Prefeasibility Report

For
Proposed Grain based 250 KLD Distillery Plant
with 12 MW Captive Cogeneration Power
Plant

PROJECT PROPONENT
M/s. AAMANYA ORGANICS PRIVATE LIMITED
RE SURVEY NO. 740, 741, 744, 745, 746 OR OLD
SURVEY NO. 1444, 1445, 1446/1, 1446/2, 1447,
VILLAGE: GANGAD, TA: BAVLA, DIST: AHMEDABAD,
GUJARAT-382240

MAY 2022
Contents
CHAPTER 1....................................................................................................................................... 2
INTRODUCTION OF THE PROJECT ................................................................................................... 2
1.1 Project Background .................................................................................................................... 2
CHAPTER 2....................................................................................................................................... 3
PROJECT DESCRIPTION .................................................................................................................... 3
2.1 Project Location.......................................................................................................................... 3
2.2 Alternate Sites Considered ......................................................................................................... 6
2.3 Products & Raw Material Details ............................................................................................... 6
2.4 Utilities Requirement ................................................................................................................. 7
2.5 List of Machinery ........................................................................................................................ 9
2.6 Air Pollution Sources ................................................................................................................ 10
2.7 Water Pollution Sources........................................................................................................... 10
2.8 Manpower Requirement ................................................................................................................. 12
Table- 2.9: Manpower Requirement ............................................................................................. 10
CHAPTER 3..................................................................................................................................... 13
SITE ANALYSIS................................................................................................................................ 13
3.1 Connectivity.............................................................................................................................. 13
3.2 Approved Land use Pattern ...................................................................................................... 13
3.3 Topography .............................................................................................................................. 13
3.4 Social Infrastructure Available: ................................................................................................ 13
3.5 Detail of CER activity ................................................................................................................ 14
3.7 Rehabilitation & Resettlement Plan ......................................................................................... 14
3.8 Land-Use Breakup .................................................................................................................... 14
CHAPTER 4..................................................................................................................................... 14
PROPOSED ENVIRONMENTAL INFRASTRUCTURE ......................................................................... 15
4.1 Management of Domestic Waste Water ................................................................................. 15
4.2 Management of Industrial Waste Water ................................................................................. 15
4.3 Air Quality Management .......................................................................................................... 15
4.4 Solid & Hazardous Waste Management .................................................................................. 15
4.5 Waste minimization measures ................................................................................................. 16
CHAPTER 5..................................................................................................................................... 17
PROJECT SCHEDULE & COST ESTIMATES ...................................................................................... 17
5.1 Cost estimates .......................................................................................................................... 17
 M/s. Aamanya Organics Private Limited Pre Feasibility Report

CHAPTER 1
INTRODUCTION OF THE PROJECT
1.1 Project Background

M/s. Aamanya Organics Private Limited (AOPL), is a new company proposing green field project at
the land situated in Re Survey No. 740, 741, 744, 745, 746 or old survey no. 1444, 1445, 1446/1,
1446/2, 1447, Village: Gangad, Ta: Bavla, Dist: Ahmedabad, Gujarat-382240 for manufacturing of
250 KLD Grain Based Ethanol Plant along with 12MW Co-generation Power Plant.
M/s. Aamanya Organics Private Limited is proposing an interlinked project with M/s. DAPS Infra
Pvt. Limited (DIPL). Both units are adjacent to each other and will share some common utilities for
individual manufacturing facilities. AOPL unit will generate 96 tons of steam &12 MW Electricity, of
which 48 tons steam &6 MW will be supplied and receive Industrial effluent for the treatment of the
M/s. DAPS Infra Private Limited for their fuel ethanol manufacturing unit.
The Government of India approved the National Policy on Bio-fuels on 4thJune 2018 stipulating
Ethanol Blended with Petrol (EBP) Programme as its main component, offering indigenous and non-
polluting renewable energy source and successful implementation of the programme would not only
result in substantial reduction in air pollution, but also saving of precious foreign exchange through
import substitutions. This policy has laid out firm targets of achieving 20% blending of ethanol in
petrol in the whole country by 2025, which has been advanced from year 2030.
Accordingly Ministry of Environment, Forest and Climate Change, to give a further boost to the
Ethanol Blending Program, Grain based distilleries, having Zero Liquid Discharge (ZLD) and setup to
produce Ethanol only for the purposes of Ethanol Blending Program of the Government, and keeping
in view overall environmental, social and economic benefits in production of ethanol from such
distilleries including reduction in Green House Gas emissions in comparison to conventional fossil-
fuel, less water and air pollution, potential boost to agricultural economy and reduced dependence
on imported fossil fuel by equivalent amount, the Central Government deems it necessary to give a
special dispensation as regards granting of Environmental Clearances (EC) to such category of
projects [Manufacturing of ethanol by Grain Based distilleries with Zero Liquid Discharge, to be used
for Ethanol Blended Petrol Programme of the Government], subject to certain conditions.
According to latest MOEFCC notification S. No. 2339(E) dated 16th June, 2021, “Grain based
distilleries with Zero Liquid Discharge producing ethanol; solely to be used for Ethanol Blended Petrol
Programme of the Government of India shall be considered under B2 Category” with condition that
the project proponent shall file a Notarized Affidavit that Ethanol produced from proposed project
shall be used completely for EBP Programme.
Accordingly, the company has filed this project proposal.
List of Directors is as follows:
Sr. No. Director’s Name Correspondence Address
1. Mr. Arpit Vyas
702, Astron Tech Park, Near Iscon Circle, Satellite Road,
2. Mr. Saurin Shah
Ahmedabad, Gujarat – 380015.
3. Mr. Sunny Pandya

