DPR 100 KLPD Shantanu Transnational Life Sciences PVT LTD

PROJECT : GRAIN BASED DISTILLERY – 100 KLPD
Confidential
Commercial Proposal
For
100
0 KLPD AA on Grain as Feedstock
Submitted to,
14 September, 2023
20
Shantanu Transnational Life Sciences PVT LTD., Assam
PRAJ Industries Limited.
274 & 275, Bhumkar Chowk, Hinjewadi Road,
Hinjewadi, Pune 411057 India
Phone: +91 20 22941000 / 71802000
info@praj.net www.praj.net
100 KLPD GRAIN BASED DISTILLERY DPR FOR MATIA, GOALPARA, ASSAM Page 1
INTELLECTUAL PROPERTY
The technology represented herein is proprietary to PRAJ INDUSTRIES LIMITED of Pune,

India. All data and information submitted now or likely to be submitted in future for
evaluation regarding design details, system operation, proces
processing
sing techniques and prices shall
be divulged only to those persons having a direct need to participate in the evaluation. No use
shall be made of any information provided herein other than for the evaluation of this
proposal, nor shall such data be transfe
transferred
rred to others without the written permission of PRAJ
INDUSTRIES LIMITED, INDIA.
A information,, content, forms, photographs, graphics available herein in this proposal

(collectively "Content") is owned or controlled by Praj Industries Limited (“PRAJ”), its
it
subsidiaries and affiliates. While PRAJ has endeavored to produce this proposal in a
professional manner, PRAJ makes no representations or warranties, express or implied, about
the information provided herein or, its accuracy. You are prohibited from (i) modifying,
copying, distributing, transmitting, displaying, publishing, selling, licensing, creating
derivative works, (ii) either setting up new ethanol plants or modifying/ altering existing
ethanol Plants, as the case may be, through third parties using
using the Content or (iii) using any
Content available herein for commercial or public purposes without the prior written
permission of PRAJ. Copyright in these pages is owned by PRAJ except where otherwise
indicated by a third party's proprietary notice. Imag
Images,
es, trademarks and brands are also
protected by other intellectual property laws and may not be reproduced or appropriated in
any manner without written permission of PRAJ INDUSTRIES LIMITED, INDIA.
THIS DOCUMENT IS THE PROPERTY OF PRAJ INDUSTRIES LIMITED, INDIA

AND SHOULD NOT BE REPRODUCED WITHOUT WRITTEN CONSENT FROM,
“PRAJ INDUSTRIES LIMITED”, PRAJ TOWER, HINJEWADI, PUNE,
411057,INDIA.
Table of Contents
INTELLECTUAL PROPERTY ................................
................................................................................................
......................................... 2
1.0 Introduction ................................
................................................................................................................................
................................. 6
1.1 Salient Features of PRAJ’s Main Process Plant: Liquefaction: ....................................................
................................ 6
1.1.1Fermentation ................................
...........................................................................................................................
........................... 7
1.1.2 Distillation................................
..............................................................................................................................
.............................. 7
1.1.3 Integrated Evaporation ................................
................................................................................................
........................................... 7
1.1.4 Dryer ................................
................................................................................................................................
...................................... 8
2.0 Project Description................................
............................................................................................................................
............................ 8
2.1 Project Profile ...............................................................................................................................
................................ ............................... 8
2.2 Land Requirement ................................
.........................................................................................................................
......................... 8
2.3 Raw Material Requirement ................................
................................................................................................
........................................... 9
2.3.1 Grain Availability ................................
....................................................................................................................
.................... 10
2.3.2 Mode of Transportation: ................................................................................................
................................ .......................................... 12
2.4 Waste Water Generation ................................................................................................
................................ ............................................. 13
2.5 Air Emission & Air Pollution Control Measure ................................................................
......................................... 13
2.6 Solid Waste Generation & Disposal ...........................................................................................
........................... 13
2.7 Water Balance ................................
............................................................................................................................
............................ 14
2.8 Figure: Grain To Ethanol Process Flow Diagram ................................................................
....................................... 15
2.9 Effluent Plant Diagram ................................
................................................................................................
............................................... 16
2.9.1 Dryer Section: ................................
..........................................................................................................................
.......................... 16
i. Feed Conditioning ................................................................................................
................................ ............................................. 16
ii. Drying ................................
...............................................................................................................................
............................... 16
2.9.2 DDGS Specifications ................................
................................................................................................
.............................................. 17
2.9.3 DDGS Specifications ................................
................................................................................................
........................................... 17
2.9.4 Technical Specification For Rotary Tube Bundle Dryer .....................................................
..................... 18
2.9.5 Technical Specification for Secondary Effluent Treatment Plant ................................
....................................... 21
2.9.6 Technical Specifications Membrane Treatment Plant .........................................................
......................... 22
2.10 Project Profile Summary ................................
................................................................................................
........................................... 22
2.11 Project Cost ................................
...............................................................................................................................
............................... 24
2.12 Location ................................
................................................................................................................................
.................................... 24
3.0 Personnel Requirement ................................
................................................................................................
................................................... 26
3.1 Staff Salary and Wages- ................................................................................................
................................ ........................................ 26
3.1.1 For 100 KLPD Grain Based Distillery Plant Staff Salary and Wages
Wages- ................................ 26
3.2 For Condensate Polishing Unit (CPU)
(CPU)- ......................................................................................
...................... 27
3.3 For Boiler section– ................................
......................................................................................................................
...................... 27
3.4 For Turbine section– ................................
................................................................................................
.................................................. 27
4.0 Section I: Introduction ................................
................................................................................................
.............................................. 28
4.1 Identification of Project Proponent-
Proponent Partner Profile ................................................................
................................... 28
4.2 Socio Economic Activities ................................................................................................

................................ .......................................... 30
4.3 Project Background and Over view ............................................................................................
............................ 31
4.4 Design parameters ................................
.......................................................................................................................
....................... 31
4.5 Technology Salient features ................................................................................................
................................ ........................................ 31
4.6 Ethanol scenario in India ................................
................................................................................................
............................................ 32
4.7 Ethanol Supply Scenario ................................................................................................
................................ ............................................. 33
4.8 Socio-economic
economic advantages of Proposed 1G ethanol project .....................................................
..................... 33
4.8.1 Reducing import dependency: .............................................................................................
............................. 33
4.8.2 Cleaner Environment’ ................................................................................................
................................ .......................................... 34
4.8.3 Employment
oyment Generation: ................................................................................................
..................................... 34
4.8.4 Income to Farmers: ................................
................................................................................................
.............................................. 34
4.8.5 Infrastructural Investment in Rural Areas:................................................................
........................................... 34
4.9 Indian Outlook for Bioethanol ................................................................................................
.................................... 35
4.9.1 Progressive Vision and Strong Policy Support ................................................................
........................................ 35
4.9.2 Highlights of national biofuels policy-
policy ....................................................................................
.................... 36
4.9.3 Other major policy measures to support
suppo the EBP ................................................................
.................................... 36
4.10 Key Drivers ................................
...............................................................................................................................
............................... 36
4.11 Ethanol demand scenario estimation for 2025 ................................................................
.......................................... 37
4.12 Ethanol supply scenario ................................
................................................................................................
............................................ 38
4.12.1 Ethanol supply trend and estimated quantity until 2022 ....................................................
.................... 38
4.12.2 Feedstock Wise Ethanol Demand - Supply Scenario Estimation For 2025 ....................... 38
4.12.3 Estimated Ethanol Supply from Sugar Sector ................................................................
.................................... 38
4.13 Grain Feedstock Scenario ................................
................................................................................................
......................................... 39
4.14 Existing and Required Capacities - India ................................................................
.................................................. 39
4.15 Project Justification ................................
................................................................................................
................................................... 40
Section5Project at a Glance ................................
................................................................................................
.................................................. 42
Section 6 Process Description ................................
................................................................................................
............................................... 43
6.1 Liquefaction ................................
................................................................................................................................
................................ 43
6.2 Fermentation ................................
..............................................................................................................................
.............................. 43
6.3 Distillation................................
................................................................................................................................
................................... 43
6.3.1 Distillation – (Wash to AA Mode) .......................................................................................
....................... 43
6.4 Molecular Sieve Dehydration Plant (MSDH): ................................................................
............................................ 43
6.5 Decantation ................................
................................................................................................................................
................................. 44
6.6 Integrated Evaporation Section ................................................................................................
................................... 44
6.7 DDGS Dryer ................................
...............................................................................................................................
............................... 44
6.8 Process Condensate Treatment Section ......................................................................................
...................... 45
Section 7 Process Design Basis ................................
................................................................................................
........................................... 46
7.1 Plant Details ................................
................................................................................................................................
................................ 46
Section8 Input requirements ................................
................................................................................................
................................................. 47
8.1 Input Requirements .....................................................................................................................

................................ ..................... 47
8.2 Input Specification ................................
......................................................................................................................
...................... 48
8.2.3 PRAJ recommended
ommended Desired Particle size distribution of Grain Flour: .............................. 48
Section 9 Output Generation ................................
................................................................................................
................................................. 52
Section 10 Budgetary Investment ................................
................................................................................................
......................................... 53
SECTION 11 Typical Economics ................................
................................................................................................
......................................... 56
11.1 Typical Cost of Production ................................
................................................................................................
....................................... 56
11.2 Typical Financial Analysis................................
................................................................................................
........................................ 56
11.3 Sensitivity- ................................
................................................................................................................................
................................ 57
11.4 Annual Key Input and Output Generation ................................................................
................................................ 57
Section 12 Conclusion ad Recommendations .......................................................................................
....................... 58
Section 13 Commercial & General Terms & Conditions ................................................................
..................................... 60
Section 14. Incineration Boiler Suppliers .............................................................................................
............................. 64
Section 15 List of C.P.U Plant Suppliers ..............................................................................................
.............................. 65
Section 16 Appendix .............................................................................................................................
................................ ............................. 66
1.0 Introduction
Shantanu Transnational Life Sciences Life Science

Sciences PVT LTD. is located on Matia,Gaolpara
Matia
Road National Highway No. 46 at AIDC Industrial Growth Center, Post Matia, Dist.
Gaolpara. Nearest railway station is Krishnai Railway Station.
We want to be active participants in the E20 Program to support and facilitate growth of
Industry and Agricultural Sector of Assam and India.
Shantanu Transnational Life Sciences PVT LTD.,, Company incorporated on 9th day of
January 2021 with its Registeredred Office at Ug- 17 Basement Floor, Sukh Sagar N.S.
Patrak Marg, Chowpaty, Grant Road, Mumbia -400007,, plans to set up a 100 KLPD
Grain Based Distillery, with co-generation
co Power Plant of 3 MW. Project comes under
Category A, 5(g), (II) All Can Juice/Non Molasses based Distilleries ≥ 100 KLPD as per EIA
Notification dated 14th September, 2006 and its subsequent amendments.
With the launch of new Ethanol Promotion Policy by the Government and in order to
enhance ethanol availability in the country for blen
blending
ding with petrol, Client is planning to set
up Grain (Rice and Maze although other grains can also be used used)) to Ethanol bio-refinery
bio
project using rice/maze as feedstock.
The project aims at construction of bio ethanol project that produces first generation (1G)
ethanol from rice as main feedstock.
The government of India is currently leveraging major grain producing states to balance the
ethanol supply from grain and sugary feedstock.
The primary feedstock is rice/maze

/maze and can also use other available grain n such as pulses,
sorgum etc.
The bio-ethanol
ethanol project will process around ~ 0.77 – 0.78 Lac MT/Annum of rice/mazerice to
produce 100 KLPD of 1G ethanol or around ~ 3.3 - 3.4 Cr lit of 1G ethanol /Annum. The
bio-ethanol
ethanol project will also generate DDGS (Distille
(Distillers
rs Dried Grain soluble) powder as a by-by
product which is highly rich in protein content and will be used as a cattle or poultry feed.
The project site selection criteria to be considered for proposed project is as follows:
 Availability of land and water
 Proximity to blending depot
 Availability of feed stock
 Preferred by ABPL
1.1 Salient Features of PRAJ’s Main Process Plant: Liquefaction:

1. Maximum conversion of starch to sugar
2. Recycle of lees thus minimizing the fresh water requirement.
1.1.1Fermentation
1. High alcohol productivity with high efficiency of fermentation of up to92%.
2. Higher alcohol content in the fermented mash, thus lower steam

requirement.
3. High ease of operation
4. Design of equipment, piping and provision of cleaning in place
ensures minimum bacterial
ba activity.
5. Mash coolers designed to reduce the possibilities of choking.
6. Water recycle and reuse system reducing fresh water requirement.
1.1.2 Distillation
1. Plant with maximum heat integration to produce alcohol with lowest
energy consumption.
2. Energy efficient integrated system Distillation efficiency up to 99.5%
whilst producing AA
3. Well-engineered
engineered plants with high efficiency trays to ensure elaborate
separation and removal of impurities ensuring superior quality of
Spirit.
4. Proper care in design of calming zone on trays, large area of down-
down
comers, gas- liquid separators with tangential entry and vapor bottles
ensures proper gas-liquid
gas liquid disengagement and eliminates chances of
liquid carry over.
5. Mash column with hyper stat Rh Grid trays ensure high turbulence on
tray, this minimizes chances of scaling. Also, this special construction
of trays and access to each tray helps in easier cleaning of column
internals.
6. Condensers are designed with multiple
multiple passes to ensure high velocity
and to minimize scaling inside tubes.
1.1.3 Integrated Evaporation
1. Concentrated thin slop up to 35 % w/w solids with low steam.

