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EXECUTIVE SUMMARY
1.0 EXECUTIVE SUMMARY
1.1 INTRODUCTION
Bio-fuels are an alternative energy option as they are clean and have low sulfur
content thereby having positive environmental impact. Therefore need of the
hour is development of second generation biofuels using agricultural residues
and waste that can be harnessed as ligno-cellulosic bio-fuel source. This
requirement is also mandated in the National Bio fuel policy (NBP) 2009, where
in ethanol blending in Gasoline is to reach 20% by 2022.
The main reasons for the enhanced development of bio-ethanol are its use as a
favorable and near carbon neutral renewable fuel, thus reducing CO2 emissions
and associated climate change. Whether first, second, or third generation
feedstock is used, fermentation produces an alcohol-lean broth only, as such
unusable in industrial and fuel applications. The ethanol must hence be purified.
Fractional distillation can concentrate ethanol to 95.6 vol% (89.5mol %),
corresponding to the azeotropic composition with a boiling point of 78.2 oC.
Remaining moisture is captured in dehydration column to produce anhydrous
fuel grade ethanol.
Table-1.1: Ethanol requirement in future for 5%, 10% and 20% blending (In
Million Lt.)
Particulars 2017-18 2018-19 2019-20 2020-21 2021-22
Petrol Sale
Projection 33091 37723 43005 49025 55889
(14 % CAGR)
Ethanol Requirement
(@ 5%
1451 1655 1886 2150 2451 2794
blending)
(@ 10%
2903 3309 3772 4300 4903 5589
blending)
(@ 20%
blending) 5805 6618 7545 8601 9805 11178
Petroleum Planning & Analysis Cell (PPAC)
In view of meeting the ethanol requirement for blending in petrol, HPCL is exploring to
set up 2G Ethanol Plant at Bathinda, Punjab and has to prepare the DFR for the
project.
HPCL has taken M/s Praj Industries Limited as technology licensor for the 2G Ethanol
plant at Bathinda.
S. No Parameters Value
Considering that the plant should be designed with the flexibility in processing several
biomasses, the 2G Ethanol plant should be feed agnostic. It should be able to process
different biomass like rice straw, wheat straw, cotton stalk, sugarcane bagasse etc. as
feedstock. The Design feedstock for the proposed 2G Ethanol Plant is Rice straw.
Cellulose is a polysaccharide composed of linear glucan chains which are held together
by intra-molecular hydrogen bonds as well as intermolecular van-der Waals forces.
The crystalline cellulose must be subjected to some preliminary chemical or
mechanical degradation before it can be broken down into glucose.
Pretreatment:
Hydrolysis:
1. Acid hydrolysis
2. Enzymatic hydrolysis.
In acid hydrolysis, mineral acids such as sulfuric acid, hydrochloric acid, hydrofluoric acid
and nitric acid are widely employed for the hydrolysis of lignocellulosic biomass.
For higher conversion and use of lower grade metallurgy in equipment, enzymatic
hydrolysis is favorable over acid hydrolysis.
Fermentation:
Fermentation is the biological process to convert the hexoses and pentoses into
ethanol by a variety of microorganisms, such as bacteria, yeast, or fungi.
From fermented mash, fuel grade ethanol is produced through distillation and
adsorption via molecular sieve. Desired separation specification of 99.5%vol ethanol
cannot be achieved by distillation alone because of the non-ideal solution behavior of
the water- ethanol mixture. An azeotrope is observed when the mixture reaches 95.5%
mole purity of ethanol. 95.5 % alcohol is passed through molecular sieve to produce
fuel grade ethanol.
1.7 UTILITIES
Utilities requirement of the 2G Ethanol project shall be met through new utility systems.
The Following are the brief details of the utilities:
Raw water
Raw water for 2G ethanol plant shall be met from the nearby canal (at a distance of
2.5 km) and storage facilities of 7 days are considered. The details of raw water
reservoir are as given below:
Cooling water
Cooling water systems of capacity 6600 m3/hr have been envisaged for meeting
process requirements.
