krishna River. Water lifting permission
has been taken from Irrigation Department; Govt. of Karnataka. Same is attached at
Annexure - V for reference. Details of water consumption for existing, after expansion of
Distillery are presented in following tables.
17
Table 1.15 Water Consumption of Existing Molasses & Grain Distillery Operations
No. Description Quantity (M3/ Day)

Existing Molasses Existing Grain Existing Molasses / Total (300 KLPD
(100 KLPD) (100 KLPD) Grain(100 KLPD) Worst Scenario)
Status on site Implemented & in Implemented & Approved; yet to be --
operation in operation implemented
1 Domestic # # # #
5 15 5 25
2 Industrial
Process 800 (♣760+#40) 610 800 (♣760+#40) 2210
(*460 + €150) (♣1520 + *460 +
€
150+#80)
300 (♣175+#125) 900 (♣175+#725)
Cooling # #
300 300
Boiler Feed # # # #
80 85 80 245
DM Plant # # # #
20 20 20 60
Lab & Wash # # # #
5 5 5 15
# # # #
Ash Quench 2 2 2 6
Industrial 1207 1022 1207 3436
Total (♣760+#447) (*460 + €150 + (♣760+#447) (♣1695 + *460 + €150
63% Rec.
♣
175 +#237) 63% Rec. + #1131)
77% Rec. 67% Rec.
Ω Ω
3 Green Belt 125 -- -- 125
Grand Total 1337 1037 1212 3586
(1+2) (♣760+ (*460 + €150 + (♣760+ #452) (♣1695+*460+
♣ #
Ω
125+#452) 175 + 252) €
150+Ω125+#1156)
Fresh Water; 4.4 KL/KL 2.3 KL/KL 4.4 KL/KL 3.7 KL/KL
Norm :10 KL/KL
Note : #-Fresh water from Krishna River, ♣ - CPU Treated Effluent, € - Recycled Thin Slop, * - Recycled Lees
& Condensate, Ω- Harvested Rainwater
Table 1.16 Water Consumption for Expansion w.r.t. Grain & Cane Syrup Distillery
Quantity (M3 / Day)
No. Description Grain Distillery Cane Syrup
(400 KLPD) (700 KLPD)
# #
1 Domestic 10 8
2 Industrial
Process 2468 (*1863 + €605) 3580 (♣2205+$1375)
Cooling 1200 (♣500 + #700) 2100 (♣505+#1595)
# #
Boiler Feed 265 100
# #
DM Plant 55 20
# #
Lab & Washing 5 10
Ω Ω
Ash Quenching 3 3
Industrial Total 3996 5813
(*1863 + €605 + ♣500 + Ω3 +#1025) (♣2710+$1375+ Ω3+#1725)
74% Rec. 70% Rec.
Ω --
3 Green Belt 62
Grand Total (1+2) 4068 5821
(*1863 + €605+♣500+ Ω65+#1035) (♣2710+$1375+ Ω3+ #1733)
Fresh Water;
2.5 KL/KL 2.4 KL/KL
Norm :10 KL/KL
Note : #-Fresh water from Krishna River, ♣ - CPU Treated Effluent, € - Recycled Thin Slop, * - Recycled Lees
& Condensate, $ - Spent wash Recycle, Ω- Harvested Rainwater.
18
Total water required for existing Distillery considering 100 KLPD Grain & 200 KLPD
Molasses operations (worst scenario) is 3586 CMD. From this, 2430 is recycled water met
from treated CPU effluent, lees, condensate & harvested rainwater. Fresh water requirement
is 1156 CMD met from Krishna River.
Total water required after expansion of Distillery unit considering 400 KLPD Grain & 700
KLPD cane syrup operations (worst scenario) will be 9889 CMD. From this, 6731 will be
recycled water met from treated CPU effluent, lees, condensate & harvested rainwater. Fresh
water requirement will be 3158 CMD met from Krishna River.
1.7.1.1 Fresh Water Adequacy
 For existing Molasses/ Grain Distillery, total fresh water requirement in a season of 330
Days is – 1156 CMD X 330 Days = 3,81,480 M3/Season
 For proposed Grain Distillery Operations of 400 KLPD, total fresh water requirement in
a season of 330 Days shall be – 1035 CMD X 330 Days = 3,41,550 M3/Season
 For proposed Cane Syrup Distillery Operations of 700 KLPD, total fresh water
requirement in a season of 180 Days shall be – 1733 CMD X 180 Days = 3,11,940
M3/Season
Hence, total maximum water requirement for worst case operations (existing Molasses/
Grain Distillery + proposed Grain Distillery Operations) shall be –
3,81,480 + 3,41,550 = 7,23,030 M3/Season
The permission granted to HDPL by Irrigation Department; Govt. of Karnataka for lifting
fresh water from Krishna River is 5,38,020 M3/Season (1630 M3/Day). An application for
additional water requirement has been made to Irrigation Department; Govt. of Karnataka
for lifting fresh water from Krishna River. Water Lifting Permission & application of
renewal as well as additional water requirement is enclosed at Annexure-V.
1.7.1.2 Effluent Generation

Total effluent will be generated from the various operations & processes from existing
activities as well as expansion project. Details of the same are presented in following tables-
Table 1.17 Effluent Generation from existing 100 KLPD Molasses & Grain based Distillery
No Process Existing Molasses Existing Grain Disposal Method
(100 KLPD) (100 KLPD)
1 Domestic 4 13 Existing: Septic tanks followed by
soak pits
Proposed: STP
2 Industrial
Process Raw Spwash- 750 Lees - 232 Spentwash from molasses distillery
Conc. Spwash – 164 concentrated & incinerated.
Spent lees – 192 Condensate - 300 Other Effluent from molasses &
Condensate - 586 grain distillery - Treatment in CPU
Cooling b/d 25 25 of 1260 CMD capacity & 100%
Boiler b/d 15 20 Recycled
DM Backwash 20 20
Lab, Wash 5 5
Conc. Spwash-175 Lees-232
Total
Other effluent- 843 Other effluent- 194
3 Bottle Washing -- 50
19
Table 1.18 Effluent Generation from Proposed Grain & Cane Syrup based Distillery Unit
No Process Proposed Grain Proposed Cane Syrup Disposal Method