2. The process condensate after the condensate treatment used as cooling
tower make up thus reducing the fresh water requirement.
3. Possibility of Higher value realization obtained from mixing of syrup
with wet cake in the dryer.
ent.
1.1.4 Dryer
2. Multiple working references
3. Low Temperature drying – No product degradation
4. 100 % syrup can be consumed
5. Robust construction
6. Process Condensate Treatment Plant

Designed to treat process condensate + Cooling Tower Blow down + Dryer vapor
condensate thus enhancing recycle and reducing fresh water requirement
2.0 Project Description
2.1 Project Profile
Name of company M/s. Shantanu Transnational Life Sciences PVT LTD.

Category of Project A
Category A,5(g), (II) All Can Juice/Non-Molasses
Molasses based
S. No. In the Schedule Distilleries ≥ 100 KLPD
Location of the project Industrial Growth Center, Matia, Goalpara, Assam.

Proposed Grain Based Distillery (100
100 KLPD
ENA/RS/Industrial Alcohol) along with co-generation
Capacity of the project Power plant of 3 MW)
General condition & Specific
condition Does not attract general condition & Specific conditions.
Total project cost Rs. 158.03 Crore
Capital Cost: Rs. 135.85 Crore &Recurring
urring cost: Rs.
Cost for EPCM 22.18 Crore
Cost for CSR activity Rs. 4 Cr shall be utilized over a period of 5 years
2.2 Land Requirement

Land requirement 81372Sq.Meter
550M3/Day.
Water requirement & its source River Water as will be provided by AIDC
Electricity requirement & its
source 3 MW Cogeneration Captive Power Plant.
204(Direct Emplyoyment) personnel and local people
Manpower requirements will be employed as far as possible.
Coal: 70 TPD or Rice Husk: 100 TP

D for 30 TPH Boiler, Coal will be Source from Assam
and Meghalaya while Rice Husk from Nearby sources.
Fuel requirement & its source HSD: 300 lit/hr for D. G. Set, from nearest sources
One 900 KVA Capacity for initial startup and
D.G. set for emergency use emergency purposes
2.3 Raw Material Requirement
NAME OF THE
CONSUMPTION MODE OF
RAW SOURCE
MT/DAY TRANSPORTATION
MATERIAL
Grains (Broken
Rice / Maize / Assam, Bihar,
Sorghum / Bajra / West Bengal, Uttar
Wheat) 150 TBD Pradesh By Road/Rail/River
Assam, Bihar,
West Bengal, Uttar
Malt 15 TPD Pradesh. By Road/Rail/River
Directly from the
Chemical
Alpha Amylase 30 Kg Companies By Road/Rail/River
Directly from the
Chemical
Amyl glucosidase 30 Kg Companies By Road/Rail/River
Sulphuric Acid 50 Kg Authorized Dealers By Road
Urea 60 Kg Local Market By Road
Nutrients Ammonia 150 Kg Local Market By Road
0.6
.6 Kg Per Kl 36
Antifoam Kg Local Market By Road
As Per
Yeast Requirement Local Market By Road
Biocides 30 Kg Local Market By Road
2.3.1 Grain Availability
Food grains in Assam, 2013-2016

(Area in hectare, Average Yield in Kg. per hectare & Production in MT)
2013-2014
2014 2014-2015
2015
Sl. District Rice Maize Rice Maize
No.
Area Avg. Prod Area Avg. Prod Area Avg. Prod Area Avg. Production
Yield Yield Yield Yield
1 Baksa 98680 1893 184041 510 4610 2351 99920 2233 219819 340 3478 1183
2 Barpeta 134698 2234 298014 67 1829 123 135966 1950 262510 70 3156 221
3 Bongaigaon 56781 2183 122486 421 4366 1839 52849 2220 115939 894 2906 2598
4 Cachar 96477 1853 176287 99 2996 297 107882 2311 245893 102 2314 236
5 Chirang 46856 1644 75939 397 1939 770 45525 1623 72856 297 2908 864
6 Darrang 69689 2341 161316 1647 6000 9882 69073 2535 173092 5085 2794 14207
7 Dhemaji 82350 1591 129145 308 5648 1739 85539 1561 131692 304 4499 1367
8 Dhubri 86604 2747 236285 1176 4334 5098 86058 2765 236461 1195 2685 3209
9 Dibrugarh 78070 1925 148054 120 3583 430 74728 1753 129091 98 2543 249
Dima
10 Hasao 15823 2044 31837 3441 3272 11259 14700 2384 34511 3405 3478 11843
11 Goalpara 83159 2531 208282 195 2100 410 84268 2325 193831 245 2375 582
12 Golaghat 124151 2412 295077 328 4011 1315 123624 2267 276255 237 2757 654
13 Hailakandi 46675 2475 113866 35 1140 40 45343 2826 126300 20 1717 34
14 Jorhat 94111 2034 188725 29 4019 117 91893 1949 176550 25 2526 63
Kamrup
15 (M) 29228 2406 69552 64 3562 228 29210 2241 64756 66 2535 167
Kamrup
16 (R) 121339 2284 274260 245 3628 889 113627 2320 260897 246 2898 713
Karbi
17 Anglong 130200 1714 219917 10601 2212 23450 127996 1730 218189 10375 3660 37969
18 Karimganj 77499 2014 153970 32 2270 73 77402 1876 143230 35 2128 74
19 Kokrajhar 109489 2063 223102 930 2960 2753 108382 1989 212989 935 2385 2230
20 Lakhimpur 141100 1872 260565 165 3426 565 124166 2128 260743 103 4485 462
21 Morigaon 90115 2780 248499 186 4316 803 89922 2401 214226 200 1648 330
22 Nagaon 196651 2244 436123 529 3920 2074 201733 2060 410571 593 3079 1826
23 Nalbari 77930 1994 153374 115 4316 496 76375 2446 184445 70 3070 215
24 Sibsagar 96532 2179 207244 36 2694 97 97859 2137 206090 32 3279 105
25 Sonitpur 166054 2079 340728 866 5266 4560 173087 2230 380946 1420 5157 7323
26 Tinsukia 62321 1724 105835 921 3750 3455 63513 1687 105543 966 2829 2732
27 Udalguri 90619 1465 130856 605 3115 1885 94657 1771 165220 595 2896 1723
Assam : 2,503,201 2,101 5,193,379 24,068 3,199 76,998 2,495,297 2,120 5,222,645 27,953 3,333 93,179
https://diragri.assam.gov.in/information
https://diragri.assam.gov.in/information-services/agricultural-statistics
statistics
*Gov Of Assam, Directorate of Agriculture.
Agricultur

2015-2016 2013-2016
2013
Sl. District Rice Maize Grain Average Yield 2013-
No. 2016
Area Avg. Prod Area Avg. Prod Area Avg. Prod
Yield Yield Yield
1 Baksa 99225 2121 207366 410 3150 1292 99695 5828 205351
2 Barpeta 130310 1806 233151 76 3575 272 133729 4850 264764
3 Bongaigaon 52185 1825 94130 491 2208 1084 54540 5236 112692
4 Cachar 108076 2076 221229 99 800 79 104245 4117 214674
5 Chirang 44619 1737 76409 403 1940 782 46032 3930 75873
6 Darrang 69954 2427 167861 5358 5761 30867 73602 7286 185742
7 Dhemaji 80570 1478 117402 265 4478 1187 83112 6418 127511
8 Dhubri 84469 2718 228072 1204 4089 4924 86902 6446 238016
9 Dibrugarh 79342 1963 153400 114 1608 183 77491 4458 143802
Dima
10 14614 2212 31831 3454 1540 5319 18479 4977 42200
Hasao
11 Goalpara 85216 2228 187923 166 763 127 84416 4107 197052
12 Golaghat 121572 2204 264148 191 907 174 123368 4853 279208
13 Hailakandi 45290 2407 107433 15 1760 26 45793 4108 115900
14 Jorhat 93738 2152 198887 24 2525 61 93273 5068 188134
Kamrup
15 29559 2364 69126 72 3562 256 29400 5557 68028
(M)
Kamrup
16 110188 2507 273394 221 3562 787 115289 5733 270313
(R)
Karbi
17 129577 1670 213171 10529 2607 27450 139759 4531 246715
Anglong
18 Karimganj 76293 1650 124132 32 3120 100 77098 4353 140526
19 Kokrajhar 107530 1710 181700 940 764 719 109402 3957 207831
20 Lakhimpur 131042 2060 266308 350 587 206 132309 4853 262950
21 Morigaon 89102 2386 210972 200 1647 329 89908 5059 225053
22 Nagaon 198698 2332 458016 747 3136 2343 199650 5590 436984
23 Nalbari 75705 2175 162519 94 4297 404 76763 6099 167151
24 Sibsagar 99720 2058 202231 46 2874 132 98075 5074 205300
25 Sonitpur 171475 2226 376792 1342 5128 6882 171415 7362 372410
26 Tinsukia 62709 1857 114684 987 816 805 63806 4221 111018
27 Udalguri 94209 1969 182817 590 652 385 93758 3956 160962
Assam : 2484987 2089 5125104 28420 3067 87175 2521309 138028 5266160
statistics

Avg.
SI.No. CROP Total Area Prod
Yield
1 Rabi 304963 2586 2089257
2 PADDY 2467135 3243 8000313
3 RICE 2467135 2078 5127435
4 PULSE 146377 735 107541
5 FOODGRAINS 26670466 2007 5352581
6 OIL SEEDS 316837 644 203961
statistics
Shantanu Transnational Life Sciences, would like to procure rice locally as being located in
Goalpara, we are located in close proximity to 5 major rice and maze growing districts in
Assam. Also our location places us closely to Meghalaya, West Bengal and Bihar for
additional rice requirements if need be.
Agriculture plays a vital role in the economy of Assam contributing 35% to the State
Domestic Product in 1996-97 97 at constant (1980
(1980-81)
81) price. The Government has, therefore,
assigned very high priority to agriculture. This was reflected through a quantum jump in rice
production to 39 lakh MT in 1999-2000
1999 from the level of 31.55 lakh MT and 33.83 lakh MT
in 1998-99 and 1997-98,
98, respectively.
From 1999-2000 to 2016-2017 2017 Assam has experienced a jump of 30% in rice production
from 39 lakh MT to 131.28 lakh MT respectively. By setting up ethanol units farmers will
further enjoy better price forr crops and waste products which can be utilized in ethanol plants.
However, there is a clear demand

demand-supply
supply mismatch, at least at present. During the first
tendering process which took place in August 2019, OMCs in India were looking to procure
5.11 billion liters of ethanol but managed only 1.4 billion liters.. A second tender for 2.53
billion liters to make up for the shortfall was floated in January 2020. However, the sugar
industry again failed to match the demand and only 0.29 billion liters of ethanol
ethano were
allocated. A new tender was opened in early March, for 2.53 billion liters.. This time the
allocation was not more than 31.5 million liters.
“if India manages to achieve 20 percent

percent ethanol blending by 2025, then it will lead to 30-35
30
percent reduction in carbon monoxide, 20 percent reduction in hydrocarbon, will divert
around 16.5 million tons of surplus grains and also 6 million tons of excess sugar thus
benefiting farmers’, Food Sectary
ectary Sudhanshu Panday said.
th
Business- standard June 16 ,2001
2.3.2 Mode of Transportation:
Road traffic to and from the proposed plant during operation of proposed project will be
increased to some extent (around 85 trucks/day). The regular maintenance of vehicle shall
limit the pollution within limits.
2.4 Waste Water Generation
The effluent generated from the ENA production process is segregated as process effluent
(spent wash and spent lees) and effluent from utilities like Boiler, Vacuum pump, washings.
The company proposes to follow & set up a “Zero Effluent Discharge” scheme. The
condensates from evaporation shall be recycled and reused in Process & Make up water
streams. Spent wash shall be decanted for separation of Suspended Solids and Multi-Effect
Multi
Evaporation arrangement. Condensate shall be reused and sp spent
ent less shall be recycled back
to Distillation. Wastewater from Boiler (Blow down) as well as miscellaneous Water shall
be used in Gardening and Green Belt development. Domestic wastewater generated shall be
disposed off through septic tanks followed by ssoak pit/well.
2.5 Air Emission & Air Pollution Control Measure
NO. STACK
STACK NAME & POLLUTION
OF HEIGHT & POLLUTA
ATTACHED QUANTITY CONTROL
STA DIAMETER NTS
TO OF FUEL EQUIPMENT
CK (M)
PM – 150
Coal 70 TPD or mg/Nm3
Ht. 45 m &
1 30 TPH Boiler Rice Husk 100 Bag Filter / ESP SO2 – 100
dia. - 2 m
TPD ppm NOx –
50 ppm
Industrial Grade
PM – 150
D. G. Set of Resistive
mg/Nm3
900 KVA Diesel 300 Mufflers and Ht. - 9 m &
2 SO2 – 100
(Standby Lit./Hr RCC room with dia. - 0.4 m
ppm NOx –
facility) proper
50 ppm
ventilation
2.6 Solid Waste Generation & Disposal
SR. TYPE OF SOLID QUANTITY PER DISPOSAL