Total steam requirement for process is 42 TPH. 2 nos. of Boiler of 60% capacity each is
considered. The boiler and associated facility i.e. De-aerator etc. are considered inside
unit B/L as the water recycle and steam systems are process oriented.
Power shall be sourced from external grid. Considering distance of 6 km which will be
detailed during execution.
Flare
Flare is not envisaged in 2G ethanol unit, since there is negligible hydrocarbon
generation which can cause any relief to flare.
Compressed Air
Total installed design capacity estimated for process plant, OSBL section and Solid
liquid separation is 6000 NM3/hr. Air compressor with 2000 NM3/hr capacity each
considered with 3 +1 combination.
Based on the above the utility summary for 2G ethanol plant facilities are tabulated
below in Table1.4:
Please note that for the DFR, the following margins are considered on the utility values
specified by the Licensor:
a) DM water : 30 %
b) Raw Water : 15 %
c) Cooling Water: 10%
Additional Consideration
In the DFR report, cost estimations are done keeping in view that power and water
requirements are met at the plant gate. Power is being imported from the grid in the
present scenario.
1.8 CAPITAL
COST ESTIMATION
Key Assumptions:
The basic assumptions made for working out the capital cost estimate are as under:
Cost estimate is valid as of 2nd Quarter 2017 price basis.
No provision has been made for any future escalation
CENVAT benefit has been considered.
No provision has been made for any exchange rate variation.
It has been assumed that the project would be implemented on
EPCM mode of execution.
All costs are reflected in INR and all foreign costs have been
converted into equivalent INR using exchange rate of 1USD=Rs. 64.54.
As indicated above, the estimated project cost for the identified scope and technical
details works out to as under:
Rs. In Lakhs
Foreign Indigenous
S. No Component Component Ic Total Cost
Fc
1 1135 108490 109625
1.9 ENVIRONMEN
T IMPACT Solids
Waste
The solid waste generated from the 2G ethanol plant, their quantity and proposed
disposal method are tabulated as below.
Table: Solid waste from 2G ethanol plant
Description Quantity, TPD Disposal
Mud from wet washing (60 – 70 %
8 - 10 Land filling
moisture)
Dewatered Sludge from process As manure on agricultural
2-3
condensate treatment plant Field
May be sold to brick,
Ash from Boiler 110 - 125
cement industries
Liquid Discharge
The proposed 2G Ethanol unit is a Zero Liquid Discharge process plant. The water from
blow-down of boiler and cooling tower will be treated through reverse osmosis and
recycled.
Gaseous emission
These gaseous emissions are from the boiler only, as the CO2 from the fermenters is
proposed to be collected and bottled.
The overall plot plan is developed as per licensor layout for the process facilities. The
utilities, Plant & Non-plant buildings as per requirements are provided. The safety
distances except ethanol storage for Process plant sections, utilities and plant buildings
like Control Room and Sub- station are adopted as per standard followed in 1G Ethanol
Plant execution. PESO and OISD-118 will be considered for ethanol storage as Class A
product. The Firewater storage & Pumping facilities are also provided. Green belt area
as available inside the boundary wall is shown.
INTRODUCTION
2.0 INTRODUCTION
Hindustan Petroleum Corporation Limited (HPCL) is a Government of India
Enterprise with a Navratna Status, a Forbes 2000 and Global Fortune 500
company, listed on the Bombay Stock exchange (BSE) and National Stock
Exchange (NSE), India. It is involved in the business of refining and marketing of
petroleum products in the country.
HPCL owns & operates two major refineries producing a wide variety of
petroleum fuels & specialties, one in Mumbai (West Coast) and the other in
Visakhapatnam, (East Coast). HPCL also owns and operates the largest Lube
Refinery in the country producing Lube Base Oils of international standards.