(400 KLPD) (700 KLPD)
1 Domestic 8 6 Proposed STP
2 Industrial
Process Lees-930 Raw Sp wash- 3445 Spentwash from cane syrup
Conc. Sp wash - 421 distillery concentrated &
incinerated.
Condensate- 1203 Spent lees - 1100 Other Effluent from grain
Condensate - 1649 & cane syrup distillery -
Cooling b/d 120 210 Treatment in CPU of 3500
Boiler b/d 53 20 CMD capacity & 100%
DM 55 20 Recycled
Backwash
Lab, Wash 5 10
Other effluent- 233 Conc. Spwash - 421
Total Other effluent- 260
1.7.1.3 Domestic Effluent
Domestic effluent generated from existing as well as expansion project will be 21 CMD,
same will be treated in proposed Sewage treatment Plant (STP) of 25 CMD capacity. Treated
effluent from STP will be used for green belt development in own factory premises.
1.7.1.4 Industrial Effluent
Raw spentwash generated from existing 100 KLPD molasses distillery is 750 M3/D, same is
concentrated in Multiple Effect Evaporator (MEE) and the conc. spentwash @ 164 M 3/D
(1.6 KL/KL of alcohol) is blended with coal and burnt in incineration boiler.
Other effluent generated @ 843 CMD in the form of spent lees, MEE condensate, boiler &
cooling blowdowns, DM backwash etc. treated in existing distillery CPU of 1260 M 3/D
capacity; treated effluent is used for cooling tower make up.
Lees generated from existing 100 KLPD grain distillery operations @232 M 3/D along with
condensate @ 300 M3/D is used in process operations. Other effluent @ 120 M3/D generated
in the form of boiler & cooling blowdowns, DM backwash, lab-wash & bottle wash effluent
etc. treated in existing distillery CPU of 1260 M3/D capacity; treated effluent is used for
cooling tower make up.
Wet cake i.e. Distillers Wet Grains with Solubles (DWGS-70% moisture) @ 128 T/D
generated after decantation of spentwash, sold to farmers as cattle feed. This wet cake further
dried in dryers result in to loss of moisture thereby forming Distillers Dry Grains with
Solubles (DDGS- 10% moisture) 80 T/D. This DDGS has more shelf life & sold as cattle
feed.
From proposed 400 KLPD grain distillery unit Lees generated @930 M 3/D along with
condensate @ 1203 M3/D will be used in process operations. Other effluent @ 285 M3/D
will be generated in the form of boiler & cooling blowdowns, DM backwash, lab-wash &
bottle wash effluent etc. will be treated in proposed distillery CPU of 3500 M 3/D capacity;
20
treated effluent will be used for cooling tower make up. Thereby, achieving Zero Liquid
Discharge (ZLD) of effluent. ZLD plan is enclosed at Annexure-VI.
DWGS generated @ 510 T/D will be sold to farmers as cattle feed. This wet cake further
dried in dryers result in to loss of moisture thereby forming DDGS @ 320 T/D will also sold
as cattle feed.
Raw spentwash generated from 700 KLPD cane syrup operations will be @ 3445 M3/D.
From this about 1375 M3/D will be used for syrup dilution & 2070 M3/D will be concentrated
in MEE. Concentrated spentwash @ 421 M3/D (0.6 KL/KL of alcohol) will be blended with
coal and burnt in incineration boiler.
Flow chart of existing & proposed CPU is presented at figure –1.9 & 1.10.
Figure 1.9 Flow Chart of Existing Distillery CPU (Cap.: 1260 M3/Day)
21
Figure 1.10 Flow Chart of Proposed Distillery CPU (Cap.: 3500 M3/Day)
Figure 1.11 Flow Chart of STP (Capacity 25 KLD)
22
Figure 1.12 Process Technology of STP
Figure 1.13 Existing Distillery CPU
23
Table 1.19 Spent wash Characteristics
No. Parameter Raw Spent wash Concentrated Spent wash

1 pH 3.9 – 4.5 4.0 –5.0
2 Total Solids (mg/l) 1,00,000- 1,20,000 5,10,000 - 5,65,000
3 SS (mg/l) 20,000 - 25,000 85,000 -1,00,000
4 TDS (mg/l) 80,000 - 95,000 4,25,000-4,65,000
5 BOD (mg/l) 60,000 - 80,000 3,35,000 - 3,80,000
6 COD (mg/l) 1,20,000-1,40,000 6,25,000- 6,50,000
Table 1.20 DDGS specifications

No. Description Quantity / Percentage (% w/w)
1 Moisture Content 10
2 Dry matter solids 90
3 Proteins 36-38
4 Fats & oils 6-8
5 Inorganic ash 3-5
6 Other organics 39-43
Table 1.21 Details of MEE

No. Description Details
Existing Proposed
1 Make Thomsa / Excel Thomsa / Excel
2 Type Falling Film evaporation system Falling Film/ Forced Evaporation
evaporation system
3 Capacity 2000 M3/D 2000 M3/D
4 Raw Sp. Wash 1600 KL/D 1600 KL/D
5 Efficiency 90% 90%
Raw spent wash tank is designed as per CPCB norms wherein HDPE layer of 500 micron
thickness & RCC lining is provided to avoid seepages & ground water contamination. 2 no.
of Piezometers are installed around spent wash storage tank and distillery premises & 2 no.
of Piezometers will be installed under expansion.
A PLC based operative system is installed in distillery wherein raw spent wash from
distillation section is automatically transferred to MEE in closed circuit. For storage of
concentrated spentwash generated from existing distillery unit Closed SS tank of 80KL
capacity is provided. Under expansion, one tank of 100 KL capacity will be provided on site.
24
Figure 1.14 MEE Installed At HDPL Site
1.7.2 Air Pollution

Air Pollution can be defined as the presence in the outdoor atmosphere, of one or more air
contaminants (i.e. dust, fumes, gas, mist, odour, smoke or vapour) in sufficient quantities, of
such characteristics and of such duration so as to threaten or to be injurious to human, plant
or animal life or to property, or which reasonably interferes with the comfortable enjoyment
of life or property. Details of existing and proposed sources of air pollution & control
equipment are presented in following Table.
Table 1.22 Details of Boiler and Stack in HDPL
Existing Expansion
No Description Boilers DG Set Boiler DG Set
B1 B2 B3 1 B4 2
Status on site In operation In Approved; In Proposed Proposed
operation yet to be operation
implemented
Capacity 750 750
1 35 TPH 36TPH 39 TPH 110 TPH
KVA KVA
Fuel type Coal/ Coal/
Coal/
2 Bagasse + Bagasse Bagasse + Diesel Diesel
Bagasse
Sp. wash Sp. wash
Fuel Qty., T/D 95/ 190 230/450 +
3 380 30 Lit/Hr 575/1200 30 Lit/Hr
+221 540
4 MOC RCC RCC RCC MS RCC MS
5 Shape Round Round Round Round Round Round
6 Height, M 72 62 50 6 (ARL) 90 6 (ARL)
7 Diameter, M 3 1.5 1.5 -- 3.5 --
APC
8 ESP ESP ESP -- ESP --
equipment
25
Stack Height Calculation for proposed boiler is enclosed at Annexure- VII.
Table 1.23 Characteristics of Fuels

Fuel
No Bagasse Spentwash Coal Diesel
Description
1 Calorific value, Kcal/Kg 2,000- 2,200 1500-2000 4000- 5500 10,200
2 Ash content 2-3% 18% 13% 0.1%
3 Sulphur content 0.05% 0.65% 0.5% 1.0%
Table 1.24 Fuel Storage Details

No. Fuel Storage Storage Capacity Handling
1 Conc. Spentwash 5 Days 100 M3 By Pipeline
2 Bagasse 10 Days 500 T Belt Conveyor
3 Coal 15 Days 50 T --
Table 1.25 Details of ESPs for Boilers