SOURCE
No WASTE DAY METHOD
Approx. 120 MT as
Grain Residue Process DWGS or Approx. 42 Dried and sold for
1 (DDGS/DWGS) MT as DDGS cattle feed
Sold to Cement or
Boiler
2 Fly ash Approx. 10 MT brick manufacturers.
2.7 Water Balance
Treated water requirement Treated water requirement With recycle

Without recycle of stream in of stream (at steady state plant operation)
Water Requirements m3/day m3/day
Process water 640 – 660 110-120
120
Soft water for Cooling

Tower makeup, Pump
sealing, FO Decanter 640-660 420-430
430
Total 1280-1300 530-550
550
2.8 Figure: Grain To Ethanol Process Flow Diagram
Grain Storage Decantation

Boiler
Grain Handling & Dry Milling
Thin stillage
TG set
Liquefaction, cooking
& post- liquefaction
Power to all electrical Evaporation
equipment
Syrup Wet
Saccharification & cake
Cooling Fermentation
Tower
Mingler
Distillation- Product
R.S. or ENA DWGS
WTP & Treatment Dryer
DDGS
R.S. to storage ENA to
storage
Impure spirit to
storage Condensate
Secondary ETP
Treated water
2.9 Effluent Plant Diagram
2.9.1 Dryer Section:
DWGS is subjected to further drying in the dryer system to produce DDGS. This
also requires additional steam.
The steam tube dryer system operation consists of the following two stages.
Feed Conditioning And Drying
i. Feed Conditioning
The wet material is sticky in nature and will result in coating of tubes if fed
as such. To temper this sticky character, the feed of wet DDGS is mixed with part
of the dry product. The resultant mixture is not sticky and can be handled in
tubular dryer. The wet material is dozed and mixed with part of the dry product in a
suitable paddle mixer. The properly mixed feed is fed to dryer.
ii. Drying
In the steam tube dryer, the wet feed is continuously agitated and heated by
means of a rotating shell type tubular dryer with steam heated tubes. The material
gets dried during its passage across the dryer. The dried material is continuously
discharged via the main rotary valve. Part of the dried material (quantity is
controlled by
y the diverter rotary valve) is sent to the paddle mixer via back mixing
conveyor. The moisture which is evaporated during the drying operation is
exhausted via an ID fan. The hot air (which is generated in a finned tube heat
exchanger, heated by steam) is used as a carrier gas for exhausting the vapors.
vapors
The final moisture content of DDGS is about 8.0 to 9.0 %. The quantity of DDGS
produced is around 250 to 260 kg per MT of corn or sorghum processed. We have
considered production of DDGS of about 28 – 30 MT/day.
T/day. DDGS specifications
are given in the following table 8.9 .
2.9.2 DDGS Specifications
Sr. Description Quantity/Percentage

No.
1. DDGS final product 250-260
260 kg/MT of grains
2. Moisture 10 %, w/w
3. Dry matter solids 90 %, w/w
4. Proteins 36.38 % ,w/w
5. Fats & oils 6-8 %, w/w
6. Inorganic ash 3-5 %, w/w
7. Other organics 39-43 %, w/w
The advantage of DDGS manufacture in the grain-based distillery is that

there is no effluent (liquid or solid) produced in the plant. Thus, the integrated grain
distillery with DDGS system becomes zero effluent discharge plant.
2.9.3 DDGS Specifications
Sr. Description Quantity/Percentage

No.
1. DDGS final product 250-260
260 kg/MT of grains
2. Moisture 10 %, w/w
3. Dry matter solids 90 %, w/w
4. Proteins 36.38 % ,w/w
5. Fats & oils 6-8 %, w/w
6. Inorganic ash 3-5 %, w/w
7. Other organics 39-43 %, w/w
The advantage of DDGS manufacture in the grain based distillery is that

there is no effluent (liquid or solid) produced in the plant. Thus, the integrated grain
distillery with DDGS system becomes zero effluent discharge plant.
2.9.4 Technical Specification

Specificati For Rotary Tube Bundle Dryer
Shell & Tube Assembly

The rotary shell of the dryer is Mild Steel construction with SS304 inside cladding.
Sufficient No. of tubes in SS304 are fitted on the outer regions of the tube sheets. The
outer periphery of the shell serves to mount on tire assemblies and a girth gear for support
and location and rotation of the dryer.
Shell Material of construction Mild steel with inside SS-304
304 cladding
Tube Material of construction SS 304, ERW
Nos. 1 No
Drive Arrangement
Drive motor rotates the dryer through a drive train of pulleys, V belts, gearbox, flexible
coupling and pinion / girth gear assembly. All drive components are mounted on a
common M.S. base frame.
Feed Section
Wet cake & concentrated Still age from Grain plant mixed in a Feed conditioner followed
by screw conveyor which is fed in dryer through a stationary cover located at a central
cut-out
out on the tube sheet.
Vapors Exhaust
On the stationary COVER on the discharge side, there is an exhaust port which is to be
connected to cyclone separator in SS304 contact parts with Rotary air lock & exhaust fan
for exhaust of vapors to atmosphere. MOC of ducting SS 304 Contact parts.
Vapor Blower
A centrifugal blower driven by a TEFC motor through V belt and pulleys is provided.
The blower is statically dynamically balanced.
Type Centrifugal
Drive Belt Driven
Material of Construction Impeller :SS-304
Casing : SS-304
Post Drying
The Product from Rotary Dryer is fed to Post Drying System to achieve 10% - 12% w/w
moisture Content in DDGS. The Material of Constriction SS
SS-304
304 for Contact Parts. Non-
Non
Contact Parts are in Mild Steel.
Product Discharge
At the end of the rotary shell, near the steam supply end, there are ports for discharge of
the feed into a fixed receiver. Product is collected from the bottom of the receiver, at an
elevation from finished floor level. This product from rotary dryer will be fed to post
drying section thru a screw conveyor in carbon steel. The final product from post drying
section will
ill be collect from discharge Rotary valve below twin cyclone separator in
carbon steel. Material of Construction – Mild Steel
Discharge Screw & Bucket Elevator
Product from rotary dryer feed to post drying section through screw conveyor followed
by bucket
et elevator. Material of Construction – Mild Steel.
Non-Condensable
Non condensable in steam are vented to atmosphere through suitable vents, valves, from
the steam manifold.
Access
The cut-out
out is large enough for partial manual access into the dryer for cleaning and
maintenance as and when required.
Cyclone Separator
High efficiency twin cyclone separator is provided for separating the product from
exhaust air and exhaust vapors. The product is discharged through a discharge Rotary
valve at the bottom
om of the cyclone.
Type Tangential Entry

Material of Construction Mild Steel for Product
Support Bracket Carbon Steel
Accessories Inspection / cleaning hand hole, support
bracket, Vortex breaker, Discharge Valve, U-
U
tube manometer.
Rotary Air Lock Valves (construction) –
A motorized rotary air lock valve is fitted to discharge the dry powder through the chute.
Material of Construction
Housing Aluminum
Rotor Carbon Steel
Ducting from Post Dryer to collection cyclone in Mild Steel. Vapor ducting from rotary
dryer to vapor cyclone inSS
inSS-304
2.9.5 Technical Specification for Secondary Effluent Treatment Plant
1. Equalization tank – One No

RCC equalization tank of Suitable capacity shall be provided
to collect vapor condensate from evaporator and spent-lees
spent
from distillation.
2. pH Dosing tank – One No

One no pH dosing tank of suitable capacity shall be provided.
3. pH Dosing pumps – Two No(1W+1SB)

Two no pH dosing pump of suitable capacity shall be provided.
4. Effluent lifting pumps – Two No(1W+1SB)

Two no condensate lifting pump of suitable capacity and suitable head shall
be provided.
5. Bio Tower – One No

One no RCC reactor of Suitable capacity shall be provided. Bio-tower
Bio and
trickling filters are relatively simple tr
treatment
eatment units with full of media over
which the process flow is distributed, or “trickled.” The media is used as a
surface on which to grow a biological mass which will contain and support
a population of microorganisms which perform the actual treatment that t
takes place in the Bio-
Bio tower and trickling filters.
6. Aeration tank – One No

The partially treated effluent from Bio tower shall then be subject to
activated sludge process for further reduction of organic matter. Aeration
tanks are provided for degradation of organic matter through biological
process. Microorganism in the controlled environment carries out the
biodegradation process.
7. Blower – I – Two Nos.

Two no blowers (1 Working + 1 Standby) of suitable capacity shall be
provided to facilitate aeration in aeration tank-I.
8. Treated Water Sump-

Sump One No.
One no RCC pre-treated
treated water sump of suitable capacity shall be provided
to collect the treated water.
9. Treated Water transfer pump – Two No(1w+1SB)

Two no filter feed pump of suitable capacity sha
shall
ll be provided to feed multi
grade filter.
10. Multi-grade
grade Filter – One No
One No suitable capacity multi-grade
multi grade filter shall be provided to remove
suspended solids in treated water. Its internals shall be fabricated of carbon
steel.
11. Activated Carbon Filter – One No

One no suitable capacity activated carbon filter shall be provided to absorb
the impurities from treated water. Its internals shall be fabricated of carbon
steel.
2.9.6 Technical Specifications Membrane Treatment Plant
Micron Filtration System - 1 Set.