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 M/s. Aamanya Organics Private Limited Pre Feasibility Report

CHAPTER 2
PROJECT DESCRIPTION
2.1 Project Location

The site is located at coordinates 22°41'29.18"N, 72°15'31.78"Eabout 7.9 km far from KothRailway
station and 55 km far from SardarVallabhbhai Patel International Airport. Site is 2.3 Km away from
SH-16 and 1.5 km away from NH-47 that provides a convenient & competitive trade gateway to
domestic market transportation. The location of the project on Satellite Image indicating the 10.0
km radius surrounding area from the site and location of the site is given below:

PROJECT LOCATION ON INDIA AND GUJARAT MAP

Table – 2.1 Latitude & Longitude of Project site

Points Latitude Longitude Points Latitude Longitude
A 22°41'35.42"N 72°15'25.80"E L 22°41'27.45"N 72°15'40.60"E
B 22°41'35.93"N 72°15'32.57"E M 22°41'25.63"N 72°15'40.60"E
C 22°41'39.92"N 72°15'32.01"E N 22°41'23.39"N 72°15'38.73"E
D 22°41'40.12"N 72°15'33.61"E O 22°41'23.20"N 72°15'37.37"E
E 22°41'41.60"N 72°15'33.46"E P 22°41'23.17"N 72°15'36.53"E
F 22°41'40.28"N 72°15'38.51"E Q 22°41'24.06"N 72°15'33.45"E
G 22°41'37.69"N 72°15'38.50"E R 22°41'24.89"N 72°15'29.31"E
H 22°41'32.36"N 72°15'38.91"E S 22°41'27.28"N 72°15'27.66"E
I 22°41'32.49"N 72°15'35.80"E T 22°41'28.55"N 72°15'27.31"E
J 22°41'28.03"N 72°15'34.99"E U 22°41'28.56"N 72°15'26.66"E
K 22°41'27.69"N 72°15'37.10"E V 22°41'32.98"N 72°15'26.39"E

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 M/s. Aamanya Organics Private Limited Pre Feasibility Report

Location of the Project Site

Location of the Project with Surroundings (500 m & 1 km)

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 M/s. Aamanya Organics Private Limited Pre Feasibility Report

Location of site Surroundings Villages with Water and Drainage

Table – 2.2 Project Site Surroundings

Sr. Aerial Distance, Km /
Particular Location Name
No. Direction (approx)
1 Village/Residential zone GangadVillage 1.6 km in SE
2 Railway Station KothRailway station 7.9 km @SE
Sardar VallabhbhaiPatel
3 Airport 55 km @ ENE
International Airport
SH-16 2.3 km @S
4 Highways
NH - 47 1.5 km @ WNW
5 Water Body Canal 577 m @NNW
6 TSDF Site Maurya Enviro Project Pvt. Ltd. 113.98 km @ENE
7 Hospital Primary Health center, Gangad 2.38 km @ ESE
8 Fire Station SanandNagarpalika Fire Station 36 km @NNE
9 Police Station Koth Police Station 7.45 @ESE
Ecological Sensitive Zones
10 None within 10 km
Within 10.0 km
11 Historical / Archeological Places None within 10 km
National Parks / Wild Life
12 None within 10 km
Sanctuary