No Description Existing - Boilers Proposed - Boiler
1 ESP Make Thermax Thermax Thermax
2 Boiler Capacity 35 & 36 39 TPH (yet to be 110 TPH
TPH implemented)
3 Fuel Bagasse Coal & Sp. wash Coal / Bagasse
4 Operating Temp. (mg/Nm3) 140 deg. C 180 deg. C 180 deg. C
5 Inlet Dust Load (Gm/Nm3) 06 20 20
6 Outlet Emission (mg/Nm3) 50 100 50
7 Removal Efficiency 95 94 95
Figure 1.15 Existing Stack & ESP of Boilers
26
1.7.2.1 Fugitive Emissions
Fugitive emission under existing and expansion activities of sugar factory shall be mainly
the dust emissions. The sources of same are mill house, sugar bagging, bagasse yard,
pressmud yard, internal kuccha roads, bagasse conveyor; feeding section and ash storage
yard in co-gen plant, improper function of APC equipment etc. The trouble with dust in work
zone and ambient atmospheres shall be controlled by certain dedicated measures. An action
plan has been prepared in the industry that includes – proper exhaust and ventilation
arrangements, monitoring of proper of working of pollution control equipment, proper
handling; storage and disposal of dust collected, use of PPEs for staff and workers,
augmentation of existing green belt with adequate density and type to control and attenuate
dust transfer in the premises, provision of properly surfaced internal roads and work premises
(tarred and concrete).
1.7.2.2 Process Emissions
The CO2 generation shall take place in fermenter of the distillery. After expansion, CO2 to
the tune of 315 T/D will be released from 700 KLPD distillery operations. Consequently,
CO2 is evolved as emission of the bio-chemical reaction. CO2 has been labeled as one of the
major gases responsible for the green-house effect, its release in the atmosphere has to be
properly controlled. To curb this process emission CO2 will be bottled and supplied to
manufacturers of beverages /secondary uses as done in existing unit.
Figure 1.16 Existing CO2 Bottling Plant
1.7.3 Solid Waste
Solid wastes from the industries are categorized as hazardous and non-hazardous. Waste that
pose a substantial danger immediately or over a period of time to human, plant, or animal
life are classified as hazardous wastes. Non-hazardous waste is defined as the waste that
contributes no damage to human or animal life. However, it only adds to the quantity of
waste.
27
Table 1.26 Solid Waste Generation & Disposal
No. Industrial Type Quantity (T/D) Disposal

Unit Existing After Expansion
1 Distillery Boiler Ash 120 300 Brick manufacturing
Yeast Sludge 25 125 Burnt in
CPU Sludge 2 5 Incineration Boiler
The ash generated shall be collected separately and taken to ash silo system. Water sprinkling
arrangement shall be made to avoid suspension of fly ash into the air.
1.7.4 Hazardous Wastes
Information about hazardous wastes being generated as well as that to be generated from
proposed activities and their disposal methods is presented in following table.
Table 1.27 Details of Hazardous Waste
Quantity (T/Yr.)
Industrial
No. Category After Disposal
Unit Existing
Expansion
Spent Oil – Cat.5.1 0.4 1.0 Forwarded to
Contaminated Cotton authorized re-
Distillery Unit 0.3 0.5
1 Waste- Cat. 33.3 processor
Empty Containers- 90 Nos. / 200 Nos. / Forwarded to
Cat. 33.1 Yr. Yr. authorized re-seller
1.7.5 Noise Pollution
Noise is normally defined as objectionable or unwanted sound, which is without agreeable

quality and essentially non-euphonious. The concern on noise depends upon the noise level
near the source, on the work environment and near the residential zone. Earlier, noise was
summarized to be exclusively an occupational problem. But, since the effects are found also
on people who are not directly involved, it has acquired wider dimension. Hence it is
necessary to know the noise levels near the sources as well as near the residential colonies.
1.7.5.1 Sources of Noise Pollution
In distillery; noise generating sources generally are the boiler house, turbine rooms,
distillation section etc. The expected noise levels in these sections will be in the range of 60
to 65 dB(A). All preventive measures such as regular operation & maintenance of pumps,
motors, and compressors will be carried out and enclosures will be provided to abate noise
levels at source.
Adequate noise abatement measures like silencer will be implemented in this section.
Moreover, enclosures to the machinery will be provided wherever possible. It is predicted
from an experience elsewhere that the magnitude of noise levels, from various sources, to
the human habitation at a distance of 0.5 Km will be around 12 dB(A). Therefore, there will
be no any significant change in the background noise levels in the premises of the industrial
unit. Already a green belt has been provided in and around the Industry. The same will be
further augmented adequately and properly so that it will further attenuate the noise levels.
The noise will also be created by movement of trucks/ tractor trolleys and other vehicles for
material transportation. However, this will not be of a continuous nature and will not have
28
much impact on the work environment of the project site. Insulation helps considerably in
limiting noise levels. The workers entering the plant shall be protected by earmuffs, which
will give the reduction of about 30 dB(A).
1.7.6 Odour Pollution
There are number of odour sources, which include molasses handling and storage, bacterial
growth in interconnecting pipes & unattended drains. The measures shall be adopted under
proposed expansion unit for controlling the same are proper housekeeping, sludge
management in biological units, steaming of major pipe lines, regular use of bleaching
powder in the drains, efficient handling, prompt.
Under expansion of distillery project also, spent wash shall be carried through closed pipeline
for concentration in MEE. Hence, odour nuisance due to spent wash storage shall be entirely
eliminated. To abate the odour nuisance, the HDPL has a concrete planning which includes
following steps and actions-
1. It is proposed to provide covered fermentation and tapping of CO 2 gas.
2. Collection of waste yeast sludge from fermentation section in a closed system and its
immediate and proper disposal.
3. Reduced volume of effluents (spent wash, spent lees) by adopting strategic approaches
such as use of the effluents back in process under Reduce-Reuse-Recycle planning.
4. Closed and online system for carrying spent wash to the treatment units, MEE etc.
5. Suitable plantation of fragrant species in and around the treatment units, which can
minimize undesirable smells.
6. Adoption of GMPs (Good Management Practices).
7. Arranging awareness and training camps for workers.
8. Use of PPEs like masks at odour prone areas.
1.7.7 Land Pollution
Land pollution may take place due to use of untreated effluent for gardening / irrigation
purpose. Fly ash, if gets deposited and /or disposed on land in haphazard manner will lead to
land pollution. Under expansion, certain steps shall be taken and many advanced
technologies shall be adopted installation of high pressure and capacity boiler to be provided
with ESP as APC equipment, adoption of automatic and continuous pollution monitoring
equipment etc. Appropriate and adequate management practices including good
housekeeping and periodic monitoring of various attributes contributing to dust shall
considerably curb these types of emissions.
1.7.8 Budgetary Allocation by Industry towards Environment Protection
The capital as well as O & M cost towards environmental aspects under the existing as well
as proposed expansion activities will be as follows –
29
Table 1.28 Capital as well as O & M Cost (Existing & Proposed)
Cost Component (Rs. Lakhs)

No. Description
Capital Annual O & M
A Existing
1 Air Pollution Control: (ESP- 2 Nos.), Stacks (2 Nos. of height 72 1000 200
M & 62 M) & OCMS, CO2 Bottling Plant
2 Water Pollution Control: CPU, MEE, Spentwash Storage Tank 2000 500
& OCMS
3 Noise Pollution Control 50 10
4 Environmental Monitoring & Management 50 10
5 Occupational Health & Safety 50 10
6 Green Belt Development & Rain Water Harvesting 100 40
Total (20% of Capital Investment of Rs. 165 Cr) 3250 770
B After Expansion
1 Air Pollution Control: 39 TPH incineration Boiler & ESP- 2 Nos. 1000 400
(Incineration Boiler & 110 TPH Boiler), Stacks of height 50 &
90 M) & OCMS
2 Water Pollution Control: CPU (3500 CMD) & STP (25 CMD) 650 150
3 Noise Pollution Control 50 10
4 Environmental Monitoring & Management 50 20
5 Occupational Health & Safety 50 10
6 Green Belt Augmentation & Rain Water Harvesting 150 50
Total (4% of Capital Investment of Rs. 450 Cr) 1950 640
Grand Total (A + B) 5200 1410
1.8 GREEN BELT DEVELOPMENT PLAN
The major impacts due to proposed expansion activities by HDPL have been described
above. Impact due to noise generation and particulate emission can be abated by plantation
of green belt. Accordingly, a comprehensive green belt has already been developed in HDPL
campus. Further, under proposed expansion augmentation of existing green belt shall be done
in phase wise manner. Native and fast-growing species shall be selected for green belt
development.
1.8.1 Area Calculation for Green Belt Plan
Table 1.29 Area Details
No. List of area Existing Expansion Total