Max. Working Pressure : 3.5 kg/cm2
M.O.C. Of Housing : FRP MEMBRANE –1No.
High Pressure pump : Vertical
Multistage SS Pump Quantity : 1nos.
Pressure tube : FRP
Skid : MS Coated with Powder paint
C.I.P. System with SS Pump
2.10 Project Profile Summary
Project
ct profile for installation of 100 KLPD grain-based distillery plant to produce
Rectified spirit or Extra Neutral Alcohol, along with stillage evaporation system, Dryer,
Secondary Effluent 8treatment system, Boiler & TG set
1 Name and Address M/s. Shantanu Transnational Life Sciences PVT

LTD..,., AIDC Park, Post. Matia,
Tal. Assam, Dist. Gaolpara
Phone No.- +91-22-62020000
62020000
Mobile Number: 7042376881, 9871774168
Email- ShantanutlsPvt
Pvt Ltd.
Ltd.@Gmail.com
2 Constitution and Type PVT LTD.
3 Project Concept
a) New plants 1. 100 KLPD grain-based distillery plant to
produce
Rectified spirit or ENA
2. Standalone stillage evaporation plant
3. Dryer
4. Boiler, 18 MT/Hr. (45 Kg/cm2)
5. TG set 3.0 MW
b) Products 1. Rectified spirit: IS:323
IS:323-1959
2. Extra Neutral Alcohol: IS: 6613
6613-2002
3. Head spirit conforming to
I.S.I. Grade - II, 323 (1959)
4. DWGS or DDGS
5. Fusel Oil
6. Steam: 18 MT/hr, 45 Kg/cm2
6. Electricity: 2.600-2.800
2.800 MW
c) Working days /Annum 330
d) Grain required /Annum 74,500 MT @ 68% % of starch
4 Main Product Kilo Liters /Day
AA (Fuel Ethanol) 100
Impure Spirit %
1%
5 Steam requirement Total- 367.80 MT /day (15.3

(15. MT/hr),
i.e.
e. For Distillery MEE & Dryer - 429 MT/day
(17.90 MT/hr), Boiler de-aerator
aerator – 67.50
MT/day (2.81MT/hr).
6 Electricity requirement for Max. 64.8 MW/day (2.7 MW/hr)
Distillery, Stillage evaporation
plant & Dryer,
Secondary ETP, boiler and
7 Water requirement 550.00 M3/day (After recycle of stillage
condensate)
8 Staff and workers Total 200 employees out of which 113 shall be
skilled
staff and 91 shall be unskilled staff.
2.11 Project Cost
The over all project cost

st has been estimated at INR 1158.03 Crore. The summary of the
project cost has been provided in the exhibit below:
INR
Sr No Particulars Crores Proportion
1 Land and Land Development Cost 6.7 4.2%
%
Building & Civil Construction &
2 Boiler 23.7 15%%
3 Plant and Machinery 102.54 64.8%
.8%
4 Furniture and Fixture 1.69 1%
%
5 Hard Cost 134.63 85.1%%
6 Contingency 7.14 4.5%%
Preliminary & Preoperative
7 Expenses 6.61 4.2%
%
8 Interest During Construction 3.39 2.1%
%
Margin Money for Working
9 Capital 6.26 3.9%
%
10 Soft Cost 23.4 14.8%
%
11 Total Project Cost 158.03 100.0%
2.12 Location
1. Location Coordinates: 26°05'50.0"N 90°43'36.1"E

2. Area : AIDC Growth Center, Matia, Gaolpara, Assam
3. Plot:
3.0 Personnel Requirement
Shantanu Transnational Life Sciences PVT LTD. have decided to install new 100
KLPD grain based distillery plant, stillage evaporation plant and secondary effluent
treatment system to achieve “Zero Liquid Discharge” (ZLD) as per CPCB/MPCB
CPCB/M
norms. The management of TLSTLSPVT LTD. has also decided to install 18 MT/hr @
2
45 Kg/cm pressure boiler and 3 MW TG set for 100 KLPD grain based distillery
plant.
The section wise requirement of staff and workers and their estimated salary and
wages aree given in the following table.
3.1 Staff Salary and Wages

Wages- (To be adjusted with prevailing market
conditions)
3.1.1 For 100 KLPD Grain Based Distillery Plant Staff Salary and Wages-
Wages
Sr. No. Designation No. of Posts Total Annual Salary

(Rs. Lac)
1. Distillery Sr. Chemist 01 4.00
2. Distillery Chemist 03 10.00
3. Assistant Engineer (Elect./Mech.) 01 3.00
4. Lab. Chemist 3+1 9.60
5. Milling plant-Operator
Operator 04 10.66
6. Liquefaction plant
plant-Attendant 03 6.00
7. Fermentation process attendant 03 6.00
8. Distillation plant - Operator 04 10.67
9. Distillation process attendant 03 6.00
10. Evaporation plant operator 04 10.67
11. Evaporation plant attendant 03 6.00
12. DDGS and Decantation plant 03 6.00
Operator
13. Decantation plant attendant 03 8.00
14. DDGS plant attendant 03 6.00
15. Ware house Attendant 02 4.00
16. Pump Attendant 03 6.00
17. Laboratory Attendant 02 4.00
18. Peon 10 2.00

19. Helper 52 3.0
Total (A) 111 545.4
3.2 For Condensate Polishing Unit (CPU)

(CPU)-

(Rs. Lac)
1 Plant Operators 07 8.00
2 Helper 13 3.00
Total (B) 20 95.00
3.3 For Boiler section–

(Rs. Lac)
1 Maintenance Engineer 04 14.40
2 Senior DCS Operator 03 9.00
3 Assistant DCS Operator 04 9.60
4 Worker 27 3.0
Total (C) 38 204
3.4 For Turbine section–

section

(Rs. Lac)
1 Turbine attendant 03 5.40
2 Assistant turbine attendant 04 4.80
3 Worker 31 3.00
Total (D) 38 128.4
Total (A+B+C+D) (Rs. Lac) 972.8
4.0 Section I: Introduction
4.1
.1 Identification of Project Proponent-
Proponent Director Profile
Shantanu Transnational Life Sciences PVT LTD., located at Industrial

Growth Center, Matia, Goalpara, Assam.
Our executive team is comprised of a team of innovative Entrepreneurs from different

fields.
Shri Vimal Kumar Dubey, worked and developed the best Carbon Black industries in
world like Thai Carbon Black –Thailand
Thailand (fortune 500 company of Birla Group),
Alexandria Carbon Black-Egypt,
Egypt, Phillips Carbon Black and Continental Carbon
India Ltd (Retired Managing Directors) (both in India), for more than 40 years. He
has been involved in commissioning;
- World’s first, Quench Boiler in tread and Carcass Reactors (patented)
- Developed arguably, highest in the world 300 metric ton production lines
- Developed Pellet less cost
cost-effective
effective packaging for Bridgestone Japan.
- National Energy Excellence Award, from the Minister of Indus
Industries.
Shri Raman Dwivedi Director of M/s. He professional qualified working in top

Management Position in Fortune 500 Companies.. He is dynamic practical and matured
professionals. He is associated with Aditya Birla Group for approx maturity 36 years
working in various projects procurement and erection and commissioning of projects .
His contact with top business houses is excellent
Shri Ravindra P. Angara He is dynamic, practical, hardworking self made Industrialist

repute of Maharashtra and Gujarat.
Gujarat. He has about 30 years of experience in industry and
has travels many countries of world for the business development activities, he is also
directors and proprietor other companies.
Shri, Mahender Gupta, also hails from agricultural sector and busine
business
ss family from Kota
Rajasthan, and is a graduate. He is also engaged in the Education, petroleum and Agro
product businesses. The experience Mr Gupta was essential for the successful running
of 2 biomass plants both producing 8 MW each in Rajasthan using Wheat Straw.
The Combination and permutation of these Directors coming together will allow
Shantanu Transnational Life Sciences Pvt Ltd to better existing technologies and
introduce new clean technologies to maximize profit centers while also keeping the
delicate ecology in mind.
Technical Advisors:
Shri Manoj Pawar - B.tech B. Tech & M. Tech in Chemical Engineering from
IIT Rourkee with specialization in Process Plant Design with an industry
experience of 30 years. Post Graduate Chemical Engineer with about three
decades of experience in Chemical Processes and Operation at global level,
During initial years of his career worked in ethanol plants at different
levels, including the position of production unit head, Hands on experience
with processes from major global process technology licensors for various
production processes, Traveled widely all over the world to source and
support the needs of new technological and marketing demands of fast
evolving process industry, He has complete insights of starch and ethanol
industries encompassing market size, technology up-gradation, competitive
forces molding growth of value-added
value products and the competition itself on
worldwide basis. Has vast experience focused on ethanol and starch
industry, right from technology marketing, process up-gradation, installation,
start-up and commissioning of green field and brown field Projects, Has deep
knowledge of effluent treatment strategies, for different types of
manufacturing industries, Deep knowledge of various process technologies
and extensive exposure to various manufacturing units at global level helps
in optimizing the CAPEX and OPEX of various processes Promoted and
successfully operating an EPC Company by the name of Vapco Engineers
Pvt. Ltd., which provides sustainable. Process technology solutions for ethanol,
starch and other process industry segments, In a short span of 7 - 8 years,
VAPCO has made a name in the field of providing EPC services on LSTK
basis for various industry segments and is on fast growth trajectory, Has
been associated with over 60 projects from concept engineering to
commissioning stages, for various grades of bio- ethanol, starches, specialty
chemicals & effluent treatment systems
Shri Pranay Dubey,, who is Director in Snow Organics Green Farms Pvt ltd, was responsible
for setting up a dairy plant derived from scientific principles, and 12 farms in India that are
working with the Govt without subsidy to showcase a subsidy free model. Working with a
Team of IIT & IIM graduates, leaders in their field have following accomplishments,
accomplishments Managing
Director of Deutsche Bank (USA), Vice president Google (USA), HCL President (USA) and
head consultant who launched the Jio Project.
Technical Advisor for the Power Plant : Mr. R. P. Sinha Shakti Punj Engineers (P) Ltd Ltd:
Started Engineering Consultancy Services Company in 2004 as Director. 2004 to till date. After
Post Graduation in Mechanical Engineering; served in both Pub
Public
lic & Private Companies at
Senior Positions for about 33 years having core competence in Power Plant – Design,
Engineering, Installation, Testing, Commissioning and O&M Services. Subsequently in 2004
started his own Engineering, Consultancy & working as Director.
Director. During the period provided
they provided their services to many companies & commissioned more than 25 power plants.
They are well know in Industry & have a excellent reputation.
4.2 Socio Economic Activities
Apart from running successful business and profit the member farmers, stakeholders the management
of STLS we also would be involved in several Socio
Socio-Economic
Economic developmental activities for member
farmers and workers. Some of the activities are briefly mentioned below,
i) Giving medical aid to the employees and their dependents.

ii) Helping member farmers by supplying fertilizers, cane seeds and also
arranges field demonstration & seminar to educate farmers.
iii) Provides financial support to implement lift irrigation schemes and drip
irrigation schemes in its area of operation.
iv) Provides the residential facility for the staff members.
v) The labor welfare activities for workers will be conducted at site.
vi) To Provide Extra Income to Farmers by improving supply chain and to create an
infrastructure of knowledge which will help increase yield while decrease cost.
In short, Shantanu Transnational Life Sciences PVT LTD. has decided to install 100 KLPD
grain-based distillery plant, boiler & TG set, stillage evaporation plant, dryer and Effluent
treatment plant etc. We want to be active participants in the E20 Program to support and
facilitate growth of Industry and Agricultural Sector of Assam and India.
4.3 Project Background and Over view
With the launch of new Ethanol Promotion Policy by the Government and in order to enhance
ethanol availability in the country for blending with petrol, Client is planning to set up Grain
(Rice) to Ethanol bio-refinery project using rice as feedstock.
The project aims at construction of bio ethanol project that produces first generation (1G) ethanol
from rice as main feedstock. The government of India is currently leveraging major grain
producing states to balance the ethanol supply from grain and sugary feedstock.
The primary feedstock is rice and can also use other available grain such as maize. he bio-ethanol
project will process around ~ 0.77 – 0.78 Lac MT/Annum of rice to produce 100 KLPD of 1G
ethanol or around ~ 3.3 - 3.4 Cr lit of 1G ethanol /Annum. The bio-ethanol
bio ethanol project will also
generate DDGS (Distillers Dried Grain soluble) powder as a by by-product
product which is highly rich in
protein content and will be used as a cattle or poultry feed.
The project site selection

n criteria to be considered for proposed project is as follows:
 Availability of land and water
 Proximity to blending depot
 Availability of feedstock
 Preferred by ABPL
4.4 Design parameters
The project aims construction of 1G ethanol plant that produces 1G ethanol using rice main
feedstock. The proposed 1G ethanol plant will be based on the most experienced and globally
recognized Indigenous technology available in India. The plant will be design to produce 100
KLPD of 1G ethanol and will process ~ 232 MMTT (inclusive of handling losses) of rice having an
starch range of around 68 % w/w per day.
In this plant , there are mechanical handling equipment like Conveyors, Size reduction equipment
like Mill , pumps, decanters, which will need routine maintenance. So Plant operation has been
considered for minimum 330 days of operation per annum.
Primary feedstock is Rice and Maze which is available as surplus currently in India .The plant
would also be designed to operate on maize which also is available in India.
4.5 Technology Salient features

1. Technology available indigenously with successful plants running based on the technology
with focus on reducing water ,energy and carbon footprint
2. Provided with most efficient Fed batch Fermentation technology
3. Distillation operating on Multi-Pressure