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 M/s. Aamanya Organics Private Limited Pre Feasibility Report

2.2 Alternate Sites Considered

This is a new unit for manufacturing of Grain Based Ethanol Plant the current location. Site is
selected for strategic reasons of vicinity to Ahmedabad, and considering advantages of sources of
raw material and market place. The company has not considered any alternate site. Necessary
permissions from State Pollution Control Board for Proposed activities will be obtained.

2.3 Products & Raw Material Details

2.3.1 Product Details

The unit intends to produce Fuel Grade Ethanol with a total capacity of 7500 KL/Month (i.e., 250
KLD)along with 12 MW Co-generation Power Plant. The Details of proposed products are given in
following Table – 2.1.

Table – 2.1: Details of Proposed Products

CAS no. /CI Remarks
Sr. Name of the Quantity/
no. If End-use of products
No. Products Month
applicable
Blending with Petrol by Main
1 Fuel Grade Ethanol 64-17-5 7500 KL
OMC’s Product
Internal consumption and
export to sister concern
For
2 Electricity -- 12 MW DAPS INFRASTRUCTURE
utilization
PVT LTD located at
adjoining land
Self use and sent to sister
concern DAPS For
3 Steam -- 96 TPH
INFRASTRUCTURE PVT LTD utilization
located at adjoining land
Dried Distillers Grains To be sold and Used as
4 -- 5150 MT By Product
with Soluble(DDGS) high protein cattle feed
124-38-9 To be bottled for sale.
Used as Fire Extinguishers
5 Carbon Dioxide (CO2) 3750 MT By Product
and other industrial
applications.

2.3.2 Details of Raw Materials

The Raw materials will be procured from different manufactures/vendors across Gujarat. All raw
materials will be transported to site in truck load by Road transport. At site, dedicated storage
facility will be provided for storage of raw materials. The required quantity of raw materials for
proposed products is given in Table-2.2.

Table – 2.2: Quantity of Proposed Raw Materials

Sr. Quantity
Name of the Products Name of the Raw Materials
no. MT/Month
Maize or Rice 20,000
1 Fuel Grade Ethanol&DDGS
Enzymes 144.0
Coal or 16,470
2 Steam & Electricity
Biomass 17,280

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 M/s. Aamanya Organics Private Limited Pre Feasibility Report

2.4 Process Description:

LIQUEFACTION:
In liquefaction process, starch is hydrolyzed to dextrin. The Liquefaction is carried out in Liquefaction
Tanks. Feedstock Flour is transferred to Pre-masher and mixed with Recycle Streams, thin stillage
and liquefying enzyme. Slurry from Pre-masher is taken to Liquefaction tank where temperature 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 and Fermentation section.

FERMENTATION:
Yeast Activation: Yeast seed material is prepared in Yeast Activation Vessel (Pre-fermenter) by
inoculating sterilized mash with yeast. Optimum temperature is maintained by circulating cooling
water. 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 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 the 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.

DISTILLATION
Pre-heated fermented wash is fed into a series of Distillation Columns to increase the alcohol
concentration and remove various impurities

DISTILLATION – (WASH TO AA MODE)

Following Columns will be under operation
1. Analyzer Column
2. Degasifying Column
3. Rectifier cum Exhaust Column
4. Alcohol Scrubber

MOLECULAR SIEVE DEHYDRATION PLANT (MSDH):

Rectified Spirit containing at least 95% v/v alcohol is pumped from RS (Rectified Spirit) 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 vapours are then passed through Product Condenser where product vapours
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.

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.

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 M/s. Aamanya Organics Private Limited Pre Feasibility Report

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 sold in dry form as Cattle feed (DDGS).

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 basic 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.

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 vapours 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.

PROCESS CONDENSATE 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.