HPCL along with M/s Mittal Energy Investments Pvt. Ltd. owns and operates a
Joint Venture Refinery at Bathinda in Punjab and also holds equity in the
Mangalore Refinery and Petrochemicals Ltd. (MRPL). HPCL has the second
largest share of product pipelines in India and a vast marketing network.
2.1 OBJECTIVE
2.2 ELEMENTS
2.3 CONFIGURATION
The 2G Ethanol plant configuration is considered as given below:
Ethanol unit.
o Biomass Handling and Size reduction
o Biomass Pre-treatment Section
o Enzymatic Hydrolysis
o Fermentation
o Distillation for Ethanol Recovery
CO2 Recovery and liquefaction plant
Multiple Effect Evaporation and RO system (Zero Liquid Discharge).
Lignin fired process steam boilers. Two Process Boilers based
on Lignin fuel at 60 % of the required capacity. i.e. 2 x 42 TPH
Power required for the 2G Plant is imported from the grid.
Raw water is obtained from the canal.
SECTION 3
PROJECT LOCATION
PROJECT LOCATION
The proposed 2G Ethanol plant in Punjab is envisaged at Bathinda. The site is located
approximately at latitude 30° 13′ 48″ N, and longitude of 74° 57′ 7″ E.
The site is well connected by road network and rail network. The distance of the
project site from nearest station/port/airport/city are as given below:
given below:
PROJECT DESCRIPTION
SECTION 4.1
PROJECT CONFIGURATION
4.1 PROJECT CONFIGURATION
M/s HPCL intends to explore the viability of producing Fuel Grade 2G Ethanol based on
the selected technology (PRAJ) and mainly produce following :
2G Ethanol
Carbon Di-Oxide
The Detailed feasibility study of 2G Ethanol plant at Bathinda, Punjab has been carried
out considering following process units:
For the proposed configuration, following are main facilities envisaged in the utility block.
a) Raw water (partial requirement)
b) DM Water
c) Recirculating Cooling water
d) Compressed Air
e) Steam, Power and Boiler feed water
f) Fire Water system
Following offsite facilities have been envisaged:
a) Biomass storage and transfer facilities
b) Product Tankage (for Ethanol and CO2)
c) By-product storage (for Ash/Silica)
d) Intermediate Tankage
Bio mass for feed shall be sourced externally through truck unloading and biomass
storage/transfer shall be part of biomass handling section. The storage of five days for
feed and two days for supplementary fuel are envisaged.
The main products from the bio refinery are Fuel Grade 2G ethanol and CO2. Ethanol
shall be stored in ethanol day storage tanks and two finished product storage tanks
(after excise check) whereas CO2 shall be stored in liquefied form in two tanks of 45 Ton
Capacity (each). Ethanol and CO2 shall be dispatched through road tankers. Ash/ Silica
and mud/silt shall be stored in the storage yard and dispatched from the complex
through trucks.
SECTION 4.2
PROCESS DESCRIPTION
4.2 INTRODUCTION
In contrast to first generation bioethanol, which is derived from sugar or starch produced by food
crops (e.g. wheat, corn, sugar beet, sugar cane, etc), cellulosic ethanol may be produced from
agricultural residues (e.g. straw, corn stover), other lignocellulosic raw materials (e.g. wood
chips) or energy crops (miscanthus, switchgrass, etc).
These lignocellulosic raw materials are more abundant and generally considered to be more
sustainable. However they need to be broken down (hydrolysed) into simple sugars prior to
distillation. This may be achieved using either acid or enzyme hydrolysis.
The main reasons for the enhanced development of bio-ethanol are its use as a favorable and
near carbon neutral renewable fuel, thus reducing CO2 emissions and associated climate change.