Multi Technology – an efficiently heat integrated system,
operating on fully automated PLC control system
4. Most efficient process technologies for liquefaction, fermentation ,MPR distillation ,

dehydration and evaporation to attain maximum and sustainable plant outputs
5. Extensively process and heat integrated system to reduce energy consumption
6. Water management design based upon three principles of reduce, reuse and recycle water to
minimize fresh water requirement.
7. Zero effluent and liquid discharge norms applied while designing the plant.
8. Ethanol produced from the proposed 1G ethanol facility will be as per Indian specifications
(IS 15464:2004) of anhydrous ethanol for use of blending in automobile fuel.
4.6 Ethanol scenario in India
CLASSIFICATION OF ETHANOL
Classification of Ethanol
 In India Ethanol is majorly classified into 4 categories namely–
namely
o Fuel Ethanol
o Potable Ethanol
o Pharma Grade Ethanol
o Industrial Ethanol
 1G technology focuses on ethanol that can be derived from category of feed stocks like–
like
o Sugary ( C Molasses , B Molasses, Cane juice/Syrup)
o Starchy (Grain like Rice, Maize, Sorghum, wheat etc.)
 2G technology focuses on ethanol that can be derived from Agri Residue like–
like
o Bagasse, Rice straw, corn
orn cobs etc.
ETHANOL DEMAND SCENARIO ESTIMATION FOR202

FOR2020
* Considering
target of pre
ponement by
2025
Source: VSI,PPAC
Others: Industrial+Pharma,
etc.
*https://pib.gov.in/Pr
essReleaselfr
essReleaselframePa
ge.aspx?PRID=168
48616dated
(14/01/2021)
The ethanol demand considering the preponement of EBP to year 2025 is of total around
~1200 Cr lit per annum out of which around ~900 Cr lit is for fuel ethanol and around ~
300 Cr lit is from other sectors
4.7 Ethanol Supply Scenario
Backed by slew of measures by the Gove Government

rnment and strong support by the OMCs the
ethanol blending targets are set to rise, but, still would fall short to achieve 20 % blending
Ethanol supply trend and estimated quantity until 2022
Source: DFPD presentation Jan2021

The key reason for this short supply being, currently the Ethanol blending is heavily
dependent on Sugar industry which is cyclic in nature and also caters to other ethanol
demands based upon price variations. This underlines the need to focus on 1G grain to bio –
ethanol projects
4.8 Socio-economic
economic advantages of Proposed 1G ethanol project
4.8.1 Reducing import dependency: The proposed 1G ethanol project will produce around ~ 3.7
–
3.9 Crore litres of Fuel Ethanol. This project is a step in utilizing renewable and
environment- friendly sources of energy like ethanol to supplement fossil fuels.
4.8.2 Cleaner Environment’s per the ministry of petroleum notification on new biofuel
policy, the proposed 1G ethanol project will produce around ~3.3 – 3.4 Crorere litres of Bio-
Bio
Fuel Ethanol which has the potential to save around 45% – 50% of CO2 emissions per year
by replacing gasoline with bio-ethanol
ethanol if biomass is considered as possible fuel source
4.8.3 Employment Generation: The proposed 100 KLPD 1G ethanol project will
create around 100+ direct jobs in plant operations, and about thousands of indirect jobs for
personnel related to various supply chain & selling of by
by-product; village level
entrepreneurs and Grain and DDGS supply chain. DDGS as a protein ric rich
h feed for animals
will boost animal husbandry development in rural India. This will provide boost to rural
economy in India.
4.8.4 Income to Farmers: Farmers will get sustainable income source by growing
feedstock and there will be assured off take and utilization
utilization of grains for biofuel production.
This will help to increase farmer’s income.
4.8.5 Infrastructural Investment in Rural Areas: Proposed 1G ethanol plant will require
Capital Investment as stated in this document. Investment in proposed 1G ethanol plant will
spur infrastructural investment in rural areas.
4.9 Indian Outlook for Bioethanol
4.9.1 Progressive Vision and Strong Policy Support
 The Government of India in January 2003 launched its Ethanol Blended Petrol (EBP)
Programme for 5% ethanol blended petrol in 9 states. India’s EBP Programme sought to
improve fuel efficiency and ensure protection from the price shocks of the global crude
market.
 In 2006, Government of India announced 5 % mandate for ethanol blend blending Pan India
excluding the entire north-eastern
eastern region, Jammu and Kashmir, and Andaman and Nicobar
Islands which were left out of the EBP Programme (source: Ministry of Petroleum & Natural
Gas, 2015)
 In 2009, the Government of India introduced a National Policy on Biofuels. The Policy
focused on further encouraging biofuel usage and reducing the prevailing dependence on
fossil fuels, while it sought to mitigate environmental and fuel efficiency concerns. The
Policy also recognized the significant opportunity
opportunity that biofuels offer to India’s agricultural
and industrial sectors. This policy also mandated a phased implementation of ethanol
blending in petrol in various states.
 In 2012, the CCEA decided that a stable EBP Programme would ensure sustainable benefits
benef
for sugarcane farmers across the nation, and the 5% mandatory ethanol blending with petrol
should be implemented across the country and that the purchase price of ethanol would be
decided between OMCs and the suppliers of ethanol. A Gazette Notification
Notificatio was issued,
directing OMCs to sell ethanol blended petrol with percentage of ethanol up to 10% and as
per the Bureau of Indian Standard (BIS) specifications (Ministry of Petroleum and Natural
Gas, 2015).
 In 2014, in order to offer OMCs and suppliers clear

clear signals, the CCEA fixed ethanol prices
based on the distance of the mill/distillery from the OMC depot/installation (Cabinet
Committee on Economic Affairs (CCEA), 2014).
 These policy measures and strong support the Indian EBP Programme managed to achie
achieve
an average blending ration of around 4.5%
 To give a further boost to the EBP Programme the Union Cabinet, chaired by the Prime
Minister Shri Nagendra Modi approved National Policy on Biofuels –2018.
4.9.2 Highlights of national biofuels policy

policy-
 Targets to achieve these key outcomes through the EBP Programme

 Ensuring energy security and self-reliance
self by enhancing bio-fuels production.
 Reducing import bill and conserving foreign exchange.
 Reduction in carbon emission
 Strengthening rural economy, En
Enhanced
hanced and sustainable income for farmers by providing
boost to agricultural sector
 Retain employment and additional employment generation in rural India.
 Targets 10% ethanol blending by 2022 and 20% blending by2030
 Allowing additional feedstock for 1st Generation like sugarcane juice/syrup,
surplus/damaged grains for production of ethanol
 Use of lingo cellulosic biomass such as agricultural crop residue, energy crops ,etc. for
production of 2nd Generation Bio ethanol
4.9.3 Other major policy measures to support the EBP

 Interest subvention schemes introduced for sugar cane and molasses based distilleries
 Remunerative ethanol pricing for various feed stocks independent of crude oil pricing
 Assurance of OMCs to purchase ethanol for 10years
 Grain to ethanol (100%
100% ) have been notified in B2category
 OMCs have modified there tender terms like
- reduction in penalties from 5% to1%,
- reduction in security deposit from 5% to 1%,
- flexibility in supply
4.10 Key Drivers
 AATMA-NIRBHAR
NIRBHAR BHARAT ABHIYAN to promote local Energy resource.
 Aggressive Biofuel policy and Ethanol Blending Program
 Target to reduce GHG emission by 30 to 35% by2030
 Enhance Energy self-reliance.
reliance.
 Availability of plenty of agro based feedstock.
 Advancements in Ethanol production (enhanced feedstock basket) and application (Flex
Fuel Vehicles) technologies.
 YoY increase in Potable and Industrial ethanol consumption.
4.11 Ethanol demand scenario estimation for 2025
* Considering
target ofpre
ponement by
2025 Source:
VSI,PPAC
Others:
Industrial+Pharma, etc.
*https://pib.gov.in/Pre
ssReleasel
ssRelease
framePage.aspx?PRID
=16848616
• TheethanoldemandconsideringthepreponementofEBPtoyear2025isoftotalaround
~1200 Cr lit per annum out of which around ~900 Cr lit is for fuel ethanol and around ~
300 Cr lit is from other sectors
• The above demand does not take into account additional requirement envisaged for diesel
blending and SAF (Sustainable aviation fuel)
4.12 Ethanol supply scenario

Backed by slew of measures by the Government and strong support by the OMCs the ethanol blending
targets are set to rise, but, still would fall short to achieve 20 % blending
4.12.1 Ethanol supply trend and estimated quantity until 2022
Source: DFPD Presentation Jan 2021
4.12.2 Feedstock Wise Ethanol Demand - Supply Scenario Estimation For 2025
20% ethanol Other Uses

Particulars Total (In
blending ( Cr.lit)
Cr.lit)
(Cr.lit.)
Total Requirement 900 300 1200
Source - DFPD presentation dated
27/01/2021
- https://pib.gov.in/PressReleaselframePage.aspx?PRID=16848616 dated (14/01/2021)
4.12.3 Estimated Ethanol Supply from Sugar Sector
Source for Sugar: VSI , PIB, Industry and mathematical

assumptions
 As derived from above maximum possible supply from Sugary feedstock is ~ 700 Cr Ltrs
post diverting 6 MMT surplus ssugar
 This clearly denotes that blending targets cannot be achieved only by diverting
sugarcane/sugar to ethanol, so there is dire need for alternative feed stock.
 Thus, the government is encouraging production of ethanol from other feedstock like
grains (Surplus rice/Maize/Damaged Food Grain(DFG)).
4.13 Grain Feedstock Scenario
The Government has notified about surplus Grain availability of around 13.5 MMT which can
be utilized to produce Ethanol.
Estimated Ethanol Supply from Grains
*Feedstock availability Source: DFPD presentation

27/01/2021
4.14 Existing and Required Capacities - India

Molasses Grain Total

Particulars
Based Based (Cr.lit)
(Cr.lit.) (Cr.lit)
Supply requirement 660 540 1200
Installed Capacity required
825 675 1500
considering 80% Capacity
Utilization
Existing Ethanol / Alcohol capacity 426 258 684
Capacity addition envisaged by 2022 93 - 93
Capacities to be Added 306 417 723
Source - DFPD presentation dated 27/01/2021
Table 4.2 Fuel Ethanol Blending Program
4.15 Project Justification

GOI is planning to reduce crude import up to 10% by 2022. EBP is one of the key facilitators of
reducing import bill by blending ethanol in gasoline thereby reducing gasoline requirement and
providing sustainable income to farmers.
The above table also depicts

picts the ethanol available and shortfall and potential demand going
ahead.
The following point’s highlight the advantages of establishing such plants in order to bring
sustainability to ethanol blending program –
1. In the current scenario Ethanol supply is dependent on Sugar sector.
2. Major Sugar Cane Crop Production is limited within Maharashtra, Uttar Pradesh, Bihar and
Karnataka. Due to this the major Alcohol Production is also from these four states only,
making imbalance for demand and supply of other states.
3. Shortage in supply of fuel ethanol post diverting excess sugar.
4. Incremental Price pressure on account of sugarcane FRP increase and subsequent

remunerative pricing of ethanol.
5. Alternative feedstock in the form of surplus grain (rice) is adequately available
6. Benefits of setting of grain to Ethanol plants:

a. Control on Ethanol supply for non
non-sugar
sugar producing states and even Sugarcane crop
deficit years.
b. Ensuring minimum quantity sustainability of the EBP
c. In case of Grain to Ethanol, ZLD can be achieved with value added - protein rich DDGS
as aco-product.
d. Decentralized units will boost in achieving state blending targets and reduce interstate
transport. This will also reduce the carbon foot print due to reduction in vehicle
travelling.
7. Benefits of setting
ng up higher capacity Grain to Ethanol plant:
a. Can achieve better Economy of Scale and reduce production costs
b. Provides cushioning against variation in Feedstock and by-product
by prices
Section5Project at a Glance
: Indicates Scope of Work normally undertaken by Praj
TYPICAL AREA REQUIREMENT – Around 20 Acres (Considering Green area requirement as per MOEF
guidelines)
Section 6 Process Description
6.1 Liquefaction
In liquefaction process, starch is hydrolyzed to dextrin. The Liquefaction is carried out in