Mass Balance:

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 M/s. Aamanya Organics Private Limited Pre Feasibility Report

CO2 Recovery Section – During the biochemical reaction in fermentation section, CO2 is generated
as by product along with ethyl alcohol. This raw CO2 gas having 99% v/v purity (DB) is taken for
purification followed liquefaction. Initially gas is taken to Foam trap to eliminate liquid particle
carried over from fermentation section. Here process water is used to rinse down the foam. Clean
gas from Foam trap is then fed to Low pressure organic removal system with the use of booster
blower. Organic impurities associated with carbon dioxide gas are scrubbed using high efficiency
packing. This purified gas is then fed liquid knock out drum for removal of water traces. Purified gas
is compressed in two stages reciprocating non lubricated water-cooled compressor. This high-
pressure gas is cooled down to desired temperature in water cooled after cooler. Additional impurity
separation step is used to enhance CO2 gas purity by scrubbing impurities present in traces by use of
potable water. Odour producing hydrocarbons and other Sulphur based compounds will be removed
in adsorption tower by using activated carbon as a media. De odorized high pressure carbon dioxide
gas will be cooled down to remove significant portion of moisture using ammonia as coolant. It will
be further dried in molecular sieve dehydration unit. This purified is carbon dioxide gas will be then
liquefied by using refrigeration system which will be disposed through tanks to the soft drink
manufacturing units.

2.5 Utilities Requirement

All utilities required for the project would be developed in the proposed facility and the utility
requirements are given in Table – 2.4.

Table-2.4: Utility required for the proposed project

Sr.
Particulars Proposed Source
No.
Co-gen power plant &Uttar
1 Power Consumption 6MW Gujarat Vij Company Limited
(UGVCL)
2 Total Fresh Water Requirement 950 KLD Ground Water
Coal or Biomass (Boiler) 549 / 576 tons per
3 Open Market
day
4 Diesel (DG set) 720 Lit Open Market

2.5 List of Machinery

The details of proposed equipment/machineries required for production is given in Table-2.5.

Table-2.5: List of Equipments / Machineries

Sr. No. Name of Equipment
1 Liquefaction tanks
2 Jet cooker along with Site fabricated
3 SS Fermenters
4 SS Pre-fermenter
5 SS Beer Well
6 Distillation Columns along with Re-boilers
7 Heat Exchangers
8 Coolers
9 Condensers
10 FF evaporator Calandria along with VLS
11 Surface Condenser

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 M/s. Aamanya Organics Private Limited Pre Feasibility Report

Sr. No. Name of Equipment

12 Cooling Tower
13 Instrument compressors
14 DG Driven Emergency Pump for Distillation

2.6 Manpower Requirement

Required specialized man power & talent would be recruited/hired locally. People will be employed.
The details of manpower requirement are given in Table-2.6.

Table- 2.6: Manpower Requirement

Employment During
Sr. no. Male Female Total
Construction phase
1. 110 60 170 140

2.7 Air Pollution Sources

2.7.1 Details of Proposed Air Pollution Sources

The details of proposed flue gas are given in Table-2.7respectively.
Table-2.7: Details of Proposed Flue Gas Stacks

Type of Air Pollution

Stack Quantity
Sr. Source of emission emissions Control
Height Type of Fuel of Fuel
no. With Capacity i.e. Air Measures
(meter) MT/Day
Pollutants (APCM)
Electrostatic
Coal/ 549 /
1 Steam Boiler (96 TPH) 75 Precipitator
Bio mass 576 PM, SO2,
(ESP)
NOx
D.G. Set, (2 X 750 KVA) 720 Adequate
2 18 Diesel
(Stand By) Lit/Day stack height

Details of Proposed Process Gas Stacks

Specific Source of emission Remarks
Sr. no. (Name of the Product & Type of emission
Process)
Will be Captured, Liquefied
1 Fermentation CO2 Bottled For Sale using pressurising
system

2.8 Water Pollution Sources

(Category-wise water consumption)

2.8.1 Fresh Water Requirement

The water consumption and wastewater generation for proposed product is given in Table-2.8.The
water would be provided from industrial estate.