1 Total Plot Area 1,56,164.0
2 Total Built up Area
Distillery, Cogen & 44,496.0 31,045.0 75,541.0
Bottling Unit
Total built up Area
3 Parking Area 13,023.0 -- 13,023.0
4 Area Under Road 13,338.0 7,000.0 20,338.0
5 Green Belt Area 27,036.0 24,498.0 51,534.0
(on lease land)
17% 16% 33%
Total Open Area 58,271.0 -- 20,226.0
30
1.8.2 Existing Tree Plantation
Total plot area of the industry is 15.61 Ha. As per MoEFCC norms, green belt should be
developed on 33% of the total plot area of industry. Under existing set up 2.7 Ha area is
under green belt which is 17% of total plot area. Thereunder, 1755 no. of trees are planted in
phase wise manner. To develop additional 2.44 Ha (16%) land area under green belt; industry
has taken land on lease.
1.8.3 Proposed Tree Plantation
HDPL will augment the densification of existing green belt. Further, additional green belt
will be developed on 24,498 Sq. M. area. Thereunder, about 11,090 trees shall be planted.
Refer Annexure-VIII for green belt development plan. A comprehensive ‘Green Belt
Development' programme will be implemented in a phase wise manner under proposed
activities, salient features of which are as follows –
1. Tree plantation at different tiers to suit existing topography

2. Avenue plantation along the roads and shelterbelt plantation along the peripheral fence
of the plots
3. Mass Plantation in certain pockets in the HDPL. campus
4. Plantation of peculiar tree species serving typical purposes such as noise attenuation and
dust suppression at selected premises
5. Lawns and landscaped gardens in the campus
6. To arrest dust and to attenuate noise, plantation of certain species like
Mangiferaindica(Mango), Sesbania grandiflora (Shewarie) Derris indica (Karanj),
Terminalia catappa (Indian Almond Tree), Polyalthialongi folia (Ashok) etc. shall be
done.
1.8.4 Criteria for Green Belt Development

Emission of SPM, SO2 is the main criteria for consideration of green belt development.
Plantation under green belt is provided to abate effects of the above emissions. Moreover,
there will also be control on noise from the industry to surrounding localities as considerable
attenuation will occur due to the barrier of trees provided in the green belt.
Preparation for Plantation:
 Take pits of 2X2X2 ft. for good soil strata while 3X3X3 ft. for poor soils or murum strata.
 Expose them to direct sun for 15 days
 Fill the pits as per availability of site soil-
o In case of shortage of good quality site soil: site soil (35%) + good fertile soil (35%)
+ good composted cow dung (30%) + Neem cake (200 gm)
o In case of good quality site soil: site soil (80%) + good composted cow dung (20%)
+ Neem cake (200gm) + leaf litter and grass or agri residue.
 Plant appropriate sapling after rain starts
 Start watering after rains
 Make shade for saplings when temperatures rise, generally after February or March
depending upon local climate and condition of plants. This can be managed with bamboo
sticks and locally available grass.
31
1.9 RAIN WATER HARVESTING
RWH could be of two types namely -
1. Harvesting from ground
2. Harvesting from rooftops.
 Average annual rainfall in the area = 550 mm = 0.55 M
 RWH = Area x Rainfall Depth x Run off Coefficient
Area consider for RWH is presented at following Table -
Table 1.30 Area Taken for RWH

RWH
Area Runoff Factors Average Annual
No. Description Quantity
(Sq.M.) considered Rain Fall (M)
(M3)
1 Roof Top Harvesting
i Rooftop Area 10,000 0.8 0.55 4328
Total Rooftop Harvesting 4328
2 Surface Water Harvesting
i Green Belt Area 27,036 0.3 0.55 4461
ii Area under Roads 20,338 0.5 0.55 5593
iii Parking Area 13,023 0.5 0.55 3581
iv Open Space 20,226 0.3 0.55 3337
Total Surface Water Harvesting 16,972
Hence, the total water becoming available after rooftop and land harvesting will be
Rooftop Harvesting + Surface Harvesting = Total RWH
4328 + 16,972 = 21,300 M3
= 21 ML
Thus, about 21,300 M3 of rainwater could become available during every season from the
RWH operations.
Two Tanks of capacity of 10,000 M3 & 1500 M3 are provided on site.
Used for Green Belt, Fire Hydrant, Washing & Flushing.
32
Figure 1.17 Existing Green Belt
33
Figure 1.18 Compliance done at HDPL w.r.t. Existing Unit
34
35
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53
F. No. J-11011/143/2014-IA II(I)
Government of India
Ministry of Environment, Forest & Climate Change
Impact Assessment Division
***
Indira Paryavaran Bhawan,
Jor Bagh Road, New Delhi-110 003
Dated: 27th June, 2022

To,
M/s. Hermes Distillery Pvt Ltd,
Village Yadrav, Taluka Raibag,
District Belagavi (Karnataka).
Sub: Expansion of Distillery from 100 KLPD to 300 KLPD by M/s

Hermes Distillery Pvt Ltd at Gat No. 96/5A, 96/5B, 96/5C,
96/3A/2, 98/1B/3, 98/1B14, 98/1B/5, Village Yadrav,
Taluka Raibag, District Belagavi (Karnataka)- Amendment in
Environmental Clearance regarding.
Sir,
This refers to your online proposal No. IA/KA/IND2/256555/2022
dated 12th March, 2022 for amendment in the environmental clearance
to the above mentioned project.
2. The Ministry of Environment, Forest and Climate Change has

considered the above proposal for amendment in the environmental
clearance granted by the Ministry vide letter No. J-11011/143/2014-IA
II(I) dated 26th February, 2019 for the project Expansion of Distillery from
100 KLPD to 300 KLPD by M/s Hermes Distillery Pvt Ltd at Gat No. 96/5A,
96/5B, 96/5C, 96/3A/2, 98/1B/3, 98/1B14, 98/1B/5, Village Yadrav,
Taluka Raibag, District Belagavi (Karnataka).
3. The project proponent has requested for amendment in the EC

with the details are as under.
Para
S of EC
r. issue Details as per the To be Revised /
N d by EC Read as
o. MoEF
&CC
1 Page “expansion of the distillery from the “expansion of the distillery from the
No. present capacity of 100 KLPD present capacity of 100 KLPD
1; (molasses based) to 300 KLPD (200 (molasses based) to 300 KLPD (100
In KLPD Molasses & 100 KLPD Grain KLPD Molasses, 100 KLPD Grain &
Line 2 based)” 100 KLPD Molasses / Grain based)”
of
para
2.0
Page 1 of 3
54
Para
S of EC
r. issue Details as per the To be Revised /
N d by EC Read as
o. MoEF
&CC
2. Page Details of product are as under- Details of product are as under-
No.
1, Product Capacity Product Capacity
Para Exis Prop To Exis Prop To
3.0 ting osed tal ting osed tal
Molasses 100 100 20 Molasses 100 -- 10
based distillery KLP KLPD 0 distillery KLP 0
(RS/ENA/Etha D KL (RS/ENA/Etha D KL
nol/Alcohol) PD nol/Alcohol) PD
Grain based -- 100 10 Grain based -- 100 10
distillery KLPD 0 distillery KLPD 0
KL KL
PD PD
Cogen Power 13 -- 13 Molasses/ -- 100 10
MW M Grain distillery KLPD 0
W (RS/ENA/Etha KL
IMFL Bottling 86.4 129.6 21 nol/Alcohol) PD
Plant KLP KLPD 6 Cogen Power 13 -- 13
D KL MW M
PD W
IMFL Bottling 86.4 129. 21
Plant KLP 6 6
D KLPD KL
PD
3. Page Spent wash will be treated through Spent wash from molasses distillery
No. multi effect evaporators (MEE) will be treated through multi effect
2, followed by incineration in boiler. evaporators (MEE) followed by
Para6 incineration in boiler.
.0,
After Lees from grain distillery will be
line 6 recycled in process. Thick Slop to be
sent to Dryer for formation of
DWGS & DDGS to be sold as Cattle
Feed
4. The proposal was appraised by the Expert Appraisal Committee