Whether first, second, or third generation feedstock is used, fermentation produces an alcohol-
lean broth only, as such unusable in industrial and fuel applications. The ethanol must hence be
purified. Fractional distillation can concentrate ethanol to 95.6 vol% (89.5mol %), corresponding
to the azeotropic composition with a boiling point of 78.2 0C. Remaining moisture is captured in
dehydration column to produce anhydrous fuel grade ethanol.
S. No Parameters Value
5 Alkalinity Nil
Cellulose
Fig 2: Schematic
diagram of
the long cellulose chains tightly together in a crystalline structure rendering the cellulose
insoluble to hydrolysis. The crystalline cellulose must be subjected to some preliminary chemical
or mechanical degradation before it can be broken down into glucose.
Hemicelluloses
Hemicellulose consists of short, highly branched chains of sugars. It contains pentoses, five-
carbon sugars such as xylose and arabinose, hexoses, six-carbon sugars such as glucose,
galactose, and mannose, and small amounts of other chemicals. Hemicelluloses chains are more
easily broken down to form their simple monomeric sugars than is cellulose because of their
highly amorphous and branched structure. Since pentose sugars comprise a high percentage of
the available sugars in plants, the ability to recover and ferment them into ethanol is important
for the efficiency and economics of the process. The exact sugar composition of hemicelluloses
can vary depending on the type of plant.
Lignin
Although lignin is a non-sugar-based polymer and cannot be used as feedstock for ethanol
production via microbial fermentation, it exerts a significant impact on the economic
performance of the corresponding bioconversion processes, since most inhibitors of microbial
growth and fermentation come from this compound during the pretreatment that is needed to
render cellulose amenable to enzymatic attack. Meanwhile, as the most abundant component in
biomass after cellulose, lignin yields more energy when burned and can be used for power
production in an eco- and environment-friendly mode of the bio-refinery. Moreover, lignin is an
excellent starting material for various products including transportation fuels and value-added
chemicals, which may add credits to the bioconversion processes and make bio-ethanol more
economically competitive.
In addition to the three major components, cellulose and hemicelluloses that can be hydrolyzed
to sugars for ethanol fermentation, and lignin left after fermentation, other components like
proteins and ashes also affect the process economics. For example,
fermentation nutrients are usually needed to nourish ethanologenic microorganisms, either
Saccharomyces cerevisiae or Zymomonas mobilis that can be engineered for ethanol production
from lignocellulosic biomass, due to insufficient nutrition in the feedstock, which raises a concern
about the supplementation of nutritional components to satisfy the basic requirements for cell
growth and ethanol fermentation.
Ligno-cellulosic biomass can be converted into bio-ethanol using following two technological
routes as shown in the Fig.3
Thermochemical conversion
In biochemical conversion the plant fiber is separated into its components cellulose,
hemicelluloses and lignin. The cellulose is then further broken down to simple sugars that are
fermented to produce ethanol.
Lignin is a byproduct of this process, and this can be used as a boiler fuel or processed
Praj industries limited has executed 1 TPD pilot plant to produce bio-ethanol from ligno- cellulosic
biomass is in operation since 2009 to till date consistently. A 12 TPD integrated smart bio refinery
demonstration plant in the state of Maharashtra is under operation since March, 2017.
Praj industries limited has divided their technology in different sections which are listed below and
shown in Figure. 6.6
A. Biomass Storage
B. Biomass Handling & Milling
2. Main Process Plant
A. Pretreatment
B. Enzymatic Hydrolysis
C. Co‐Fermentation
D. Distillation
E. Dehydration
3. Utilities & Auxiliaries
A. Boiler
B. Water Treatment Plant
C. Chemical Storage
D. Cooling Tower
E. Raw water treatment
F. DM water
G. Air Compressor
H. Enzyme Storage
4. Residue Handling Section
A. Solid Liquid Separation
B. Evaporation
C. Process condensate treatment plant
5. Off‐Site Packages
A. Fire Fighting System
B. Control System
C. Weigh Bridge
Washing is done at ambient conditions. The wet washed, sized feed stock shall be conveyed from wet
washing system to pretreatment section with belt / chain conveyor and washed water will be sent to
clarification section for recycle. The clarified water will be recycled back to washing section and
clarifier bottom will be sent for water recovery to evaporation section.