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 M/s. Aamanya Organics Private Limited Pre Feasibility Report

Table-2.8: Details of Water requirement

Quantity Waste Water
Category Remarks Remarks
KLD KLD
(A) Domestic 15.0 Fresh Water 13.5 Treated In STP
Treated water
(B) Gardening 13.5 0.0 --
from STP
(C) Industrial

Process 1387.0 (267 F + 1120 R) 635.0 Primary and

Tertiary ETP
Washing 67.0 Recycled Water 50.0
followed by RO
Boiler 1191.0 (236 F + 955 R) 168.0 and RO reject sent
Cooling 1269.0 (362 F + 907 R) 150.0 to MEE for further
Others (Auxiliaries treatment.
70.0 Fresh Water 23.0
& pump sealing)
Industrial Total 3984.0 (935 F + 3049 R) 1026 --
Effluent received
for treatment
(D) Other 1026
From sister
concern DIPL
Grand Total
4012.5 (950 F + 3062.5 R) 2065.5 --
(A+B+C+D)

2.8.2 Effluent Treatment:

The details of effluent treatment plant are given in Table-2.9

Table-2.9: Details of Effluent Treatment Units (2100 KLD)

Tank No. Description Nos. Capacity (m3)

1. Collection Tank 2 300 m3 each
2. Flash mixer 1 50 m3
3. Flocculator 1 100 m3
4. Tube settler 2 100 m3
5. Holding tank 1 400 m3
6. Dual Media Filter 1 100 m3/hour
7. RO system 1 100 m3/hour
8. MEE System 1 100 m3/hour

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 M/s. Aamanya Organics Private Limited Pre Feasibility Report

Water Balance Diagram:

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CHAPTER 3
SITE ANALYSIS
3.1 Connectivity

District head quarter is well connected by rail, road & air.

Road: Plant is 2.3 Km away from SH-16 and 1.5 km away from NH-47 that provides a convenient &
competitive trade gateway to domestic market transportation.

Rail:7.9 km far from KothRailway station and

Air: Site is approx. 55 km far from SardarVallabhbhai International Airport.

3.2 Approved Land use Pattern

Currently the land is leased by Project Proponent. No agricultural activities are done on this land.
There will not be any additional requirement of land.

3.3 Topography

The area is flat in nature. It is a build-up plot. The average elevation above mean sea level is 14 m.
Toposheet of the area covering site is as follows:

3.4 Social Infrastructure Available:

The social infrastructure available is listed below.

• Housing colonies
• Public School
• ITI centre
• Healthcare Centre
• Children’s Park
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 M/s. Aamanya Organics Private Limited Pre Feasibility Report

• Community Centres
• Pharmacy
• Market
• And all very well developed urban facilities

3.5 Detail of CER activity

Project proponent will approach villages in vicinity to find out the requirement of people and
accordingly allot 4.175 Cr. (i.e., 1.5% of the total cost) funds for CER activities.

3.6 Rehabilitation & Resettlement Plan

The land is already in the possession of the project proponent. Therefore, resettlement and
rehabilitation is not involved.

3.7 Land-Use Breakup

This plant has an area of 100444Sq. Meter andGreen belt area is 33,146 Sq. mtr. The land-use break-
up is given in Table-3.1.The plot layout is given in Annexure-III.
Table-3.1: Land-Use Break-up
Sr. Area Area(sq.
Description Sr. No Description
No (sq. m.) m.)
Cooing Tower for
1 Security Cabin 20 15 780
Distillation Section
2 Weigh Bridge cum Office 75 16 Water Treatment Plant 1890
Condensate Polishing
3 Grain Feed Section 160 17 4650
Unit
Grain Storage Silo-6000MT X
4 2100 18 Turbine Section 713
2 Nos.
5 Milling Section 166.25 19 Boiler Section 1260
Liquefaction Section &
6 1617 20 Fuel Yard 2373
Fermentation Section
7 MCC Room for Plant Building 330 21 Workshop 450
Distillation & Evaporation
8 360 22 Store Room 450
Diction
9 Ethanol Storage Section 6256 23 CO2 Plant 918
10 Decantation & Dryer Section 588 24 Canteen 70
11 DDGS Storage 364 25 Open Area 14717.43
12 Workers Toilet 19.2 26 Road & Parking Area 26304.6
13 Admin Building 196 27 Greenery Area 33146.52
Cooling Tower for
14 450 28 OHC room
Fermentation Section 20
TOTAL 100444

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 M/s. Aamanya Organics Private Limited Pre Feasibility Report

CHAPTER 4
PROPOSED ENVIRONMENTAL INFRASTRUCTURE
Company will obtain Consent to Operate from Gujarat Pollution Control Board for the proposed unit
for manufacturing of Active Pharmaceutical Ingredients and Intermediates products. The company
will take into account all environmental aspects for expansion also so that no pollution hazard is ever
created in and around the plant. Every effort is being made to keep zero air pollution as well as
water pollution. In addition to the above, care has been taken to provide green belt around the
plant.