Liquefaction Tanks. Feedstock Flour is transferred to Pre
Pre-masher
masher and mixed with Recycle Streams,
thin stillage and liquefying enzyme. Slurry from Pre-masher
Pre masher is taken to Liquefaction tank where
temperature
rature is maintained by means of steam. Necessary retention time is maintained in the
Liquefaction Tank. Contents in Slurry Tank are kept in suspension by Agitation. The Liquefied Slurry
is then cooled in Slurry Cooler (wide Gap PHE) and transferred to Pre-fermentation
Pre fermentation and Fermentation
section.
6.2 Fermentation
Yeast Activation:
Yeast seed material is prepared in Yeast Activation Vessel (Pre
(Pre-fermenter)
fermenter) by inoculating sterilized
mash with yeast. Optimum temperature is maintained by circulating cooling wat water.
er. The contents of
the Yeast Activation Vessel are then transferred to Fermenter.
The purpose of Fermentation is to convert the fermentable substrate into alcohol. To prepare the mash
for Fermentation, it is diluted with water. Yeast is added in sufficient
sufficient quantity to complete
Fermentation to produce alcohol.
Significant heat release takes place during Fermentation. This is removed by passing the mash
through heat exchangers to maintain an optimum temperature. The recirculating pumps also serve to
empty thee Fermenters into Beer Well. CO2 can then be taken to CO2 vent line where it is vented out.
After emptying of Fermenter, it is cleaned with CIP using cleaning nozzles. After CIP, Fermenter is
ready for next batch to be filled.
6.3 Distillation
Pre-heated fermented wash is fed into a series of Distillation Columns to increase the alcohol
concentration and remove various impurities
6.3.1 Distillation – (Wash to AA Mode)

Mode
Following Columns will be under operation
1. Analyser Column
2. Degasifying Column
3. Rectifier cum Exhaust Column
4. Alcohol Scrubber
6.4 Molecular Sieve Dehydration Plant (MSDH):

Rectified Spirit containing at least 95% v/v alcohol is pumped from RS feed tank to dehydration
section.
Superheated hydrous alcohol vapors are sent to twin Adsorbent Beds. The twin Adsorbent Beds
operate in cyclic manner. Twin beds are provided to allow for bed regeneration in continuous
operation. While one bed is in dehydration mode, the other is in regeneration mode.
The Adsorbent Bed will absorb moisture present in feed vapors and dehydrated product alcohol
vapors are obtained from bottom of the bed.
The Product alcohol vapors are then passed through Product Condenser where product vapors are
condensed with the help of cooling water. Condensed product alcohol (@ 99.8
% v/v strength as required for fuel blending) is collected in product receiver.
The Product alcohol from Product Receiver is pumped to Product Cooler where it is cooled with
the help of cooling water and then sent for anhydrous alcohol storage.
6.5 Decantation
Decantation section comprises of a Centrifuge Decanter for separation of suspended solids from
Spent Wash coming out of Grain Distillation Plant. Wet cake is removed from bottom of Decanter.
Thin slops coming out of Decanter are collected in a tank and partly recycled into the process &
Evaporation for further concentration. The concentrated thin slops called as Syrup is mixed with Wet
cake and sold in wet form as cattle feed (DWGS).
Or as an option, the entire mixture can be dried in a DWGS Dryer and then
then sold in dry form as Cattle
feed(DDGS).
6.6 Integrated Evaporation Section
The suggested treatment scheme is a THREE EFFECT working on the principle of falling film
Evaporation for Thin Slop Evaporation Plant.
The following points will elucidate the bbasic working principle:
1. Shell & Tube type Evaporators working on the principle of Falling film Evaporation has been
used.
2. Steam of medium pressure is fed to the first effect.
3. The product at the desired concentration is obtained at the outlet of the finisher.
4. The Pure steam condensate are collected in receiving vessels and can be pumped to desired battery
limit
5. The plant is having high level of automation to get consistent output at required concentration.
6. The system operates under vacuum.
6.7 DDGS Dryer
 Wet distiller’s grains shall be fed into the dryer housing at controlled rate through a suitable
feeding system. The Rotary Tube Bundle is enclosed in an insulated dryer housing and on its outer
flights are fixed. Dry, saturated steam is to be supplied to the tube bundle through rotary joint at one
end & the condensate is discharged through rotary joint mounted of another end.
 The heat transfer is primarily by conduction. The water vapors are exhausted through an Exhaust
Blower & passed through a cyclone separator for separating fines.
 Dry product partially recycled back to Feed conditioner for feed conditioning through Product
Screw & Recycle Conveyor.
6.8 Process Condensate

nsate Treatment Section
 The process condensate from the evaporation section is treated in this unit and this treated
condensate is then recycled back to process thus reducing the fresh water consumption.
Section 7 Process Design Basis
7.1 Plant Details
Parameter Details
Grain Flour (Broken Rice/Maze) Grain flour containing minimum 68 %

w/w enzymatically convertible starch.
Products
AA @ Purity 99.8 % v/v 100 Kilo Liters per day (KLPD AA)
Yield
Liter of alcohol (95%v/v) per ton of Grain flour
466
(@ 68 % Convertible starch is calculated by
Lit/MT
enzymatic hydrolysis method
Liter of alcohol (95%v/v) per ton of Grain flour
(@ 60 % Convertible starch is calculated by 411
Lit/MT
enzymatic hydrolysis method
Notes:
 Plant is designed to operate on single grain flour i.e. Broken Rice Flour for purpose of
conducting Performance Guarantee.
Section8 Input requirements
8.1 Input Requirements
INPUT BASIS QUANTITY

MATERIAL
Convertible Flou
Grain handling losses (assumed 1.5 %)
Starch % r
w/w TPD
Broken Rice 68 (Min) 232 – 235
Maize 60 (Min) 263 – 265

Steam requirement
Liquefaction + Distillation + Evaporation +
Kg/lit of TS 3.4 (15.3 TPH)
Dryer (B.Rice)
Water requirement – Including Boiler
Raw water requirement with recycle of stream (at
M3/day Around 550
5 *
steady state plant operation) m3/day – AA Case
Chemicals requirement Kg per KL Of Total Spirit
Distillery As per process requirement
Evaporation & Process Condensate Treatment plant. As per process requirement
Culture Yeast As per process requirement
Boiler + Turbine
Boiler – Rice Husk 25
Turbine – SBP TPH**
3 MW**
Notes
: * Above water requirement is subject to vary as per water quality and WTP reject
1. treatment decided going ahead.
Requirement of power indicated above is subject to variation and will be confirmed
2. after detailed engineering.
** Boiler and Turbine configuration would be fixed upon discussions considering
3 possible Other requirements and combinations
Yield Table:
S.n Convertible Yield @ 95 % DDGS in
o Starch v/v MT/day
1 68 % w/w 465 – 466 44 - 45
2 60 % w/w 410 – 412 66 - 68
8.2 Input Specification

– Grain Flour
Clean Grain /flour should be free from Fermentation inhibiting substances and micro-
micro organism
producing side products, sand and other foreign particles. The raw material (flour) should be of
quality as mentioned below:
Sr. No. Description B.Rice Corn/Maize

1 Enzymatically Convertible Starch 68 % min 60 % min
3 Moisture Content 10% - 11% 12% - 13%
w/w w/w
4 Others 21 – 22 % w/w 27 – 28 % w/w
8.2.3 PRAJ recommended Desired Particle size distribution of Grain Flour:
Sr. No. Particle size in mm % w/w of Total

flour
1. Above 1.2 NIL
2. 1 – 1.2 10 – 12
3. 0.85 – 1 15 – 20
4. 0.6 - 0.85 20 – 35
5. 0.3 - 0.6 25 – 35
6. Less than 0.3 15 – 20
Note: 1 mm = 1000 microns

A. Utility Specifications :
i. Dry Saturated Steam Specifications:
Dry, Saturated, De-superheated
superheated & Regulated Steam should be available at the inlet of
steam header as per details given below with respect to battery limits.
 Liquefaction Section:
Steam pressure should be 3.5 kg/cm2 g +/- 0.05 at temperature of 1460C at the inlet of
steam header in Liquefaction section.
 MPR Distillation Section:
Steam pressure should be 3.5 kg/cm2 g +/- 0.05 at temperature of 1460C the inlet of
steam header in distillation section.
 Evaporation Section:
Steam pressure should be 11.5 kg/cm2 g+/- 0.05 at temperature of 1250C the inlet of
steam header in Integrated Evaporation section.
 DDGS Dryer Section:
Steam pressure should be 3.5 kg/cm2 g +/- 0.05 at temperature of 1460C the inlet of
steam header in Dryer section.
ii. Electricity
Supply condition-33 phase/ 4
wire Voltage- 11 KVA / 415

V AC
For control system: 230 V, 50 Hz (3), 11-phase, 2-wire supply

iii. Water specifications
 Process water: (Dilu
(Dilution
tion water in Fermentation / Liquefaction, CO2 Scrubber
water, Air blower sealing water etc.)
Sr.No Paramete Unit Value
. r
1 pH - 6-9
2 Chloride (Cl-)) (Expressed as NaCl) mg/lit < 250
3 H2S mg/lit Nil
4 Residual free chlorine mg/lit <1
5 Silica (SiO2) mg/lit <30
6 Turbidity NTU <5
7 Total germs Nos./m <60 CFU
l
8 Coliform Bacteria Nos./m Nil
l
9 E. Coil Nos./m Nil
l
 Soft water (For Cooling tower make up, Dilution water for fusel oil decanter,
Alcohol scrubber water, & pump sealing etc.)
. r
1 pH - 6-9
2 Chloride (Cl-)) (Expressed as NaCl) mg/lit < 50
3 H2S mg/lit Nil
5 Silica (SiO2) mg/lit < 50
6 Total Hardness (Expressed as CaCO3) mg/lit <5
7 Turbidity NTU < 10
mg/lit <550
8 Total Dissolved Solids
 Dilution water: for Extractive Distillation Column (For Future ENA Scope).

. r
1 pH - 6-9
2 H2S mg/lit Nil
4 Total Hardness (Expressed as CaCO3) mg/lit <5

5 Turbidity NTU <1
6 Total Dissolved Solids mg/lit <50
Note:
Water should be free from any smelling / odor
components. Mg/lit – Parts per Million (PPM).
1. Chemicals specifications:
The Specification and Consumption Details for Auxiliary and Chemicals required are as below
i. Urea
Urea is used as nutrient to supplement Nitrogen source to maintain desired level of FAN
(Free Amino Nitrogen) content in the Fermented Mash.
The consumption of Nutrient depends on the FAN (Free Amino Nitrogen) content in Feed
Stock.
Sr. Parameter Unit Value
No.
1 Nitrogen % w/w 46
(Min)
2 Moisture % w/w 0.5
(Max)
3 Arsenic % w/w 0.0001
(Max)
4 Iron % w/w 0.01
(Max)
5 Lead % w/w 0.001
(Max)
ii. Sodium Hydroxide (CausticLye):

Sodium Hydroxide is used in CIP solution for CIP of Yeast Propagator, Pre-fermentation
Pre
vessels, Fermenters and beer well.
Consumption of Sodium Hydroxide Lye depends on the Frequency of Cleaning.
Sr. Compositio Unit Concentratio
No. n n
1. Sodium carbonate (as Na2CO3) % w/w 2.00
(Max)
2. Sodium Hydroxide (as NaOH) % w/w 50.00
(Min)
iii. Input Specification for Active Dry Yeast (ADY):

Make: Lallemand, Fali
Section 9 Output Generation
OUTPU UNIT QUANTITY

T
Main Products
AA Kilo Liters per day 100
Impure Spirit % 1 %*
Bi-product generation
Steam condensate
Distillation TPH 80% of steam consumed at 55
55-60 °C
CO2 gas –
Recoverable Fermentation TPD ~ 50
DDGS
Broken Rice Operation @ 68
TPD 44 – 45
% w/w Convertible starch
Blow Down
Boiler Blow Down (max) M3/day 15 – 18
WTP reject M3/day 130 – 150
Note -
 The above expected other output generation are subject to Plant Design basis considered
in respective section and are indicative in nature.
 Quantities & solids content in dried cake mentioned depend on grain quality.
 Blow down and reject quantity mentioned is subject to water quality.
 * TA cut can be varied depending upon quality requirement
Section 10 Budgetary Investment
Budgetary Investment for Designing, Basic, Detailed Engineering, Fabrication, Supply,

Supervision of Installation and commissioning of Plant and Machinery for Distillery of 100
KLPD AA on B.Rice is as follows:
Value in
S. N Particula
rs INR Lacs
Liquefaction Section :
1.
Consisting of SS 304 Liquefaction tanks, Jet cooker along with Site
fabricated, Shop Fabricated, Bought outs, Piping & Valves, Electrical &
Instrumentation
Fermentation Section
Consisting of SS Fermenters – 3 No’s, SS Pre-fermenter, SS Beer
2.
Well, Site fabricated, Shop Fabricated, Bought outs, Piping &
Valves, Electrical & Instrumentation
Multi Pressure Distillation & MSDH Section
Consist of shop fabricated Distillation Columns along with Re
Re-boilers,
3.
Heat Exchangers, Coolers, Condensers, Site fabricated, shop fabricated,
Bought outs, piping & valves, Electricals & instrumentation
Integrated Evaporation Section + Dryer Vapour integration
4. Consist of FF evaporator Calendria along with VLS, Surface Condenser,
Site fabricated, shop fabricated, Bought outs, piping & valves, Electricals &
instrumentation
4600.00
Dryer Section + Decantation excluding Decanters
5. Drier along with Site fabricated, shop fabricated, Bought outs, piping &
valves, Electricals & instrumentation
Process Condensate Treatment Section – Includes C/T blow down +
Dryer Vapour condensate treatment
6.
Consist of RO system along with pumps, tanks, piping and valves, electrical
& Instrumentation
Utility Section and Alcohol storage critical
7. Cooling Towers, Air compressor along with pumps, vent condensers,
tank nozzles ,Piping, valves, electrical & Instrumentation etc.
8. Yard piping, Process Plant lighting
9. Civil Design & Engineering of for Praj’s scope of section only
Installation of the above sections shall be carried out by M/s
10.
PrajEngineering & Infra Ltd. Pune, a wholly owned subsidiary
company of PRAJ
11. Packing & Forwarding, Transit Insurance & Loading
Total 4600.00
PART B - BALANCE OF PLANT
Value in
S. Particula INR Lacs
N rs
Alcohol Storage Section for 30 days AA – supply and installation
1. Inclusive of tankages for MS Daily Receivers AA – 110m3 x 3 No’s,
MS Bulk Storage for AA tankages – 1500 m3 x 2 No’s, MSDH Feed
tank – 110 m3 x 1 no
Structural Works:
2. Supply & Installation of structural work
Grain storage, handling, cleaning and milling and Flour storage section
- Indicative
3. Consisting of Grain storage silos (4000 MT x 2 No), pre cleaners, Hammer
Mills indigenous, Flour storage silo along with dust extraction systems,
elevators, conveyors, Piping & Valves, Electrical & Instrumentation
Decantation –
4. Consist of Decanters – (2 + 1)
Boiler with Accessories including structure - Uttam/Privilege
5. Equivalent 25 TPH with Ash handling, Fuel handling & pollution
control accessories 5654
Turbine with Accessories – Chola/Triveni/Equivalent
6.
Turbine (3 MW) with all auxiliaries, HP/LP piping,
PRDS etc.
Plant Electrical Up to MCC inlet
Bus Duct Alternator to Breaker Panel,
7. PCC PCC to MCC cabling - Max dist.
100 Mt
DG set for emergency
power Yard Lighting
WTP Section
8. Inclusive of site Fabricated, shop Fabricated, Bought out Items,
Instrumentation and MCC onwards Electricals, Piping and valves as per
specifications
9. Fire Fighting – As per TEC/IS guidelines
10. Lab Equipment , Chemical bulk storage
11. Weigh Bridge
12. Packing & Forwarding, Transit Insurance, Loading & Unloading etc.
Total 5600.00
GRAND TOTAL
S. N Particula Value in
rs INR
Lacss.
1 GRAND TOTAL (PART A + B) 10254.00
Notes:
1. The Above Prices Excludes the following:
a. Civil supply and execution indicative at around – INR 2406.00Lacs
b. Land and land development costs -INR 670.00 Lacs
2. Contingency
3. Preliminary preoperative expenses
4. Interest During Construction
ction
5. Margin Money for Working Capital
Capi
GST and shall be paid by purchaser at actual

actual.
6. Civil Cost will vary depend on Soil Condition.
7. WTP cost will vary as per water quality
8. The part B values are indicative and orders to be directly placed on the OEMs (Original
Equipment manufacturers) and a possible 5% – 10% variation is envisaged.
9. Price estimated based on current rates as mentioned below.
 SS 304 – INR 250 per Kg
 MS – INR 65 per Kg
SECTION 11 Typical
ypical Economics
11.1 Typical
ypical Cost of Production
Grain B.Rice
S.no Particular
(68 w/w %
Starch)
Variable Cost - A INR/lit
1 Raw Material 37.00
2 Utility 10.90
3 Chemical ,Enzymes 2.25
TOTAL A 50.15
Less Credit - B
1 Power, Impure Spirit, Ash, DDGS, CO2* 16.60
NET VARIABLE COST (A-B)
(A ~ 33.55
Fixed Cost
1 Manpower/O&M
~ 10.87
2 Interest
TOTAL COST in INR/lit ~ 43.87
NET Margin ~ 10.20
INR/lit
11.2 Typical
ypical Financial Analysis
S.N Particular
A PLANT CONFIGURATION
1 Distillery 100 KLPD
AA
2 Distillery Operating Days – 330 Days 330 days
3 Feedstock (Broken Rice) Required annually – TPA ~ 74,500
4 Fuel Ethanol Generation (Cr.lit) ~ 3.3
B REVENUE STREAMS – Distillery
1 From Ethanol in Rs Cr ~ 170.00
2 From DDGS (Distillers Dried Grain Soluble) ~ 34.90
TOTAL REVENUE in Rs. Cr ~ 204.90
Approx. Investment in Rs. Cr Excl. Taxes and Duties
C ~ 134.63
1
(Plant and Machinery + Structure + Civil)
Soft Cost additional in Rs Cr( WC Margin+ IDC+
D Contingencies+ Pre- operative expenses + CER)+ ~ 23.4
Site development,Misc costs
Notes:
1. Operation philosophy – 100 % Grain used to produce AA
2. GST of 18 % on plant and machinery and civil additionally can be set off against GST of
5 % on sale of ethanol in around 2.4 – 2.6years
Assumptions
Raw Material Rates
 Broken Rice – 16000 INR /MT

 Rice Husk with GCV of 3200 kcal/kg ~ 3000INR/MT
Product rates
 Ethanol – 51.55 INR/lit basic (1 Rs /lit deducted from 51.55 Rs/lit on account of
transport cost)
 DDGS – Broken Rice – 24000INR/MT
Financial
 Debt Equity Ratio – 70 :30
 Corporate Tax – 17 % (Considering new company formation)
 Interest – 10%
11.3 Sensitivity-
PROJECT INVESTMENT ~
Appx. Payback
Broken DDGS AA Project IRR Equity period as per
Rice Rate Rate IRR FCFF post 0 year
Rs/MT Rs/MT Rs/Lit % % Years
16000 29% 57% 3.3 – 3.5
24000 51.55
17000 25% 43% 3.9 - 3.11
11.4 Annual
nnual Key Input and Output Generation
Generation*
S.no Particular Unit Value

INPUTS
1 Feedstock
A Broken Rice post losses MTP ~ 74,500
A
2 FUEL For steam and Power
A Rice Husk @ 3200 kcal/kg MTP ~ 61900
A
3 Power (Self generation) KWH ~ 2500
OUTPUT
1 MAIN PRODUCT
A AA (Absolute alcohol or fuel ethanol) Cr. lit ~ 3.3
2 BY PRODUCT
B Distillers Dried Grain Soluble MTP Around 14550
A MT
Note: The above inputs and outputs are mentioned considering 330 Days operation
Section 12 Conclusion ad Recommendations
 The feasibility report is prepared based on information provided by Shantanu Transitional Life
Sciences PVT LTD. to the Institute.
 The new 100 KLPD grain based distillery plant is to be based on latest technology to produce
Rectified Spirit or Extra Neutra
Neutral Alcohol.
 The total requirement of grain is 337,498 MT for proposed 100 KLPD grain based distillery plant
considering working for 33300 days per annum (100% capacity utilization). Shantanu transnational
life sciences will purchase grain quantity 74,500 MT from nearby market.
 The total investment for 100 KLPD grain-based

grain based distillery plant based on multi pressure
distillation technology, Stillage evaporation, DDGS dryer, Secondary effluent treatment system,
boiler (steam production capacity 18MT/hr, steam pre pressure @45 Kg/cm2), T.G. set (3 MW/hr),
civil & structural works including taxes and duties shall be Rs. 155.26 Lacs.
 Special arrangement for water treatment should be undertaken depending on raw water quality.
 The technical specifications included in thi

thiss feasibility report are based on information supplied
by Plant supplier’s to other Distilleries. Institute has updated it from time to time. However, it
will be guideline and may change/improve further depending on quality.
 Some of the inputs and utilities are available with the sugar mill. It needs to be discussed
thoroughly at the time of inviting and technical discussion before negotiation and finalization of
order.
 It is recommended to operate the distillery throughout the year (3

(330 days/annum). For this
2
purpose, special boiler (18 MT/hr, 45 Kg/cm g) and new T.G. set (3 MW) has been
recommended for meeting the requirement of steam and power and to achieve “Zero Liquid
Discharge” of stillage.
 As regards effluent treatment; modern method of dec decantation

antation followed by evaporation and
followed by dryer will result in total conversion of stillage in to animal feed (either as DWGS or
DDGS). For other effluents such as process
condensate, spent lees, boiler / cooling tower blow down water, vacuum pump/ pump gland
cooling water etc. a secondary effluent treatment system is required so as to achieve “ZLD” as
per CPCB norms.
 The earlier discussions on technical configurations and financial parameters in foregoing

chapters reveal that this project is technically feasible and financially viable. The financial
projection indicates higher percentage of profits, sufficient cash generations to repay the loan
with interest. All the financial parameters normally considered for financing the project are
quite favorable. We conclude that the proposal in the present form is technically feasible,
financially viable and so can be considered favorably for financing.
Section 13 Commercial & General Terms & Conditions
VALIDITY:
Our offer is valid for your acceptance
ance for a period of 10 days from date hereof & thereafter subject to our
confirmation. The seller has right to revise the price beyond the validity Period of the Offer and in case of
material rate increase
We reserve the right to modify, alter the specifications

specifications and design of the equipment with our constant aim to
improve the same. PRAJ shall discuss these changes with client, before implementation.
PRICE:
The above mentioned prices remain same during the execution of project subject to the fulfillment of
commercial terms & conditions by client,
The above mentioned price is exclusive of:

Transportation charges for the entire plant & Machinery in our scope up to the site.
Transit Insurance charges
All Applicable taxes and duties.
All levies such as single point taxes and duties on various items will either be paid by the Purchaser directly
or will be reimbursed to us at actual.
Any other statutory obligation including but not limited to taxes and duties or other levies which may
become payable at any time including those which may become payable retrospectively even after the
fulfillment of the contract due to change in present laws or due to reinterpretation of existing or future laws
will be to the account of the Purchaser.
The Purchaser will either pay such duties directly, whenever a claim is made or will immediately reimburse
it to us at actual,, if we are called upon to pay these.
PRICE ESCALATIONFORMULA
In view of the extremely erratic behavior in the prices of raw ma
materials,
terials, the prices quoted are subject
to the PRICE ESCALATION FORMULA givenbelow:
Po { SSf MSf }
Pf = {35 + 60 +
}
5
100 { SSo MSo }
WHERE
Pf = The final contract price. Po = The quoted price.

SSf = Average base SAIL Price of SS 304 sheets Ex-Bombay
Bombay Stockyard, months prior to ourcommitted
delivery.
SSo = Average base SAIL price of SS 304 sheets Ex-Bombay
Ex Bombay stockyard at the time of quotation.
MSf = Average SAIL price of 3.15 mm, 5 mm, 6 mm and 8 mm MS sheets /plates Ex Pune stockyard, ssix
months prior to our committed delivery.
Mso = Average base SAIL price of 3.15 mm, 5 mm, 6 mm and 8 mm MS sheets / plates Ex-
Ex
Punestockyard.
Variation in the rates including but not limited to taxes and duties during the execution of the project on all
inputs, bought out and raw material will be to the account of Purchaser and can be mutually discussed.
Our Offer is based on the following Terms of Payment:-

FOR SUPPLY OF PLANT & MACHINERY: - PRAJ INDUSTRIES LIMITED
15 % of the Order value as interest free
ee advance along with LOI
20 % of the Order value as interest free advance along with signing of agreement
10 % of the Order value shall be paid within 5 (Five)days from submission of relevant documents
55 % of the value of the order along with applicable Taxes & Duties in full on Pro-rata
rata basis, within 5
(Five) Days from the receipt of pro form a invoice.
All payments shall be released through RTGS/ Cheque / demand draft payable at par, at Pune. All Bank
charges to your account.
Bifurcation of the Order:
FOR ERECTION OF PLANT & MACHINERY

15% of the contract value as advance along with LOI.
20 % of the Order value as interest free advance along with signing of agreement
10 % 0f the contract value against site mobilization
55 % of the contract value along with
th applicable taxes in full, shall be paid on pro-rata
pro rata basis for the work
completed on site within 7 (Seven) days from the date of submission of bills for the entire work envisaged.
PRAJ shall submit their billing break--up within 30 days from the date of signing
igning of agreement/release of
clear PO.
The Purchaser will provide suitable accommodation free of cost at site, for our Engineers, Staff, and
workers.
Following facilities are also to be made available by the Purchaser, free of Charge:
Electricity, steam,, water etc. as required during commissioning and execution of project.
Process Chemicals, lubricants, fuels, air, etc. as necessary during various stages of Commissioning.
All arrangement and other facilities including the operating personnel required dur
during
ing the Pre-
Pre
commissioning and commissioning stages.
Furnished site office with communication facility for our Engineer (s) /Staff.
The Plant will be handed over for commercial use after satisfactory 72 hours Continuous operation trials in
presence of the purchaser’s representative.
The purchaser shall not unreasonably hold back the issuance of Taking over Certificate as soon as the
equipment has been satisfactorily commissioned.
Unless a proper reason is advanced by the purchaser for non-issuance
non of the
Certificate,
ertificate, equipment will be deemed to have been taken over, seven days after the date of Commissioning
and we shall be relieved from any further responsibility.
Since, we, as a matter of common practice, We dispatch to the site a number of spare material or excess
material to site without invoicing them to the purchaser, in the interest of smooth and uninterrupted
completion of work. These excess material (unused) items will be our property and will be removed by us
from the site after completion of work.
Should the Purchaser desire to retain any of the items for his future use, we shall consider selling these
items to Purchaser at mutually agreed price against immediate payment.
WARRANTY:
Period of warranty for faulty materials or workmanship will be 6 months
months from the date of mechanical
completion or 12 months from the date of the last invoice whichever is earlier.
This warranty is, however, not applicable to parts which are subject to normal wear and tear or bought out
components including electrical, instruments,
struments, motors, switch gears, refractory’s, etc. Our liabilities under
this clause will be restricted to only repair of defective components.
CANCELLATION OF THE ORDER:

You shall not unilaterally cancel the order once placed on us. In the event of the order being cancelled by
you with our consent, you shall be liable to pay to us cancellation charges, either proportional to the
contract period already over up to the date of cancellation or the actual cost of work completed by us,
whichever is higher, subject
bject to a minimum of 20 % of the value of the contract.
However under no circumstances, you shall cancel the order after expiry of 75 % of the contract period,
nor shall you have any claim over designs, drawings and material lying with us, which after
aft cancellation of
the order, will become our property.
INSPECTION &DISPATCH:
All equipment and Machinery manufactured or procured by PRAJ shall be subject to quality assurance plan
of PRAJ.
PRAJ shall submit “QAP” after signing of agreement mentioning al alll stages of inspection(s), format of
inspection reports. PRAJ shall strictly follow these procedures.
THIRD PARTY INSPECTION:

Third party inspection of the goods has not been considered in the estimates, if third party inspection is
required the same shalll be arranged by the Client and the charges for the same shall be borne by the Client.
DELIVERY SCHEDULE:
11 –12
12 months from the date of signing of agreement, receipt of necessary advance and SLP approval;
whichever is later. This will also be subject to the following:
Force Majeure clause as mentioned in General Terms and Conditions.
Timely release of payments
Timely completion of responsibilities of Client including civil.
CHANGE IN WORK / LAW:

If there is any change in the scope and/or nature of work during the execution of this project because of the
change in local Government’s ruling/regulations/order an adjustment in terms including, but not limited to
prices, deliveries etc. shall be negotiated.
We are not obliged to proceed with the changes until we have received the Clients approval
of the proposed changes as well as adjustments, if any, in terms of the contract.
DELAY IN COMPLETION:
If the completion of dispatch is delayed beyond the contractual date for reasons beyond Praj
control
ntrol as listed out hereunder but not limited to them, we shall be untitled to suitable
Readjustment in the period of completion by mutual consent and the contract will Stand
amended to that extend:
Delay in inspection by Clients appointed agency beyond th thee appointed date or delay in
approval or test certificates, which ever required, beyond a period of 7 days from the date of
submission by Praj.
Delay attributable for Force Majeure conditions, more particularly detailed under appropriate
clause here under.
FORCE MAJEURE:
In the event of any force majeure circumstances affecting the ability of either party to
perform in accordance with this contract for extended periods of time exceeding 3 week, the
parties hereto shall meet and jointly decide the future course of action. Force Majeure shall
include but not restricted to Acts of God or enemy, action of the government in its sovereign
capacity, floods, fires, earthquakes, explosions, accident, epidemics, civil commotion’s, riots
etc. including factors beyondd PRAJ’s control.
We shall have a general lien on all the documents/ information supplied by us as well as the
work carried out by us till the final payments due to us, are released in full. No part of work
carried out by PRAJ will be put to commercial use without our permission.
LIABILITY TOWARDS CONSEQUENTIAL LOSS:

Praj shall not, under any circumstances or at any time, be liable to the Company under or in
connection with this Agreement in tort or otherwise for any special or any direct or indirect
loss or damage or any remote or consequential loss or damage, including but not limited to
loss of profits, loss of production, reduced production or loss of business or business
opportunity. Praj shall not be liable to the Company or the Subcontractors of the Company
for any consequential losses of any kind or nature arising out of or alleged to arise out of
furnishing of any services, personnel information or other assistance by Praj.
Other terms and conditions will be subject to mutual discussions and confir
confirmation
mation thereafter,
in writing by us.
For PRAJ INDUSTRIES LIMITED
Hrishikesh Deo
Business Development
Section 14. Incineration Boiler Suppliers
1. Chima Boilers
S.C.O. 523-524, Sector-70
70
Mohali, Chandigarh-160071
160071
Fax :0172-5090486
2. Mr. Kumar Buch

(Luz-Hou,
Hou, Thermal Power Equipment Company Ltd.) 6,
Soubhagyanagar,Vihitgaon
Soubhagyanagar,Vihitgaon-Lam Road,
Nasik Road-422101
Telephone- (0253)-2451275
2451275
3. Thermax Babcock &Wilcox

Wilcox
Division of Thermax Ltd., D-
D
1MIDC, R. D. AgaRoad,
Chinchwad, Pune-411019
411019 Kind Attn:vMr.JohnAlwaris Fax: 020-27479200
27479200
4. Fives-Cail KCP Ltd.,

RamkrishnaBuilding
No.2, Dr. P. V. Cherian Crescent
Egome, Chennai-600008,
600008,
Tel:91 44 66772755, Fax: 91 44 66772799
5. SSP (Pvt.)Limited,
13, Milestone, Mathura Road,
Faridabad – 121003 (Haryana) Ph.
No.- 0129-2275968, 2277442
Fax – 0129 – 2277441.
6. ISGEC
JohnThompson
A-7,Sector63,
Noida –201301
U. P.
Email:-ijtsales@ijt.co.in
Section 15 List of C.P.U Plant Suppliers
1. M M Enviro Projects Pvt. Ltd., Aakanksha

Arcade, KDK College Road,
Nandanvan,Nagpur-440009
440009
Ph. No. - +91-712-2714960
2714960
Fax No. - +91-712-2714968
2714968
email-mmenviro@gmail.com
mmenviro@gmail.com
2. Global Enviro Tech. Services,

Flat No. 704, “A” wing,
KalparukhaJawalkar Nagar,
Kashid Park, Pimple Gurav,
Pune-411061.
Ph. No. 7875157070
emails:awantmadhukar@rediffmail.com
emails:awantmadhukar@rediffmail.comgets7070@gmail.c
om
3. Water Treatment Equipments,

Sr. No. 80/1, Bhosari-Alandi
Alandi Road,
Behind Hotel Pragati, Wadmukhwadi,
Charholi (Bk), Pune-412105,
412105,
Ph. No. 020-32009688,
email-contact@watertreatmentindia.net
contact@watertreatmentindia.net
4. Praj Industries Limited, Praj

Tower, 274/75, Hinjawadi,
LonkarChowk, Phase-III,Pune.
III,Pune.
Ph. No.- 020-22951511,22952214
22951511,22952214
Fax – 020 – 22951515 /22951718.
5. NaranLala Pvt. Limited,

Post Box No.20,
Near Railway Station,
Navsari – 396445, (G.S.)
Ph. No. 02637-250371/2561
250371/256192
Fax No. 02637-252092
email-technical@naranlala.com
technical@naranlala.com
Section 16 Appendix
Appendix A – Technical Proposal/Report From Praj Industries Limited
Appendix B- Government of Assam, State/District Wise Area, Production, Price and Value
of Ten Major Crops in Assam from 2003-04
2003 to 2012-13.
Appendix C- Government of Assam, Agricultural Department, Area , Production and

Productivity of Crops – Assam, 20
2016-17.
Appendix D- Water Balance Report
Appendix E- Shantau Layout

DPR 100 KLPD Shantanu Transnational Life Sciences PVT LTD

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PROJECT : GRAIN BASED DISTILLERY – 100 KLPD

PRAJ Industries Limited.

274 & 275, Bhumkar Chowk, Hinjewadi Road,

Hinjewadi, Pune 411057 India

Phone: +91 20 22941000 / 71802000

The technology represented herein is proprietary to PRAJ INDUSTRIES LIMITED of Pune,

A information,, content, forms, photographs, graphics available herein in this proposal

THIS DOCUMENT IS THE PROPERTY OF PRAJ INDUSTRIES LIMITED, INDIA

4.2 Socio Economic Activities ................................................................................................

8.1 Input Requirements .....................................................................................................................

Shantanu Transnational Life Sciences Life Science

The primary feedstock is rice/maze

1.1 Salient Features of PRAJ’s Main Process Plant: Liquefaction:

2. Recycle of lees thus minimizing the fresh water requirement.

2. Higher alcohol content in the fermented mash, thus lower steam

1.1.3 Integrated Evaporation

1. Concentrated thin slop up to 35 % w/w solids with low steam.

6. Process Condensate Treatment Plant

2.0 Project Description

2.1 Project Profile

Name of company M/s. Shantanu Transnational Life Sciences PVT LTD.

Location of the project Industrial Growth Center, Matia, Goalpara, Assam.

2.2 Land Requirement

Coal: 70 TPD or Rice Husk: 100 TP

2.3 Raw Material Requirement

2.3.1 Grain Availability

Food grains in Assam, 2013-2016

Food grains in Assam, 2013-2016

Food grains in Assam, 2016-17

However, there is a clear demand

“if India manages to achieve 20 percent

2.3.2 Mode of Transportation:

2.4 Waste Water Generation

2.5 Air Emission & Air Pollution Control Measure

2.6 Solid Waste Generation & Disposal

SR. TYPE OF SOLID QUANTITY PER DISPOSAL

2.7 Water Balance

Treated water requirement Treated water requirement With recycle

Soft water for Cooling

2.8 Figure: Grain To Ethanol Process Flow Diagram

Grain Storage Decantation

WTP & Treatment Dryer

2.9 Effluent Plant Diagram

2.9.1 Dryer Section:

Feed Conditioning And Drying

2.9.2 DDGS Specifications

Sr. Description Quantity/Percentage

The advantage of DDGS manufacture in the grain-based distillery is that

2.9.3 DDGS Specifications

Sr. Description Quantity/Percentage

The advantage of DDGS manufacture in the grain based distillery is that

distillery with DDGS system becomes zero effluent discharge plant.

2.9.4 Technical Specification

Shell & Tube Assembly

Discharge Screw & Bucket Elevator

Type Tangential Entry

2.9.5 Technical Specification for Secondary Effluent Treatment Plant

1. Equalization tank – One No

2. pH Dosing tank – One No

3. pH Dosing pumps – Two No(1W+1SB)

4. Effluent lifting pumps – Two No(1W+1SB)

5. Bio Tower – One No

6. Aeration tank – One No