Pre-treatment section:
In this section, C5 hydrolysis is done (i.e. conversion of Xylan to Xylose) in a reactor. The mixed acid
solution is continuously fed as per the requirement. The slurry is treated at high temperature and
pressure. The slurry from reactor is flashed in a flash vessel and then pumped to enzymatic
hydrolysis section. Water from the steam flashing shall be recycled back to process.
The pretreated slurry is fed to the pre-hydrolysis reactor. Reaction conditions maintained are pH in
the range of 5.0 to 5.5, temperature of about 48 to 55 oC at atmospheric pressure before enzyme
addition. Enzyme shall be added to the reactor as per required dose. The reaction will continue in
the pre-hydrolysis reactor for few hrs and then the contents are transferred to main hydrolysis
reactor for further processing.
Fermentation Section:
The sugar rich slurry from hydrolysis reactor is then cooled to normal temperature and fed to the
fermenter. Pre-fermenters are provided for yeast propagation and different nutrients are added as
per the required dosages. The pre-fermenter volume is transferred to main fermenter for
fermentation process.
Distillation Section:
Once the desired alcohol is achieved, fermented wash is transferred from fermenter to beer well
and from beer well to distillation section. The fermented mash from the co- fermentation section is
distilled and dehydrated to get Fuel grade ethanol.
Dehydration Section:
The process drives the rectified feed through a system of molsieve beds. To allow for molsieve
bed regeneration in continuous operation, twin beds are provided of which one is in dehydration
mode while the other is in regenerating mode. Depending on feed and product specifications, the
dehydration regeneration exchange takes place based on set time cycle. As the regeneration process
releases the adsorbed water together with ethanol content, it is recycled back to system for
reprocessing.
The feed is pumped to evaporator column after preheating in feed pre-heater. The overhead vapor
of evaporator column is superheated to the required operating temperature and circulated to sieve
bed one. After passing through the molsieve, the vapor is condensed, cooled and sent to storage.
The regeneration operation forces the release of the moisture from the molsieve, making the sieve
bed 2 ready for the next cycle. The whole stillage generated in distillation shall be pumped to bio-
methanation.
The solid fuel fired boiler package is envisaged for steam requirements of plant. The high pressure
steam generated in the boiler will be supplied to the process plant through steam distribution
network. Pressure Reduction DeSuperheater (PRDS) system is used to reduce the steam pressure
whenever required. The condensate from process plant will be partly returned back to the boiler
package.
The boiler package comprises the complete boiler system (combustion system, water tube boiler,
super‐heaters, evaporators, economizers, air pre‐heaters), the boiler feed water system (pressurized
de‐aerator tank, boiler feed water pump, chemical dosing systems), fuel and ash handling system,
pollution control system, chimney and balanced draft system, electrical and instrumentation system
for fully automatic operation of the boiler package.
The wet biomass cake (lignin cake) produced in the process is blended with supplementary fuel such
as rice straw in appropriate percentage. This well blended mixture will be supplied to boiler as fuel
along with concentrated syrup produced from evaporation system.
Spent wash generated from the bottoms of the distillation section is transferred to solid liquid
separation section. Series of filter press system is used to separate lignin rich solid stream from
liquid. The solid stream is used as a feed to boiler and the liquid stream (Thin slop) shall be sent to
evaporation section.
Evaporation Section:
The thin slop is further concentrated by water evaporation in evaporators to produce the
concentrated syrup which will be mixed with solid stream generated from solid liquid separation
before being fed to boiler. Evaporation (water evaporated) process condensate will be partially
recycled back to process and remaining will be sent to polishing unit for further treatment.