4.1 Management of Domestic Waste Water

The domestic effluent (13.5 KL/day) shall be sent to STP and treated sewage will be used for
gardening purpose within premises.
4.2 Management of Industrial Waste Water

The total wastewater generation from process will be 1026.0 KL/day including equipment/floor
washing and utilities. The generated effluent will be treated in ETP and then sent to Reverse Osmosis
plant followed by Multiple Effect Evaporator. The RO permeate and MEE condensate will be
recycled, resulting in reduction of overall fresh water requirement.

4.3 Air Quality Management

 The source of gaseous emission will be flue gas emission & process emission. The source of
Flue gas emission is steam boiler and D.G. Set which consumes Biomass/ Coal and Diesel
with quantity of @24 TPH or 23 TPH and @ 720 Lit/ day during initial start-up of boiler
respectively. Most probable flue gas pollutants will be SPM, SO2 and NOx.
 There will be emissions of the process gas from the Fermentation reaction in the proposed
unit. CO2 gas will be Captured, Liquefied & Bottled For Sale using pressurising system

4.4 Solid & Hazardous Waste Management

The details of hazardous wastes generation from the proposed project & its management &
Handling are listed in the following tables. All the requirements of hazardous waste rules shall be
complied with. Details of Hazardous & Other Waste Rule as per 2016 are as follows.

Specific Source
Type/Name of of generation Category and Total
Sr. Management of Hazardous
Hazardous (Name of the Schedule as Quantity
No. Waste
waste Activity, Product per HW Rules. (MT/Year)
etc.)
Collection, Storage and Disposal
Effluent
1. ETP sludge 35.3 180 to Sludge Drying bed as Manure
Treatment Plant
or sent to TSDF
Collection, Storage,
Machineries and 1500 Transportation, reused as
2. Used Oil 5.1
DG Set lit/Annum lubricant plant machinery or Sale
to registered recycler.

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Specific Source
Type/Name of of generation Category and Total
Sr. Management of Hazardous
Hazardous (Name of the Schedule as Quantity
No. Waste
waste Activity, Product per HW Rules. (MT/Year)
etc.)
3 Discarded Collection, Storage,
Material
Containers 33.1 35 Transportation, Disposal and Sale
Handling
to registered recycler
4 Spent Ion Water Collection, Storage,
35.1 15
Exchange Resins Treatment Plant Transportation, Disposal at TSDF

Solid Waste Generation:

Type/Name Specific Source of generation

Sr. Quantity
of Other (Name of the Activity, Product Management of Wastes
no. (MT/Annum)
wastes etc.)
To Be Sold To Brick
1 Fly Ash From power plant 52500 Manufacturing Or Cement
Industry
Collection, Storage and Disposal
2 STP sludge Sewage Treatment 3.0
to Sludge Drying bed as Manure
3 Syrup from Included in Product list as DDGS-
Evaporation of water in MEE
MEE mixed 50000 a high protein cattle feed.
&DDGS Dryer
with DDGS

4.5 Waste minimization measures

 Metering and control of quantities of active ingredients to minimize waste.

 Reuse of by-products from the process as raw materials or as raw material substitutes in other
processes.
 Use of automated filling to minimize spillage.
 Use of Close Feed system into batch reactors.
 Venting equipment through vapor recovery system.
 Use of CIP (Clean in Place) systems inside equipments to ensure hygiene & efficiency of
equipment’s after production of each batch. The clean liquids are then sent to the ETP plant for
treatment.

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CHAPTER 5
PROJECT SCHEDULE & COST ESTIMATES

5.1 Cost estimates

As it is a new green field project, it includes land, building and process & utility equipment cost as
follows:

Sr. No. Details Rs. Crore

1 Land 20
2 Building 46
3 Machinery 150.3
4 Env & Safety 56.0
5 Miscellaneous 6
Total 278.3

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