(Industry-2) in its 06th meeting held on 19th May, 2022 and EAC
recommended the amendments in the condition of environmental clearance
dated 26th February, 2019, as proposed by the project proponent in para 3
above, with all other terms and conditions remain unchanged subject to the
following additional specific conditions:
i. Prescribed norms for particulate emissions from boiler’s stack shall

be 50 mg/Nm3.
ii. Greenbelt shall be developed in 33% area and it shall be completed
in upcoming monsoon (i.e. before 31.08.2022) @ 2500 trees per
hectares. Indigenous species shall be grown after consultation from
Page 2 of 3
55
State Forest Department and as per CPCB guidelines.
iii. The project proponent will treat and reuse the treated water within
the factory and no waste or treated water shall be discharged
outside the premises.
iv. Continuous Emission Monitoring System for PM, SO2, NOx shall be
installed to meet prescribed norms for all emissions and connect to
CPCB/SPCB servers for continuous transmission.
5. Based on recommendations of the EAC, the Ministry of Environment, Forest

and Climate Change hereby accords approval to the proposed amendments to the
environmental clearance letter dated 26th February, 2019 as stated in para 4
above, for the project titled expansion of Distillery from 100 KLPD to 300
KLPD by M/s Hermes Distillery Pvt Ltd at Gat No. 96/5A, 96/5B, 96/5C,
96/3A/2, 98/1B/3, 98/1B14, 98/1B/5, Village Yadrav, Taluka Raibag,
District Belagavi (Karnataka
6. This issues with approval of the competent authority.
(A. N. Singh)
Scientist-'E'
Copy to: -
1. The Secretary, Department of Forest, Environment & Ecology,
Government of Karnataka, Room No. 708, Gate 2, Multi Storey
Building, Dr. Ambedkar Veedhi, Bangalore - 1
2. The Regional Officer, Ministry of Env., Forest and Climate Change,
Integrated Regional Office, Kendriya Sadan, 4th Floor, E&F Wings,
17th Main Road, Koramangala II Block, Bangalore - 34
3. The Member Secretary, Central Pollution Control Board, Parivesh
Bhawan, CBD-cum-Office Complex East Arjun Nagar, Delhi - 32
4. The Member Secretary, Karnataka State Pollution Control Board,
Parisara Bhavan, #49, 4th& 5th Floor, Church Street, Bangalore -1
5. Monitoring Cell, Ministry of Environment, Forest and Climate Change,
Indira Paryavaran Bhawan, Jor Bagh Road, New Delhi
6. The District Collector, District Belagavi, Karnataka
7. Guard File/Monitoring File/Parivesh portal/Record File
(A.N. Singh)
Scientist-'E'
E-mail: aditya.narayan@nic.in
Tel. No. 11-24642176
Page 3 of 3
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HDPL Land NA
Documents
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Annexure-II
Letter of Intent From
Shivshakti Sugars Ltd. (SSL)
w.r.t. Sale of Land to HDPL, 7/12
Extracts & Land NA Documents
(S. No. 95/2, 95/3, 99/1, 99/2, 99/3, 98/1B/1 & 99/4)
95
96
7/12 Extracts of SSL Land
(S. No. 95/2, 95/3, 99/1, 99/2, 99/3, 98/1B/1
& 99/4)
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Land NA Documents
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Khasra Undertaking
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Additional Land Taken on
Lease For Green Belt
Development
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Consent F
Consent No. AW-328290

Valid upto: 30/06/2026
Location:
Address: 96/5A, 96/5B, 96/5C, 96/3A/2, 98/1B/3, 98/1B/4, 98/1B/5, 98/1C, Yadravi village Belgavi District
519317
Not In I.A, Yadravi ,
Taluk: Raibhag , District: Chikkodi
Page-1 e_outwardno45832--24/11/2021 Printed from XGN

224
Consent For Operation
(CFO-Air,Water)

225
(CFO-Air,Water)

226
C


227
(CFO-Air,Water)

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237
A ZLD Plan for
Hermes Distillery Pvt. Ltd. (HDPL)
A/P: Yadrav, Tal.: Raibag, Dist.: Belgaum, Karnataka State
A. Mass Balance for Distillery

Figure 1 Mass Balance and Process Flow Chart for Existing 100 KLPD Molasses Distillery
Figure 2 Mass Balance and Process Flow Chart for Existing 100 KLPD Grain Distillery
238
Figure 3 Mass Balance and Process Flow Chart for Proposed 400 KLPD Grain Distillery
Figure 4 Mass Balance and Process Flow Chart for 700 KLPD Sugarcane Juice/ Syrup Distillery
239
B. Water Consumption:
Table 1 Water Consumption of Existing Molasses & Grain Distillery Operations
Quantity (M3/day)
Existing Grain Existing Molasses / Total
No. Description Existing Molasses
(100 KLPD) Grain (300 KLPD –
(100 KLPD)
(100 KLPD) Worst Scenario)
Status on site Implemented & in Implemented & in Approved; yet to be --
operation operation implemented
1 Domestic # # # #
5 15 5 25
2 Industrial
Process ♣ 610 ♣ 2210
800 800
(*460 + €150) ♣
( 1600 + *460+€150)
Cooling 300 (♣30+#270) 300 (♣238+#62) 300 (♣30+#270) 900 (♣298+#602)
Boiler Feed # # # #
85 86 85 256
DM Plant # # # #
20 17 20 57
Lab, washing # # # #
5 5 5 15
Ω Ω Ω Ω
Ash Quenching 2 2 2 6
Industrial Total 1212 1020 1212 3444
(♣830+ Ω2+#380) (*460 + €150+♣238+ (♣830+ Ω2+#380) (♣1898+*460+
Ω
69% Rec. 2+#170) 69% Rec. €
150+Ω6+#930)
73% Rec. 73% Rec.
4 Ω Ω
Green Belt & 125 -- -- 125
Gardening
Grand Total (1+2) 1342 1035 1217 3594
(♣830+ Ω127+#385) (*460 + €150+♣238+ (♣830+ Ω2+#385) (♣1898+*460+
Ω
2+#185) €
150+Ω131+#955)
Fresh Water; Norm :10
3.8 KL/KL 1.7 KL/KL 2.4 KL/KL 3.1 KL/KL
KL/KL
Note : #-Fresh water from Krishna River, ♣ - CPU Treated Effluent, € - Recycled Thin Slop, * - Recycled Lees &
Condensate, Ω- Harvested Rainwater
Other effluent generated from existing operations will be @ 2101 CMD; is treated in CPU. Total
treated effluent available @ 1898 CMD (after loss) reused for-
1. Process- Fermentation & Dilution= 1600 CMD

2. Cooling Make up = 298 CMD
Thus, the existing Distillery becomes a Total ZLD Project.
240
Table 2 Water Consumption for Expansion of Grain & Cane Juice Distillery Unit
Quantity (M3/day)
No. Description Grain Distillery Cane Juice
(400 KLPD) (700 KLPD)
# #
1 Domestic 10 8
2 Industrial
♣
Process 2468 3580
(*1863 + €605)
Cooling 1200 (♣500+#700) 2100 (♣115+#1985)
# #
Boiler Feed 265 100
# #
DM Plant 55 20
# #
Lab, washing 5 10
Ω Ω
Ash Quenching 3 3
Industrial Total 3996 5813 (♣3695+ Ω3+#2115)
(*1863 + €605+♣500+ Ω3+#1025) 64% Rec.
74% Rec.
Ω --
3 Green Belt & Gardening 62
Grand Total (1+2) 4068 5821 ( 3695+ Ω3+#2123)
♣
(*1863 + €605+♣500+
Ω
65+#1035)
Fresh Water; Norm :10 KL/KL 2.5 KL/KL 3 KL/KL
Note : #-Fresh water from Krishna River, ♣ - CPU Treated Effluent, € - Recycled Thin Slop, * - Recycled Lees &
Condensate, Ω- Harvested Rainwater.
Other effluent generated during 400 KLPD grain operations will be @555 CMD; shall be treated
in proposed CPU. Total treated effluent available @ 500 CMD (after loss) shall be reused for
Cooling Make up @ 96 CMD.
Other effluent generated during 700 KLPD cane juice operations will be @ 4105 CMD; shall
be treated in proposed CPU. Total treated effluent available @ 3695 CMD (after loss) shall be
reused in process @3580 CMD & for Cooling Make up @ 115 CMD.
Thus, the Distillery becomes a Total ZLD Project.
241
Expansion of Molasses/Grain based Distillery from 300 KLPD to 700 KLPD using C / B Heavy Molasses/
Grain /Sugarcane Syrup/ juice for Ethanol Production with 17 MW Electricity Generation by
Hermes Distillery Pvt. Ltd., A/P: Yadrav, Tal.: Raibag, Dist.: Belgaum, Karnataka State
Stack Height Calculations
No Description
Stack Height Calculations for worst case w.r.t. Pollutants while using Coal/ Bagasse as Fuel.
Ref.: CPCB; Comprehensive Industry Document, Series: COINDS/18/1984-85
1 Proposed 110 TPH Bagasse Boiler
Ref. : CPCB; Comprehensive Industry Document Series : COINDS /18 / 1984-85 )
1. Formula for Stack Height calculations,
H= 74(Q) 0.27
Where, Q= Discharge of Total Particulate Matter (TPM) expressed in T/Hr.
2. Fuel Used : Bagasse
3. Fuel Consumption: 1200T/Day, i.e. 50 T / Hr.
4. Ash generation from bagasse burning is to the tune of 2.5%.
5. Hence, Total ash generation rate in T / Hr will be 2.5% of above fuel consumption i.e. 2.5% of 50
T/Hr.
Thus, ash generation = 1.25 T / Hr
6. Fly Ash emission Rate in T / Hr will be 80% of the total ash generated in light of the convention –
80% fly ash + 20% bottom ash
i.e. 80% of 1.25 T / Hr = 1 T / Hr
a. Stack Height Calculation with APC Equipment Functioning :

Air Pollution Control Equipment to be provided is (Electrostatic Precipitator) ESP with removal efficiency
of 98% for particulates. Ash emission rate after APC equipment is 2% of 1 T/Hr. i.e. 0.02 T/Hr.
Therefore, required Height of Stack shall be,
H = 74 (Q) 0.27
= 74 X (0.02)0.27
= 74 X 0.347
= 25.7 M
i.e. Say 26 M
b. Stack Height Calculation without APC Equipment Functioning :
of 98% for particulates. Ash emission rate without APC equipment is 1 T/Hr
H = 74 (Q) 0.27
= 74 X (1)0.27
= 74 X 1
= 74 M
i.e. 74 M
Proposed 110 TPH Coal Boiler
For Total Particulate Matter (TPM)
1. Formula for Stack Height Calculation,

H = 74 (Q)0.27
Where, Q=Discharge of TPM expressed in MT/Hr.
2. Fuel Used: Coal
3. Fuel Consumption : 575 T/Day, i.e. 24 T/Hr.
4. Ash generation from Coal burning is to the tune of 10%.
5. Total Ash generation for utilization of Coal @ 24 T/Hr is 2.4 T/Hr
6. Ash distribution as - 80 % Fly Ash + 20% Bottom Ash
7. Fly Ash Emission Rate in T/Hr: 80% of Total Ash
242
No Description
i.e. 80% of 2.4 T/Hr = 1.91 T/Hr
H = 74 * (Q)0.27
=74 * (1.91) 0.27
=74* (1.19)
= 88 M
B For Sulphur Di-oxide (SO2)

1. Formula for Stack Height calculations,
H= 14 (Q) 0.3
Where, Q= Discharge of SO2 expressed in Kg/Hr.
2. Fuel Used: Coal
3. Fuel Consumption: Coal: 575 MT/Day, i.e. 24 MT/Hr.
4. Sulphur content of Coal @ 0.5%, Sulphur Di-oxide (SO2) released after coal burning is 1%
5. Total SO2 emissions: 1% of 24 MT/Hr = 0.23 MT/Hr; i.e. 230 Kg/Hr
Stack Height Calculation

H = 14 (Q) 0.3
= 14 X (230)0.3
= 14 X 5.111
= 71.5
i.e. Say 72 M
2 Existing Boiler of 39 TPH Capacity (Yet to be implemented on site)

Fuel: Coal + Spentwash
 Formula for Stack Height calculations,
H= 74(Q) 0.27
 Where, Q= Discharge of Total Particulate Matter (TPM) expressed in T/Hr.

 Fuel Used : Coal & Spentwash
 Fuel Consumption: 175 T/D i.e. 7.29 T/Hr & 900 T/Day, i.e. 37.5 T / Hr.
 Ash generation from Coal & Spentwash burning is to the tune of 10% & 18%.
 Total Ash generation –
 Coal; 0.729 T / Hr + 6.75 T / Hr Spentwash = 7.47 T/Hr.
 Fly Ash emission Rate in T / Hr will be 80% of the total ash generated in light of the convention
– 80% fly ash + 20% bottom ash
 i.e. 80% of 7.47 T / Hr = 5.98 T / Hr
c. Stack Height Calculation with APC Equipment Functioning
of 98% for particulates. Ash emission rate after APC equipment is 2% of 5.98 MT/Hr. i.e. 0.119 MT/Hr.

H = 74 (Q) 0.27
= 74 X (0.119)0.27
= 74 X 0.562
= 41.6 M
i.e. Say 50 M
243
No Description
d. Stack Height Calculation without APC Equipment Functioning

H = 74 (Q) 0.27
= 74 X (5.98)0.27
= 74 X 1.62
= 119.88 M
i.e. Say 120 M
Stack Height, M
Boiler Fuel
Calculated Proposed
Proposed 110 TPH Coal 24 T/Hr or 88 M 72 M
(TPM) (SO2)
90 M
Proposed 110 TPH Bagasse 50 T/Hr 26 M 74 M
(With APC) (Without APC)
Existing 39 TPH Boiler Coal 7.29 T/Hr + Sp. Wash 42 M 120 M 90 M
(To be implemented) 37.5 T / Hr (With APC) (Without APC)
244
Proposed Tree Plantation
A comprehensive ‘Green Belt Development Program’ would be implemented in a phase wise manner
under the proposed project development.
Features of proposed green belt development program -
 A thick barrier of trees would be created along the entire periphery of the plot.
 Trees would be planted in the project’s premises along the internal roads and open plot.
 Indigenous, fast growing, evergreen and semi evergreen tree species would be planted.
 As per the recommendations by Central Pollution Control Board (CPCB) and Ministry of
Environment & Forests (MoEFCC) and the ToR given to the project, the green belt development
plan has been designed.
For shelter belt and mass plantation, trees with 3 to 5 SQM. canopies with distance of 2 M between two
trees and 2 M between two adjacent rows would be planted.
1M
1M
2M 2M
2M
2M
2.3 M
2M
4M
4M
2.3 M
2M
2M
4M
2M
2M
2M
1M
Moreover, plantation along the internal roads would be done in single row on either side of the road. Here
the distance between adjacent trees is considered as 2 M with 2 M width and area covered by a single tree
is taken as 3 to 5 SQM.
2M
2.7 M
The GB area (34% of TPA) is 51,534 sq. m. with minimum plantation of 12,884 trees. Based on the
above facts and figures, the green belt development plan has been designed and presented in following
Table No.1.
245
Table No. 1 Green Belt (GB) Design Details
GB GB
GB Area No. of Tree Trees / Total
Length Width
(Sq. M) Rows Row Trees
Type of Location on (M) (M)
Trees Characteristics
Plantation Plot D = B/2 E = A/2
A B C = A*B (2= Dist. (2= Dist. F = D*E
Bet. 2 Rows) Bet. 2 trees)
North 160 6 960 3 80 240
Neem, Shisav, Karanj, Trees with round &
Shelter Belt East 520 6 3,120 3 260 780 Wilayati Chinch, oblong canopy, native,
along
Saptaparni, Apta, evergreen, pollution
Compound South 360 10 3,600 5 180 900
Mahogani, Ran Bibba, resistant, fast growing,
Wall
Kadamb high dust settling index
West 470 10 4,700 5 235 1,175
Tree with round &

Khair, Saag, Bel,
Mass At Internal Open Space with About 4 Sq. M. Area for oblong canopy, native,
29,554 7,389 Shivan, Nandruk, Palas,
Plantation Areas Uneven Shape Each Tree Species evergreen, pollution
Limbara
resistance
Tree species with
conical, columnar
Bakul, Bahava, canopy, ornamental,
Avenue
Roadside 1,600 6 9,600 3 800 2,400 Tamhan, Ashoka, fast growing, pollution
Plantation
Saptaparni resistance will be
planted as avenue
plantation
Total 51,534 12,884
246
Table No. 2 No. of trees to be planted
Sr. No. Name of the plant Common Name Quantity Characteristics & Ecological Importance
1 Azadirachta indica Neem 1600 Native, evergreen, fast growing, tolerant
2 Dalbergia sissoo Shisav, Shisham 360 Native, evergreen, tolerant
3 Mimusops elengi Bakul 480 Native, ornamental, host plant for bees and butterflies.
4 Pongamia pinnata Karanj 360 Pollution tolerant
5 Acacia Catechu Khair 900 Native and pollution resistant
6 Tectona grandis Saag 1100 Native and pollution resistant
7 Neolamarckia cadamba Kadamb 360 Native, evergreen, fast growing, pollution tolerant
8 Cassia fistula Bahava 480 Native, ornamental, host plant for bees and butterflies.
9 Gmelina arborea Shivan 900 Native and pollution resistant
10 Pithecellobium dulce Wilayati Chinch 320 Native, ornamental, host plant for bees and butterflies.
11 Alstonia scholaris Saptaparni 480 Native, evergreen, higher dust settling index
12 Swietenia mahogani Mahogani 360 Native, evergreen, higher dust settling index
13 Aegle marmelos Bel 900 Native and pollution resistant
14 Holigarna grahamii Ran Bibba 315 Native and pollution resistant
15 Ficus macrocarpa Nandruk 889 Native and pollution resistant
16 Melia azedarach Limbara 900 Native and pollution resistant
17 Bauhinia racemosa Apta 320 Native and pollution resistant
18 Butea monosperma Palas 900 Native, Evergreen tree,
19 Lagerstroemia speciosa Tamhan 480 Native, State flower of Maharashtra
20 Polyalthia longifolia Ashoka 480 Air pollution absorbing species
Total 12,884
247
IX
Air Quality Report
248
AIR QUALITY REPORT
M/s. Hermes Distillery Pvt. Ltd.

A/P: Yadrav, Tal.: Raibag, Dist.:
Belgaum, Karnataka State
Table 1 Details of Boiler and Stack in HDPL
Existing Expansion
No Description Boilers DG Set Boiler DG Set
B1 B2 B3 1 B4 2
Capacity 750 750
1 35 TPH 36 TPH 39 TPH 110 TPH
KVA KVA
Fuel type Coal/ Coal/
Coal/
2 Bagasse + Bagasse Bagasse + Diesel Diesel
Bagasse
Sp. wash Sp. wash
Fuel Qty., T/D 95/ 190 230/ 450 +
3 380 30 Lit/Hr 575/1200 30 Lit/Hr
+221 540
4 MOC RCC RCC RCC MS RCC MS
5 Shape Round Round Round Round Round Round
6 Height, M 72 62 50 6 (ARL) 90 6 (ARL)
7 Diameter, M 3 1.5 1.5 -- 3.5 --
APC
8 ESP ESP ESP -- ESP --
equipment
Presently, 35 TPH incineration boiler & 36 TPH bagasse boilers are installed on site. 110
TPH boiler is proposed under expansion project. Further, 39 TPH incineration boiler is
approved but yet to be implemented on site. Accordingly, total incremental concentration of
emissions from 39 TPH & 110 TPH boilers is considered.
A. AIR QUALITY
• GLC Evaluation through Air Dispersion Modeling
In order to study movement of particulate matter release into atmosphere from the source, Air
Dispersion Model - AERMOD developed by the US Environmental Protection Agency
(USEPA) is used. Software helps in knowing details of particulate dispersed in down wind
direction and finally reaching the ground at farther distance from the source, Ground Level
Concentrations (GLC) mainly depend upon the strength of emission source &
micrometeorology of the study area. Site specific meteorological and AAQM data were
collected and accordingly GLC was carried out.
Output of GLC run for various scenarios in respect of activities to be undertaken under the
project is presented in following tables.
Table 1. GLC with Maximum Incremental Increase (µg/m3)
Max Distance
Baseline
SR. Incremental (Km) Direction
Parameters Conc. NAAQS
NO. (GLC)
(µg/m3)
(µg/m3)
1. Particulate Matter (PM10) 64.2 2.45 1.03 E 100.00
249
µg/m3
60.00
2. Particulate Matter (PM2.5) 25.8 0.613 1.01 E
µg/m3
80.00
3. Sulphur Dioxide (SO2) 20.7 13.4 0.97 E
µg/m3
80.00
4. Oxides of Nitrogen(NOX) 25.4 2.60 1.02 E
µg/m3
250
I. Predictions for Emissions from stack (Scenario- during operation of APC)
Figure 1.Isopleths of PM10 (24 Hrs Max. Conc. in µg/m3)
Maximum concentration of PM10 is 2.45µg/m3 towards East direction at 1.03 Km from Site
Table 2.GLC with Incremental Increase in PM10 Values (µg/m3)