The process condensate from evaporation plant will be treated through anaerobic followed by
aerobic biological process in addition to separation in condensate polishing unit. The treated process
condensate then will be sent OSBL (outside battery limit) for utility makeup.
4.3 MATERIAL BALANCE
Overall material balance of the 100 KLPD 2G ethanol unit on dry basis
Table : 6.4 In and out flow from main Ethanol Unit (Dry basis)
Feed 93.75
Wet lignin 50
Concentrated syrup 60
SECTION 4.4
WATER BALANCE
SECTION 4.5
UTILITIES DESCRIPTION
4.5 UTILITY DESCRIPTION:
This section provides details of utility requirements and description of utility system
envisaged for 2G ethanol plant.
The following utility systems are reviewed for DFR:
7. Condensate System
The utility consumption and the facilities required have been done based on estimation of
utility consumption of the process units based on the following.
Licensor Data
In-house data as applicable
Treated water required for CO2 plant is additional requirement and considered
in the overall design.
Days Cover: Raw water reservoir should be utilized for storing the raw water required for 2G
ethanol plant. Following are the details of reservoir:
Total Capacity: 17640 m3
No. of days of storage for 2G ethanol plant: 7 days (#)
DM water storage:
Two fixed roof type DM water tanks of 12 hrs storage shall be provided & 80% of the operating
volume. Normally one tank will be receiving DM water from the DM plant and the second tank
will be supplying DM water to consumers. DM water system is designed considering guaranteed
DM water consumption of 28 m3/hr as provided by licensor.
Steam Requirement:
Total steam requirement for boiler operation is 60 TPH including de-aeration steam. 2
nos. boiler of 42 TPH capacity each is considered.
Power Requirement: Power requirement for ISBL+OSBL is 11.5 MW
Boiler feed requirement of various units is given in Table 6.16. The values have
been arrived at from the steam generation figures (excluding the steam
generation from the back pressure drives) and considering 3% blow down losses.
CONDENSATE SYSTEM:
Condensate is recovered from all the process heat exchangers.
Raw water received in the complex shall be stored in a raw water reservoir and
then pumped for treatment in a Raw Water Treatment Plant (RWTP). The design
capacity of the Raw Water Treatment Plant shall be 95 m3/hr of treated raw
water. The design feed raw water quality at inlet to the RWTP shall be as follows:
Table 6.17: Inlet Raw Water Feed Quality
Inlet Raw Water
No. Parameters Unit
Quality
1. pH -- 7.2
2. Mineral Oil ppm <0.01
Total Suspended Solids
3. ppm -
(TSS)
4. Turbidity NTU <1.0
5. Total Alkalinity as CaCO3 ppm 303.9
6. Total Hardness as CaCO3 ppm 227.7
7. Total Iron as Fe ppm <0.01
550 (as per ionic
8. Total Dissolved Solids (TDS) ppm
balance)
9. Calcium ppm 79.2
10. Magnesium ppm 7.1
11. Chlorides ppm 15
12. Sulphates ppm 21.8
The treated raw water quality at outlet of the RWTP shall be as follows:
The treated water shall be stored in treated raw water tanks from where it will
be pumped to various consumers in the complex to meet their requirements.
Treated raw water shall be used to meet the following requirements:
RECYCLE PLANT
The backwash/regeneration effluents from RWTP & DM Plant along with CTBD &
blow-down from 2G ethanol project will comprise the feed to the Recycle Plant.
Treated water from the Recycle Plant (complying to the treated raw water quality
as indicated earlier) shall be sent to RWTP for being utilized as treated raw water
in the complex.
SEWAGE TREATMENT PLANT (STP)
MBR (Membrane Bio-reactor) based Sewage Treatment Plant (STP) is envisaged.
The design capacity of STP shall be 10 KLD (10 m3/day). The scheme consists of
the following stages:
Screen chamber with bar screen & debris retaining grid, and oil & grease trap
in the STP inlet channel.