No Location Direction Distance 98 Incremental Total % Remark Impa
(Km) Percentile PM10 GLC PM10 Incremental ct
baseline (µg /m3) Predictive
PM10 GLC(µg
Conc. /m3)
(µg/m3)
A B C D E F= (D+E) G=(E/D) x 100 -- --
1. Industrial --- --- 64.2 0.20 64.4 0.311 Total Insig
Site PM10 nific
Predicti ant
ve GLC
lower
than
standar
d
100
µg/m3
251
Figure 2. Isopleths of PM2.5 (24 Hrs Max.Conc. in µg/m3)
Maximum concentration of PM2.5 is 0.613 µg/m3 towards East direction at 1.01 Km from site
Table 3.GLC with Incremental Increase in PM2.5 Values (µg/m3)
No Locati Directi Distan 98 Incremen Total % Rema Impact
on on ce Percent tal PM2.5 PM2.5 Incremen rk
(Km) ile GLC Predicti tal
baselin (µg/m3) ve GLC
e PM2.5 (µg /m3)
Conc.
(µg/m3)
A B C D E F= G=(E/D) x -- --
(D+E) 100
1. Indust --- --- 25.8 0.01 25.81 0.039 Total Insignific
rial PM2.5 ant
Site Predicti
ve GLC
is lower
than
standard
of
60
µg/m3
252
Figure 3. Isopleths of SO2 (24 Hrs Max. Conc. in µg/m3)
Maximum Concentration of SO2 is 13.4 µg/m3 at 0.97 Km on East side of project site
Table 4. GLC with Incremental Increase in SO2 values (µg/M3) with operation of APC
Location Directio Distance 98 Incremental Total % Remark
No. n from Percentile SO2 GLC SO2 Increase
the baseline 3
(µg /m ) Predictive Impact
Centre SO2 GLC
of Study Conc. µg/m3
Area µg/m3
(Km)
A B C D E F= G=(E/D)
(D+E) x100
1 Industrial --- --- 20.7 0.50 21.2 2.41 Total SO2

Site Predicti Insigni
ve GLC ficant
is lower
than
prescribed
standard
of
80 µg/m3
253
Figure 4. Isopleths of NOx (24 Hrs Max. Conc. in µg/m3)
Maximum Concentration of NOx is 2.60 µg/m3 at 1.02 Km on East Side of project site
Table 5.GLC with Incremental Increase in NOx values (µg/M3) with APC in operation
N Location Dire Distanc 98 Increm Total % Remark Impact
o ctio e from Perce ental NOx Incre
. n the ntile NOx Predicti menta
Centre baseli GLC ve GLC l
of ne Value 3
(µg /m )
Study NOx (µg /m3)
Area(K Conc.
m) (µg
/m3
)
A B C D E F= (D+E) G=(E/D) -- --
x100
1 Industrial --- --- 25.4 0.06 25.46 0.23 Total Insignific
Site NOx ant
Predictiv
e GLC
is lower
than
prescribe
d
standard
of
80 µg/m3
254
II. Predictions for emissions from stack in worst case (Scenario -
during non-operation of APC)
Figure 5.Isopleths of PM10 (24 Hrs Max Conc. in µg/M3)
Maximum concentration of PM10 is 84.4 µg/m3 towards East direction at 0.99 Km from site
Table 6.GLC with Incremental Increase in PM10 values for Non-Operation of APC
N Location Directi Distan 98 Increme Total PM10 % Remark Impact
o. on ce Percentile ntal Predictive Increme
(Km) baseline PM10 GLCµg/M3 ntal
PM10 Conc. GLC
(µg/m3) µg/m3
A B C D E F= (D+E) G=(E/D) -- --
x 100
1. Industrial --- --- 64.2 5.0 69.20 7.7 Total PM10 Insignifi
Site Predictive cant
GLC
lower than
standard
of
100 µg/m3
255
Figure 6. Isopleths of PM2.5 (24 Hrs Max Conc. in µg/m3)
Maximum concentration of PM2.5 is 21.0 µg/m3 towards East direction at 1.00 Km from site
Table 7.GLC with Incremental Increase in PM2.5 Values for Non-Operation of APC(µg/M3)
No Location Directio Distan 98 Incremental Total % Remark Impac
n ce Percentile PM2.5 GLC PM2.5 Incremental t
(Km) baseline µg/m3 Predictive
PM2.5 GLC
Conc.
(µg/m3)
A B C D E F= (D+E) G=(E/D) x -- --
100
1. Industrial --- --- 25.8 0.6 26.4 2.32 Total PM2.5 Insigni
Site Predictive ficant
GLC is
lower than
standard
of
60 µg/m3
From the above observations, it could be concluded that the impact on air quality at Industrial
Site due to the boilers (stack emissions) with air pollution control equipment in operation and
during non-operation is non-significant.
256
Certificate of Incorporation
257
258

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A Report

EXPANSION OF EXISTING MOLASSES/ GRAIN BASED

Hermes Distillery Pvt. Ltd. (HDPL),

CHAPTER 1 – PROJECT DESCRIPTION 01-34

1.1 Type of Project 1

Table No. Table Page No.

Figure No. Figure Page No.

No. Description Page No.

1.2 NEED OF PROJECT

1.2.1 Employment Generation Potential

Table 1.1 Details of Manpower

No. Manpower Existing Plant Proposed Plant Total

1.2.2 Potential of the Products

Table 1.2 Project Siting & Environmental Settings

1.3.1 Site History

Table 1.3 ECs Granted To HDPL

No. Description EC Dates Total Capacity Status On Site

1.4 DETAILS OF LAND REQUIREMENT

Table 1.4 Area Statement of HDPL

No Description Existing Area Expansion Total

Table 1.5 Project Investment Details

Table 1.6 Working Pattern

1.5.1 Plan for Approval and Implementation Schedule

1.6 TECHNOLOGY & PROCESS DESCRIPTION

Table 1.8 List of Raw Materials Consumed in Distillery Complex

1.6.3 Raw Material and Product Transportation Details

Table 1.9 Raw Material Transportation Details (Traffic Density)

Avg. wt. (T) Daily No. of Vehicles

Table 1.10 Product & By-product Transportation Details

Table 1.12 Product Storage Details

1.6.4 Manufacturing Process

1.6.4.1 Distillery Manufacturing Process

1.6.4.2 Manufacturing Process using Cane Syrup as Raw Material

1.6.4.3 Manufacturing Process for Grain Based Operations

Figure 1.4 Grain Distillery Operations

A. Grain Milling Section

E. Multi pressure Wash to ENA, RS Distillation

Table 1.14 Distribution of Electricity Generated from Co-gen Plant

1.7 SOURCES OF POLLUTION AND THEIR CONTROL

1.7.1 Water Pollution (WP)

No. Description Quantity (M3/ Day)

1.7.1.2 Effluent Generation

No Process Proposed Grain Proposed Cane Syrup Disposal Method

1.7.1.3 Domestic Effluent

1.7.1.4 Industrial Effluent

Figure 1.11 Flow Chart of STP (Capacity 25 KLD)

Figure 1.13 Existing Distillery CPU

No. Parameter Raw Spent wash Concentrated Spent wash

Table 1.20 DDGS specifications

Table 1.21 Details of MEE

1.7.2 Air Pollution

Table 1.23 Characteristics of Fuels

Table 1.24 Fuel Storage Details

Table 1.25 Details of ESPs for Boilers

Figure 1.15 Existing Stack & ESP of Boilers

1.7.2.2 Process Emissions

Figure 1.16 Existing CO2 Bottling Plant

1.7.3 Solid Waste

No. Industrial Type Quantity (T/D) Disposal

1.7.4 Hazardous Wastes

Table 1.27 Details of Hazardous Waste

1.7.5 Noise Pollution

Noise is normally defined as objectionable or unwanted sound, which is without agreeable