The bio-sludge generated from the STP shall be dewatered employing Bag
Filters and the filtered effluent water shall be recycled back to the Sewage
Collection Sump.
NaOCl dosing shall be provided at for the disinfection of the treated sewage
water.
OFFSITES DESCRIPTION
4.6 OFFSITE SYSTEM
Storage and Transfer System
This section describes the storage and pumping facilities for feed/intermediate and
finished product based on the material balance, unit capacities, block flow diagrams and
storage & shutdown philosophy of 2G Ethanol Plant for the selected configuration.
Storage capacity is based on the process unit feed / products rates, criticality of
operation, turnaround schedules, emergency operation, etc.
The philosophy and facilities for storage and transfer is discussed below. Offsite facilities
are divided into three sections:
Biomass storage and transfer
Intermediate Feed / Intermediate product storage and transfer
Finished product storage
Biomass Storage and Transfer
Five days storage for feed biomass (rice straw) is considered inside the plant
area. Biomass will be stacked in open area and put in to a conveyor by
mechanical loader to feed to the 2G ethanol unit.
Two days storage for secondary fuel (Cotton Stalk) is considered inside the plant
area. Secondary fuel will also be stored in open area and put in to a conveyor by
mechanical loader to feed to the boiler unit.
Two intermediate product storage is considered for the proposed 2G ethanol plant.
1) Lignin rich wet cake: Lignin rich wet cake produced from solid – liquid separation unit
contains about 60% moisture and shall be feed to boiler as a fuel. One day
intermediate storage is consider to address start-up /shutdown and short term
problem encounter in plant operation. Wet lignin produced in a day about 400 MT
shall be stored in this area.
10 days ethanol storage is considered for this unit. Two tanks of equal capacity is used for
this purpos. More over three daily receiver tanksare also considered in view of Indian
excise rule.
Gantry:
The dispatch of product is considered through road tankers. The basis of dispatch facilities
by road (Tanker) for the product is considered based on Product ethanol flow for 100 KL
per Day:
No. of bays & gantries and gantry configuration are listed below:
1 1 1 CO2 Bottom
Ash Storage:
Ash generated from boiler shall be stored for 2 day before disposal or take off by third
party. Ash is collected in ash pond/pit.
Mud/slit Storage:
Periodically mud/slit removed from the wet washing section is stored in site for 7 days.
The mud/slit is collected in a pit and removed periodically for land filing. The
estimated
generation of mud is 8 - 10 MT per day with 70 – 75% moisture.
FO & TA Storage:
For fusel oil storage ~40 m3 storage tank is consider. FO generated from the plant at a rate
of 0.4 – 0.5 m3/day. Storage is sufficient for 15 day storage. FO can either sell to marked
or burn in boiler. For Technical Alcohol storage ~51 m3 storage tank is consider. TA
generated from the plant at a rate of 1.5 – 2.0 m3/day. Storage is sufficient for 15 day
storage. TA can either sell to marked or burn in boiler.
For storing the off spec product, one off-spec receiver tank is considered. Off spec
product is pumped back to system to produce final product.
Sl Description Day of
No storage
1 Chemical – I bulk 15
storage
2 Acid – I bulk 15
storage
3 Acid – II bulk 15
storage
4 Chemical – III 15
bulk storage
5 Molasses 15
Other chemical in solid form are stored in warehouse the quantity of storage as
tabulated below.
1 Chemical – II 15 25 - 50 kg
2 Nutrient – I 15 25 - 50 kg
3 Nutrient – II 15 25 - 50 kg
4 Nutrient – III 15 25 - 50 kg
Yeast will be stored in a closed packing in day form and the storage duration is considered
for 15 day.
LAGOONS
Two lagoons are consider in plant to divert the stream from evaporation section during
start-up, shutdown and abnormalities arises during plant operation.
DIESEL TANK
A diesel tank storage is considered for emergency DG set.
BUILDINGS
The following buildings as have been rationalized have been considered for DFR.
Sl No
Name Carpet Area in m2
3. Workshop 100
4. Canteen 200
5. Laboratory (1st floor above control room) 160
6. Control room with rooms for operating
160
supervisors (Ground floor)
7. Training Center and conference rooms 200
8. Substations 1500
9. Fire station 200
10. Operator Cabins 2 portable cabin
11. Security Cabins 18
12. Medical centre 60
13. Any other building as required (Shed for contract 200
worker, drivers etc.)
14. Cold enzyme Storage (8 OC) 150
ENVIRONMENT CONSIDERATIONS
5.0 ENVIRONMENT CONSIDERATIONS
The design of the Project will be on a minimum pollution basis and include all the features required to
ensure that control of all forms of pollution will comply with regulatory & governmental requirements.
The PROJECT is also designed to minimise emissions and the production of waste. The solid waste that
is produced during construction phase will be segregated to allow for safe disposal and preferably
recycle/reuse. Such wastes includes; sieves, activated carbon filters and ion exchange resins, as well as
oily sludge, sanitary sludge, maintenance wastes and spent batteries.
The solid waste that is produced during operation phase will be mostly used for combustion in boiler
and left out portion will be either sold as manure for agricultural fields or to brick and cement
industries.
Any waste that must be disposed of off-site, shall be disposed of by an appropriately authorised
organisation recognised by Central Pollution Control Board/State Pollution Control Board.
During the operation phase, the treated waste water will be recycled using RO based recycle plant.
Backwash/ regeneration effluent generated from recycle plant shall be stored in the recycle plant and
then pumped for use as horticulture water, fire water make-up and for ash quenching.
Solids Waste
The solid waste generated from the 2G ethanol plant, their quantity and proposed
disposal method are tabulated as below.
Table : Solid waste from 2G ethanol plant
Description Quantity, TPD Disposal
Mud from wet washing (60 – 70 %
8 - 10 Land filling
moisture)
Dewatered Sludge from process As manure on agricultural
2-3
condensate treatment plant field
May be sold to brick,
Ash from Boiler 110 - 125
cement industries
Liquid Discharge
The proposed 2G Ethanol unit is a Zero Liquid Discharge process plant. The water from blow-down of
boiler and cooling tower will be treated through reverse osmosis and recycled.
Gaseous emission
Since lignin is burnt, the quality and quantity of the effluent gases will vary with the biomass. These
gaseous emissions are from the boiler only, as the CO2 from the fermenters is proposed to be collected
and bottled.
Storm water for first 5 to 10 min from the main process plant pit will be transferred to ETP to recycle
effluent. After 10 min, it will be connected to common storm water collection header. The oil skimmer
will be installed on storm water collection pond and removed periodically. The oil free storm water will
be connected to common storm water nearest header outside plant boundary
Section -6
PROJECT
COST
CAPEX
Sr. No. Description Capacity Total Cost (Rs. Lacs)
Foreign Indian
Total
Component Component
LAND LEASE COST (DURING
1 120 120
CONSTRUCTION) 0
2 SITE DEVELOPMENT 1043 1043
PROCESS KHOW HOW,BASIC ENGG/START
3 2275 2275
UP ASSISTANCE & LICENSE FEES
4 EPCM SERVICES 5310 5310
CONSULTANCY SERVIES FOR CATEGORY-I
4.1 236 236
EQUIPMENT
SUB_TOTAL (1-4) 0 8984 8984
5 PLANT AND MACHINERY
5.1 UNITS
(Ethanol Unit + Utilities + Off-sites) 100 KLPD 1076 77060 78136
SUB_TOTAL (5.1) 1076 77060 78136
* Various options are being evaluated to delink storage of biomass from procurement by setting up biomass
storage depots which may increase efficiency of biomass supply change and bring down biomass supply cost
to 2500 Rs/MT, considering which OPEX will be Rs. 212 Crs per annum.
Revenue: