pre - feasibility report -...

Proposed Expansion of Existing Grain/ Molasses based Distillery (45 to 205 KLPD) and Co Generation Power Plant (0.8 to 8.3 MW)

At Village Khasa, Block Verka, Tehsil Amritsar 2, District Amritsar (Punjab)

Pre- Feasibility Report

M/s. Khasa Distillery Company 1 (A Unit of Digvijay Chemicals Ltd.)

PRE - FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY

(I) INTRODUCTION

M/s. Khasa Distillery Company (A Unit of Digvijay Chemicals Ltd.) is proposing expansion of existing

Grain/Molasses based Distillery (45 to 205 KLPD) & Co-generation Power Plant (0.8 to 8.3 MW) at

Village Khasa, Block Verka, Tehsil Amritsar 2, District Amritsar (Punjab). A variety of agricultural

products such as Molasses, Grains, Sweet Sorghum, Corn, Bajra etc. will be used as raw materials.

As per EIA Notification dated 14th Sep., 2006 and as amended from time to time; the project falls in

Category ‘A’, Project or Activity – 5(g).

TABLE – 1

SALIENT FEATURES OF THE PROJECT

S. NO.

PARTICULARS DETAILS

A. Nature & Size of the Project Units Existing Capacity

Proposed Expansion in

capacity

Total Capacity after

Expansion

Grain/Molasses Based Distillery

45 160 205

Co-generation Power Plant (MW)

0.8 7.5 8.3

B. Category of the Project As per EIA Notification dated 14th September, 2006 and as amended from time to time; the project falls in Category ‘A’, S. No. – 5(g).

Location Details

Village Khasa

Block Verka

Tehsil Amritsar 2

District Amritsar

State (Punjab)

Latitude 31o36’58.78”N to 31o36’44.02”N

Longitude 74o43’20.57”E to 74o43’36.47”E

Toposheet No. 44 I/10, 44 I/14

C. Area Details

Total Plant Area o Existing plant area: 12.02 ha (29.7 acres)

o No additional land is required for the proposed expansion, as the same will be done within the existing plant premises.

Greenbelt / Plantation Area (ha)

4.21 ha (10.4 acres), i.e. ~35% of the total plant area has already been developed under greenbelt/plantation.

D. Environmental Setting Details (with approximate aerial distance & direction from plant site)

1. Nearest Village Khasa Village (~0.5 km in NW direction)

2. Nearest City Amritsar (~14 km in East direction)

3. Nearest National Highway / NH-1 Grand Truck Road (~0.5 km in North direction)





State Highway

4. Nearest Railway station Chheharta (~7.0 km in East direction)

5. Nearest Airport Sri Guru Ram Dass Jee International Airport (~12.5 km in NNE direction)

6. National Parks, Wild Life Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors/ Reserved Forests (RF) / Protected Forests (PF) etc. within 10 km radius

No National Parks, Wild Life Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors exist etc. within 10 km radius.

7. Reserved Forest/Protected Forests within 10 km radius

• Rakh Sarai Amanat Khan RF (~7.5 km in SSW Direction)

8. River / Water Body (within 10 km radius)

• Upper Bari Doan Canal (Lahore Branch) (~8.0 km in NW direction)

• Majitha Hudiara Drain (~3.0 km in NW direction)

• Tungdhab Drain (~5.0 km in North Direction)

• Khaira Drain (~6.0 km in SSW direction)

Few distributaries also exist within 10 km radius of the plant site.

E. Cost Details

Total Cost of the Expansion Project

Rs. 150 Crores

Cost for Environment Management Plan

o Capital Cost - Rs. 25 Crores.

o Recurring Cost - Rs. 1.5 Crores / annum.

F. Basic Requirements for the project

Existing Additional for proposed Expansion

Total after proposed Expansion

Water Requirement (KLD) 316 1124 1440

Source: Ground Water & Recycle water

Power Requirement (MW) 1.4 2.1 3.5

Source: Co-generation Power Plant, State Electricity Board & D.G Sets (for emergency).

Man Power Requirement Skilled 40 20 60

Semi-skilled

20 10 30

Unskilled 10 20 30

Total 120

Source: Unskilled / Semi-Skilled - Local Area; Skilled - Outside Punjab.

G. Product ENA / RS / DNS / Ethanol / Industrial Alcohol / Country Liquor / IMFL / Absolute Alcohol

H. Working Days 330 Days per Annum

1.1 Environment Management Plan

Particulars Details

Air Management � Cyclones have already been installed in existing boiler.

� ESP/Bag House will be installed in proposed boiler.





� Stack heights maintained as per CPCB norms.

� Green Belt/Plantation has already been developed in ~35% of the total plant area.

� Internal Roads have been paved / asphalted.

� Designated Parking areas have been provided.

� CO2 Plant has been installed to remove the CO2 generated during fermentation

process.

� Regular monitoring of ambient air quality and stack emissions is being/will be done.

Water

Management

� The distillery is/will be based on “Zero Effluent Discharge”

� Fresh water requirement of the project will be met by Ground Water & recycled

water. Efforts will be made to conserve as much water as possible by recycling and

reuse.

� Record of wastewater returned back to process for utilization in

Fermentation/cooling tower and to gardening is being/will be kept.

� A regular monitoring of the water table around the project site has been/shall be

included in the Environmental Monitoring Plan.

� Spent Wash is being/will be sent for decantation followed by evaporation.

� Rainwater would be utilised to recharge the underground resource through

scientifically designed rainwater harvesting system.

� The waste water generated from the sanitary blocks will be disposed off via septic

tank followed by soak Pit.

Noise Management � Proper maintenance, oiling and greasing of machines at regular intervals.

� PPEs like earplugs and earmuffs to the workers exposed to high noise level.

� Development of Green Belt/Plantation for ~35% of the total plant area.

� Regular monitoring of noise level.

� D.G sets are being/will be provided with acoustic enclosures to control the noise

level within the prescribed limit.

� Regular monitoring of noise levels is being/will be carried out and corrective

measures in concerned machinery will be adapted accordingly to the possible

extent.

Solid & Hazardous

Waste

Management

� Solid waste generated is/would be DDGS which will be sold as Cattle/Poultry feed

and ash from the boiler which will be sold to brick manufacturers.

� Used oil & grease generated from plant machinery/Gear boxes as hazardous waste

will be sold out to the CPCB authorized recycler.

� Ash from the Boiler is being/will be sold to Brick manufacturers/land filling.





Green Belt

Development /

Plantation

� ~35% of total plant area has already been developed under green belt/plantation.

Same will be maintained after proposed expansion also.

� All the barren areas have been vegetated.

� Native plant species have been planted in consultation with local horticulturist.

� Green belt development along with the road & plant boundary attenuates noise

level arrest dust and improves the environment in surrounding.

Odour

Management

� Good operational practices, including physical and management control measures

at source.

� Better housekeeping with good hygiene condition by regular steaming of all

fermentation equipment.

� Use of efficient bio-cides to control bacterial contamination.

� Control of temperature during fermentation to avoid in-activation / killing of yeast.

� Avoiding staling of fermented wash.

� Regular use of bleaching powder in the drains to avoid generation of putrefying

micro-organisms.

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of Project and Project Proponent

Khasa Distillery Company was established in the year 1945 Village Khasa, Block Verka, Tehsil Amritsar 2,

District Amritsar (Punjab) to produce ENA, DNS, Industrial Alcohol/ RS/CL/IMFL using Molasses as Raw

Material. Presently, the company is running on 45 KLPD Grain/Molasses based distillery at the same

location.

Khasa Distillery Company (A unit of Digvijay Chemicals) is currently engaged in making high quality

spirits and enjoys a very high share of CL market in the state of Punjab. The company is also having a

tie up with M/s. Diageo for their IMFL brands like Royal Challenge, Signature and McDowell No. 1. The

company has also set up a state of art IMFL production facilities for their own brands.

(ii) Brief description of nature of the project

Consumption of alcoholic beverages in different parts of the world is influenced by economic, social,

religious, and traditional forces; therefore countries differ significantly in the amount and type of

alcohol consumed and in the temporal trends of use of alcoholic beverages. India has the world’s

largest youth population which is getting influenced by external factors and has started consuming

alcohol at a much higher rate and from a smaller age.

India is the third largest market for alcoholic beverages in the world. The demand for spirits and beer

is estimated to be around 373 million cases. (Source: Annual Report, Government of India, Ministry of

Food Processing Industries). In India, majority of distilleries manufacture alcohol from Sugar Cane

Molasses compared to international trend of grain based (rice, wheat, millet, Barley, corm and oat)





alcohol.

(iii) Need for the project and its importance to the country and or region

Advancement in science and technology has created so many products that have enhanced the quality

of human life in every passing year. The human race is largely dependent on industrialization for up

gradation in quality of life. Progress of the nation is judged through its economic growth which is

largely dependent on industrial productivity. In Indian economy (which is agro based) many industries

are dependent over agricultural produce for production of luxury and need based commodities.

Alcohol has assumed a very important place in the Country’s economy. It is a vital raw material for a

number of chemicals. It has been a source of revenue by way of excise duty levied by the State

Government on alcohol liquors. It has a potential as fuel in the form of power alcohol for blending with

petrol in the ratio of 20:80. The use of alcohol for the purpose of potable liquor is as high as its use for

industrial purposes. The Country Liquor is mainly used by the common masses.

According to analysts, the Indian alcoholic beverages industry is expected to witness accelerating

growth in coming years with the consumer base likely to expand amidst rising disposable income. The

domestic alcoholic drinks market is estimated around $13 billion and has been growing at a

compounded annual growth rate in excess of 10% in the past few years. The growth rate is higher than

other major Asian markets like China and South Korea, etc.

In the path of company’s growth and development this project will serve as yet another milestone.

(iv) Demand- Supply Gap

Not required in this Project. This depends on Excise Department.

(v) Import vs. Indigenous Production

Indian market could not meet present alcohol demand. So they import alcohol 5-7% of total demand.

As far as ENA production is concerned, Indian market play a vital role at both domestic & international

level. So they require to produce more alcohol to meet the demand. Annual increase in demand of

alcohol is approx. 10%.

(vi) Export Possibility

There will be possibility of export of alcohol to African, European & Asian countries.

(vii) Domestic / Export Markets

Market depends on Excise Department.

(viii) Employment Generation (Direct and Indirect) due to the project

The total manpower requirement after the proposed expansion project will be around 120 persons.

3.0 PROJECT DESCRIPTION

(i) Type of Project including interlinked and independent projects, if any.

There are no interlinked projects related to this proposed expansion project.

(ii) Location (map showing general location, specific location, and project boundary & project site

layout) with coordinates





FIGURE - 1: LOCATION MAP





Key Plan

FIGURE 2: KEY PLAN





(iii) Details of alternative sites consideration and basis of selecting the proposed site, particularly

the environmental considerations gone into should be highlighted.

Since, the proposed expansion will be done within the existing distillery plant premises and no

additional land will be required; therefore, no alternative site has been considered.

(iv) Size or magnitude of operation

M/s. Khasa Distillery Company is proposing expansion of existing grain/ molasses based distillery (45

to 205 KLPD) and co-generation power plant (0.8 to 8.3 MW) at Village Khasa, Block Verka, Tehsil

Amritsar 2, District Amritsar (Punjab).

As per EIA Notification dated 14th September, 2006 and as amended from time to time; the project

falls in Category ‘A’, S. No. - 5 (g).

(v) Project Description with Process Details

Project Description

Units Existing Capacity Proposed Capacity Expansion

Total Capacity after Expansion

Grain Based Distillery 45 160 205

Co-generation Power Plant (MW) 0.8 7.5 8.3

A) Molasses Based Operation

Alcohol is produced from carbohydrates by fermentation with yeast. Yeasts are unicellular,

uninucleate fungi that can reproduce by budding, fission or both. They have been used for

centuries to brew alcoholic beverages and are the most commonly used micro organism in the

industrial production of alcohol by fermentation. Ethanol production by fermentation

comprises four steps:

� Yeast propagation from yeast slant from the laboratory.

� Fermentation to produce fermented wash containing alcohol.

� Recovery, enrichment and purification of alcohol from fermented wash to produce 95.5

V/V alcohol.

� Production of absolute alcohol by dehydration of 95.5% V/V alcohol to produce absolute

alcohol.

A proper choice of appropriate technology in each of these steps governs the efficient and

viable operation of fermentation alcohol plant.

1) Yeast Propagation

Yeast, for the production of alcohol is characterized by high selectivity of the yeast

species, low production of by-products (side products), high ethanol yield, high

fermentation rate, good tolerance towards both high ethanol concentration and high in

organics in the fermenting substrate, high temperature tolerance, land high genetically

stability. Although finding a strain that has all these characteristics is difficult, a proper

selection and development of the best possible strain is needed. Sacharomycetes cervisiae

and Sacharomycetes pom be are the commonly deployed yeast strains in alcohol





fermentation of sugars. The purity and sterility of yeast culture used as inoculums have

great influence on the alcohol yield and longevity of yeast in fermenter. Flocculating

yeasts are deployed for continuous fermentation particularly with yeast recycle system.

The selectivity of yeast is also essential to maintain the required metabolic reaction

pathways specific to conversion of sugars to alcohol. The side products are higher

alcohols, acids, etc. which naturally reduce the alcohol yields and final quality of alcohol.

It is, therefore, customary to propagate yeast from laboratory strain in increasing volumes

under sterile and aerobic conditions protecting the same from other wild yeasts and

moulds during their growth. This is done in 3 or four stages starting from a 1 lit inoculums

developed in laboratory from a well preserved yeast culture slant.

Yeast will be developed in plant from fresh slant to laboratory flash culture and then in 3

stage S.S. yeast propagation vessels (VO1, VO2 and VO3) which operate in series but in

batch mode. When enough bio mass strength is developed, it is pitched Into Fermenter

(VO4)

2) Fermentation

The yeast propagation is only at the start and stabilization of the fermenter. When once

the continuous fermentation is on, the yeast propagation is stopped and only a periodic

continuous addition of small make up of fresh culture from yeast vessel is done to

maintain the activity of yeast in the active yeast count in the fermenter. The yeast vessels

are fitted with jacket for sterilizing and cooling the medium in situ. Sterile air is supplied

to these vessels through compressor (G-01) and the sterilization-system comprising a

series of fine filters followed by HEPA filters. Molasses from the molasses tank T-01 in the

yard are pumped to transfer pump (P-02) into tipper type molasses weighing system W-01

and weighed molasses feed tank (T-03) from where molasses feed pump it to yeast

vessels (when necessary) or to fermenter (V-04) through a static mixer type molasses

diluter. Main fermenter could be one or two stages depending on the control system

envisaged based on the final designs. The heat of fermentation is extracted by circulating

the fermenter contents through wort coolers (EO1 & EO3). Temperature in the fermenter

is to be maintained at 32 – 34°C. Carbon dioxide evolved during fermentation is vented

out through scrubber (C-03) to recover entrained alcohol vapors. Dilute molasses are fed

to the fermenter continuously. The final fermented wash is transferred by wash pump (P-

05) to yeast separation system comprising hydrocolones F-01 & F-02 and centrifuge F-03.

The sludge and dead yeast are purged into sludge tank and yeast cream is returned to the

fermenter (V-04) while clear fermented wash is collected in wash tank V-02. Sludge from

sludge tank is fed to the bottom of Analyzer Column (C-01) in the distillation section. Part

of spent wash from a selected tray in the column C-01 is returned to fermenter V-04 after

cooling the same to as near to ambient temperature as possible. Anti-foam oil is added

from T-04 whenever necessary when the level in the fermenter rises beyond a limit due to





foaming because of runaway fermentation rate. The operations in the fermenter can be

controlled closely through automation. Process water is taken into scrubber water tank

from where it is fed to scrubber (C-03) and overhead water tank (T-12) by water pump (P-

10). All process water in the fermentation section is supplied by gravity from this

overhead tank (T-12).

3) Rectified /ENA Spirit Distillation

Fermented wash from wash holding tank T-01 is pumped by wash feed pump P-01 to the

top of degassing column (C-2) after preheating the same in beer heater E-02 and spent

wash heat exchanger E-01. The vapors along with non-condensable gases from the top of

degassing column (C-02) are rectified in Heads column (C-03), to expel the high volatiles,

technically know as heads. Bottom liquid from the degasser flows into analyzer column (C-

01) where alcohol is stripped from the liquid. The liquid from bottom of analyzer column

(C-01) is completely stripped of alcohol and is pumped out by spent wash discharge pump

P-02 through heat exchanger E-01 where it preheats the fermented wash before it enters

degassing column. Part of spent wash from a tray, few numbers above the bottom tray is

cooled and returned to the fermenters as a measure of water saving and reduction of

effluent discharge.

The dilute alcohol vapors from near the top of analyzer column (C-01) are condensed first

in beer heater (E-02) while exchanging heat with wash feed and then in analyzer

condenser (E-03). Degasser and analyzer operate under vacuum. The condensate from E-

02 and E-03 is collected in Rectifier Feed Tank V-02. The vapors for stripping alcohol are

generated from analyzer column bottom liquid in the analyzer column re-boiler (E-04) by

using the rectified column top vapors, as discussed subsequently.

Vapors from the top of heads column (C-03) are condensed in heads column condenser (E-

06) and then in head column vent condenser (E-07). Part of the condensate is returned to

column C-03 as reflux while a small portion is taken out as an impure spirit cut. Liquid

from bottom of C-03 is also taken into Rectified feed tank V-02.

Dilute alcohol water mixture from rectifier feed tank (V-02) are pumped by rectifier feed

pump (P-04) through rectifier feed pre-heater E-11 in to rectifying column (C-04). Rectifier

and its associated equipment work under pressure so that these vapors can supply the

necessary heat for generating the vapors

The condensate from E-04 is then pumped as Reflux to rectifying column C-04. Rich

alcohol vapors at a concentration of 95.5% v/v from top of rectifying column (C-04) are

condensed first in Analyzer (E-04) and then in Reflux Vent Condenser (E-05). The liquid

from E04 and E-05 are collected in Rectifier Reflux Tank (V-01). Part of the liquid from E-05

may be drawn off as impure spirit. The impure spirit cut will be maintained as little as

possible to maintain aldehyde levels to meet the required limits in Absolute Alcohol.





Liquid from the reflux tank (V-01) is pumped by Product Pump (P-03) partly as product and

partly as reflux to the top of the Rectifying Column (C-04). The necessary rectifying

vapors to C-04 are generated by boiling the C-04 bottom liquid in Rectifier Column Re-

boiler E-08 using medium pressure steam. Some side streams are drawn from rectifier

column as light and heavy fractions of higher alcohols called fusel oils and cooled in fusel

oil coolers E-09 and E-10 and are mixed with water and allowed to separate out in fuel oil

separator F-01. All vents from E-03, E-07, V-02 and E-05 are connected to Vent Gas

Absorber (C-05) where the vent gases are scrubbed with water to recover entrained

alcohol. The scrubber water is used for washing the fusel oils in fusel oil separator to

recover alcohol from the fusel oil fractions. The absorber vent is connected to vacuum

pump (G-01) which is used to create vacuum in the analyzer and degasser.

The products Rectified Spirit and Impure Spirit, are cooled in product coolers and

collected in the respective receiver tanks prior to pumping the same through respective

transfer pumps into storage tanks in the excise godown. Impure spirit, is however,

returned to Ethanol plant along with the rectified spirit feed, subject to maintaining, the

Absolute Alcohol quality required for blending with petrol.

4) Fuel Grade Ethanol

Absolute alcohol is manufactured by dehydration of Rectified Spirit. The process adopted

here is based on Pressure Swing Adsorption (PSA) system using Molecular Sieves (3-A).

The flow scheme is shown in below referred flow diagram.

Rectified spirit, after preheating by waste hot streams, is vaporized and superheated in E-

03 and E-04 by using medium pressure steam at 6 Kg/cm2g pressure. Hot vapors at

kg/cm² g pressure and 130° C temperature pass through PSA column S-01A/S-01B where

the water vapors are retained while water free alcohol is released as vapors. The vapors

are condensed in E-07 and E-08 and collected as Absolute Alcohol. When the molecular

sieve bed is saturated with water the alcohol vapors are shifted to the other tower and

the first tower is taken for regeneration. Regeneration is done first by pressure releasing

and creating vacuum and then by elutriating with dehydrated alcohol vapors from the

tower in dehydration operation. The vapors are condensed in E-06 and E-05 and the vent

vapors are recovered through scrubber C-02. Vacuum can be created vacuum by P-04.

(Eductor may also be considered for this duty). Product is cooled in E-09 and transferred

to Absolute Alcohol receiving tank and then on to storage tank.





FIGURE 3: PROCESS FLOW CHART FOR MOLASSES BASED DISTILLERY

GRAIN BASED TECHNOLOGY AND PROCESS DESCRIPTION

1. LIQUEFACTION

Single Tank Liquefaction: In liquefaction process, starch is hydrolysed to dextrins. The

Liquefaction is carried out in Single Liquefaction Tank. 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

injection of direct steam through steam sparger / Eductor. Necessary retention time is

maintained in the Liquefaction Tank. Slurry pH is maintained by supplying dilute caustic

solution. Contents in Slurry Tank are kept in suspension by Agitation. The Liquefied Slurry is

then cooled in Slurry Cooler using cooling water supply and transferred to Pre-

fermentation and Fermentation section.

2. 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.

At the start of the cycle, the Fermenter is charged with mash and contents of the Yeast

Activation Vessel (Pre Fermenter). 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 for next batch.

3. DISTILLATION - Wash to ENA Mode: -

Multi-Pressure Distillation system having several Distillation columns operating at various

pressure conditions. Heat energy from columns operating under high pressure is utilized

for columns operating under low pressure to optimize the operation for energy

consumption.





Following Columns will be under operation

• Analyser Column

• Degasifying Column

• Pre-Rectifier Column cum

• Exhaust Column

• Extractive Distillation Column

• Rectifier cum Exhaust Column

• Recovery Column

• Simmering Column

Pre-heated fermented wash is fed at the top of the Degasifying column. Analyser Column is

provided with Reboiler. Top vapors of Analyser column containing all the alcohol in the

wash are sent to Pre-Rectifier column. Rest of the fermented wash flows down the

Analyser column and is taken out as thick slops from Analyser column bottom. Low boiling

impurities are concentrated in the Pre-Rectifier column. A draw of impure alcohol is taken

out from the top of the Pre-Rectifier column. RS draw is taken from the top of Pre rectifier

column, which further is sent to Extractive Distillation column. Dilution water is fed to this

column. The Extractive Column operates on the principle of inversion of relative volatility.

Low boiling impurities are separated in the Extractive Distillation Column & bottom is sent

to Rectifier cum Exhaust column. The Rectifier/Exhaust column concentrates the alcohol to

96% v/v. The spirit is drawn from the upper trays of the Rectification Column. Fusel oil build

up is avoided in the Rectifier cum exhaust column by withdrawing side streams (fusel oils).

ED condensates, fusel oil draw from R/E column are sent to Recovery column where these

fusel oils are concentrated and then sent to decanter where these streams are diluted with

water and fusel oil rich layer is separated. Washings are sent back to the column to recover

alcohol. The spirit Draw from the Rectifier column is sent to the Simmering column where

methanol is separated in the form of a cut from the top and ENA is taken out from the

bottom. ENA drawn from the Simmering Column is taken to the receiver after cooling in

ENA cooler.

4. EVAPORATION:

The suggested treatment scheme is a Four Effect (Integrated) plus Two Finisher working

on the principle of falling film Evaporation & Forced circulation. Simmering vapours is fed

to the first effect evaporator shell side and Exhaust vapour is fed to shell side of finisher at

the given pressure and temperature as the heating medium. The Feed at predetermined

temperature is fed from the top of First effect evaporator. Vapours generated in 1st effect

VLS (Vapour Liquid Separator) are used as heat source in the 2nd effect which is in series to

the first effect & so on. A Shell & tube type Multi-pass Surface condenser is employed for

condensing the shell side vapours. The product at the desired concentration is obtained at

the outlet of last effect. Each effect is provided with recirculation cum transfer pump. The

condensate from surface condensers is collected in a common condensate pot. The





condensate is transferred for further treatment / drain by using centrifugal pump. The

system operates under vacuum. Water-ring vacuum pumps will be used to maintain a

desired vacuum. Cooling water from cooling tower is used in the surface condensers for

condensing the vapours.

5. 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

• During the course of rotation, these flights pick up the material and shower them on

to the tube bundles. 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.

• Entire operation of the Dryer is controlled through Control panel.

FIGURE - 4: PROCESS FLOW CHART FOR GRAIN BASED DISTILLERY

B) Power Co-generation (8.3 MW)

OPERATIONS

� 35 TPH boiler will be installed based on Biomass/Rice Husk/Pet coke as available fuel

options. This Boiler will operate mainly to feed steam to grain based operations and 8.3

MW power generations from Turbine.

� Co-generation plant consists of a high pressure water tube steam boiler extraction cum

condensing steam turbine. Fuel in the steam boiler will be burnt with the help of air in

the boiler furnace. Water will be circulated in the boiler drum and tubes thus getting





heated by the flame burning in the boiler furnace. Water comes out of the boiler drum

located at the top of the boiler as steam. Flue gases rise in the boiler furnace and come in

contact with the steam coming out of boiler drum. Steam after coming in contact with

flue gases gets heated up further thus getting superheated. Super heated steam leaves

the boiler in a pipe. Flue gases after super heating the steam pass through economizer

where they pre-heat the boiler feed water before it enters the boiler drum. After

economizer, flue gases pass through air pre-heaters where they heat the air which is fed

to the boiler furnace for burning the fuel. After air pre heaters flue gases pass through

ESP/Bag House where the dust particles are collected. The dust is collected from here.

� High pressure superheated steam from boiler is passed through a steam turbine, which is

used for distillery process operations. While passing through the turbine, the high

pressure and temperature steam rotates the turbine rotor and an electric alternator

mounted on the same shaft. Electric power is generated by the alternator. This electric

power generated is consumed in house i.e. for running the distillery and utilities like

boilers auxiliaries etc.

FIGURE 5: PROCESS FLOW CHART FOR COGENERATION POWER PLANT

(vi) Raw material required along with estimated quantity, likely source, marketing area of final

products, mode of transport of raw material and finished product.

(a) Raw Material Requirement

The basic raw materials required for the distillery are Grain / Molasses.

In the present scenario, grains with different starch content are used like broken Rice,

sorghum, bajra, maize etc. The process requires the above grains to be milled into specific

flour size. The fuel for the boiler is/will be Biomass/Rice Husk/Pet Coke.

TABLE 2

RAW MATERIAL REQUIREMENT

S. Particular Total Requirement after proposed Source & Mode of





No. Capacity Expansion Transportation

1 Grain or 539 TPD Through Local vendors / By road Molasses 1138 TPD

2 Chemicals Near-by Markets / By road

Sodium Hydroxide (Caustic) 350 kg/day

Nutrients 1300 kg/day

Enzymes 120 kg/day

Antifoam Agent 220 kg/day

Yeast (Active Dry Yeast/Distiller’s Yeast)

70kg/day

(b) Fuel Requirement

TABLE 3

FUEL REQUIREMENT

Name of Raw Material

Total Quantity after Proposed Capacity Expansion

Source & Mode of Transportation

Biomass/Rice Husk 312 TPD Through Local vendors / By road

(vii) Resources optimization/ recycling and reuse envisaged in the project, if any, should be briefly

outlined.

Water as a resource will be recycled at each possible step of the process and latest technology

and methodology will be adopted to conserve and reuse the resources. Waste water will be

generated from the process and treated water after pH corrections is used back again into the

various processes.

(viii) Availability of water it’s source, energy /power requirement and source should be given.

(a) Water Requirement and Source

The total water requirement for the distillery is estimated at, worked out as per details given

below:

TABLE - 4 (A)

TOTAL WATER INPUT

S. No. Section Water Consumption (KLD)

1. Water for Slurry preparation 1920

2. Boiler feed Water 1090

3. DM Water for blending 192

4. Make up water for cooling tower 1025

5. Bottle Washing 128

6. Domestic water 115

TOTAL 4470

TABLE - 4 (B)

RECYCLE & UTILIZATION STREAMS

S. No. Section Water Consumption (KLD)

1. Spent Lease (ENA) 492





2. Steam Condenser 845

3. Evaporator Condenser 1152

4. Spent Lease (RS) 255

5. Thin Slope Recycle 236

6. Bottle Washing 50

TOTAL 3030

TOTAL FRESH WATER INPUT 1440

Hence, net fresh water Requirement is 1440 KLD.





(b) Power Requirement and Source

Total power requirement after proposed expansion will be 3.5 MW.

TABLE - 5

POWER REQUIREMENT

Existing Additional for proposed Expansion

Total after proposed Expansion

Source

1.4 2.1 3.5 Co-generation Power Plant, State Electricity Board & D.G Set (for emergency).

(c) Steam Requirement

TABLE - 6

STEAM REQUIREMENT

Existing Additional for proposed Expansion Total after proposed Expansion Source

15 MT 35 MT 50 MT Own Boiler

Boiler Details

TABLE – 6 (A)

BOILER DETAILS

S.No. Existing Boiler Proposed Boiler

1. Type of Fuel Rice Husk/Biomass Rice Husk/Biomass/Pet Coke

2. Capacity of Boiler 15 TPH 35 TPH

3. Stack Height 45 m As per CPCB/SPCB norms

4. Pollution Control Equipments Cyclones ESP or Bag House

(d) Details regarding the D.G. Set

4 X 1000 KVA D.G. Sets will be required for the power back-up. Details regarding the D.G.

Sets are mentioned in the table given below:

TABLE – 7

D.G. SETS DETAILS

S.No. Details

1. Type of Fuel HSD

2. Capacity 4 X 1000 KVA

3. Stack Height As per CPCB/SPCB norms

4. Pollution Control Equipments Adequate Stack Height/Acoustic

(ix) Quantity of waste to be generated (liquid and solid) and scheme for their

management/disposal

o The plant is/will be based on “ZERO EFFLUENT DISCHARGE”.

o Spent Wash is being/will be taken through Centrifuge Decanters for separation of

Suspended Solids separated as Wet Cake.

o Thin Slops from the Decanter Centrifuge are being/will be partly recycled back to process

and partly taken to Thins Slops Evaporation Plant for concentration of remaining solids





to form a Syrup. This Syrup is mixed with the Wet Cake coming out of Decanter

Centrifuge and forms part of Cattle Feed. (Also known as Distillers Wet Grain Solubles -

Collectively known as DWGS).

o DWGS is being/will be taken to a dryer operating on steam and is being/will be dried to

make it DDGS – Distillers Dried Grain Solubles.

o The process condensate is being/will be cooled and collected into a neutralization tank

with sufficient residence time. After Neutralization, this process condensate is being/will

be recycled into process.

o A stream of low BOD lees comes out which is being/will be used for Cooling water make-

up and process recycle.

o Solid waste from the Grain based operations generally comprises of Fibres and proteins

in the form of DDGS, which is being/will be used as Cattle/Poultry Feed.

o Ash from the Boiler is being/will be sold to Brick manufacturers/land filling.

o Used oil & grease generated from plant machinery / Gear boxes & D.G. Sets is being/ will

be partly used in oiling & greasing as lubrication of external parts of machinery & partly is

being/will be sold to the CPCB authorized recycler.

4.0 SITE ANALYSIS

(i) Connectivity

The Plant site is well connected to NH-1 Grand Truck Road (~0.5 km in North direction). The

nearest railway station is Chheharta (~6.5 km in East direction) and nearest airport is Sri Guru

Ram Dass Jee International Airport (~12.5 km in NNE direction).

The site is suitably located with respect to availability of raw material, water, road network,

skilled/semi skilled/unskilled and professional manpower etc. All communication facilities such

as telephone, telefax & internet are available in the vicinity of the plant site.

(ii) Land from Land use and Land ownership

This is an existing plant and expansion will be within the existing plant premises.

(iii) Topography

The topography of the area is almost flat.

(iv) Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area

under CRZ)), shortest distances from the periphery of the project to periphery of the forests,

national park, wild life sanctuary, eco sensitive areas, water bodies (distance from the HFL of

the river), CRZ. In case of notified industrial area, a copy of the Gazette notification should be

given.

TABLE 8

ENVIRONMENTAL SETTINGS OF THE AREA

S. NO. PARTICULARS DETAILS

(with approx aerial distance & direction from the plant site)

1. Nearest Village Khasa Village (~0.5 km in NW direction)





2. Nearest City Amritsar (~14 km in East direction)

3. Nearest National Highway / State Highway

NH-1 Grand Truck Road (~0.5 km in North direction)

4. Nearest Railway station Chheharta (~6.5 km in East direction)

5. Nearest Airport Sri Guru Ram Dass Jee International Airport (~12.5 km in NNE direction)

6. National Parks, Wild Life Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors/ Reserved Forests (RF) / Protected Forests (PF) etc. within 10 km radius

No National Parks, Wild Life Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors/ Reserved Forests (RF) / Protected Forests (PF) exist etc. within 10 km radius.

7. Reserved Forest/Protected Forests within 10 km radius

• Rakh Sarai Amanat Khan RF (~7.5 km in SSW Direction)

8. River / Water Body (within 10 km radius)

• Upper Bari Doan Canal Lahore Branch (~8.0 km in NW direction)

• Majitha Hudiara Drain (~3.0 km in NW direction)

• Tungdhab Drain (~5.0 km in North Direction)

• Khaira Drain (~6.0 km in SSW direction)

(v) Existing Infrastructure

Total plant area is about 12.02 ha (29.7 acres). Proposed expansion will be done within the

existing plant premises.

(vi) Soil classification

Soils in the western part of the district are coarse loamy, calcareous soils, where as in the

central part of the district soils are fine loamy, calcareous and are well drained. The soils are

Ustochrepts to Haplustaff type.

(vii) Climatic data from secondary sources

The climate of the district is classified as tropical steppe, semi arid and hot which is mainly dry

with very hot summer and cold winter except during south west monsoon season. There are

four seasons in a year namely cold season from November to March, hot season from April to

June, south west monsoon season from last week of June to middle September and post

monsoon season from September to beginning of November. During cold season, series of

western disturbances affect the climate of the district.

The normal annual rainfall of the district is 680 mm unevenly distributed over 31 rainy days. The

south west monsoon contributes 75 % rainfall and sets in last week of June and withdraws in

middle of September. Rest 25% of annual rainfall occurs in the in non monsoon months in the

wake of western disturbances and thunder storms. The rainfall increases from south west to

north eastern part of the district.

(viii) Social Infrastructure available

Telephone and medical facilities are available in the nearby towns. Adequate infrastructure has

been developed by the company around their existing plant premises. Various infrastructure

development activities, toilets, drinking water facility etc has been brought into existence.





Other facilities like small shops and markets are existing in the area that supports the basic

lifestyle of the people.

5.0 PLANNING BRIEF

(i) Planning Concept (type of industries, facilities, transportation etc.) Town and country

Planning/ Development authority classification.

The existing industry is Distillery industry and proposed expansion will be within the existing

plant premises. Facilities required for the proposed expansion will be provided as per the

requirement. Transportation of raw material and final product will be done via existing road

and rail network and pucca road has been developed within the existing plant premises.

(ii) Population Projection

Temporary influx of people will be there as the managerial and supervisory staff will generally

be outsider. A projection may be made by a governmental organization, or by those unaffiliated

with a government.

(iii) Land use planning (breakup along with green belt etc)

Total Plant area is 12.02 ha (29.7 acres). Proposed expansion plant will be set up in the existing

plant premises. No additional land will be required. Approx 35 % of the total plant area is already

under green belt / plantation in order to reduce dust & noise pollution levels & to increase

aesthetic beauty of the area. The same will be maintained after the proposed expansion also.

(iv) Assessment of infrastructure demand (Physical & Social)

The company has assessed the demand of infrastructure (Physical & Social) in nearby area of

the plant site and development activities are being undertaken under corporate social

responsibilities program for rural development initiatives for the upliftment of the nearby

communities from time to time.

(v) Amenities/Facilities

The company has constructed dispensary, canteen etc for the permanent and contract

employees. The company will develop the Amenities/Facilities in nearby area of the plant site as

per requirement of local people of the nearby area under corporate social responsibilities

programme.

6.0 PROPOSED INFRASTRUCTURE

(i) Industrial Area (Processing Area)

No additional infrastructure will be required for the proposed expansion project as the

proposed expansion plant will be set up in the existing plant premises.

(ii) Residential area (Non Processing area)

There is no residential area within the plant premises.

(iii) Green Belt

Approx 35 % of the total plant area is already covered under green belt/plantation. The same

will be maintained.





(iv) Social Infrastructure

Proposed expansion project will result in growth of the surrounding areas by increased direct

and indirect employment opportunities in the region including ancillary development and

supporting infrastructure.

(v) Connectivity

The site is well connected with communication facilities like telephone, fax, and wireless as

such, no constraints are envisaged in this aspect as the Tehsil and District headquarters are near

to the site.

(vi) Drinking Water

As the proposal is of the expansion of the facility at the existing site therefore approximate

increase will be in the range of 1 KLPD.

(vii) Sewage Treatment System

The waste water generated from the sanitary blocks will be disposed off via septic tank

followed by soak Pit.

(viii) Industrial Waste management

The plant is/will be based on “Zero Effluent Discharge”.

(ix) Solid Waste Management

� Solid waste generated is/would be DDGS which will be sold as Cattle/Poultry feed and ash

from the boiler which will be sold to brick manufacturers.

� Used oil & grease generated from plant machinery/Gear boxes as hazardous waste will

be sold out to the CPCB authorized recycler.

� Ash from the Boiler is being/will be sold to Brick manufacturers/land filling.

(x) Power requirement and source

The total power requirement after proposed expansion project will be 3.5 MW, which will be

sourced from Co-generation Power Plant, State Electricity Board & D.G Set (for emergency).

7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

(i) Policy to be adopted (Central/State) in respect of the project affected persons including home

oustees, land oustees and landless labourers (a brief outline to be given).

Proposed capacity expansion will be done within the existing plant premises. No additional land

is required for proposed capacity expansion project. Therefore, there will not be displacement

of people and hence, Rehabilitation & Resettlement is not applicable.

8.0 PROJECT SCHEDULE AND COST ESTIMATES

(i) Likely date of start of construction and likely date of completion (time schedule for the

project to be given).

The proposed expansion will start only after obtaining Environmental Clearance and other

statutory permissions. Project will be completed in 18 months period after getting all the

regulatory approvals.

(ii) Estimated project cost along with analysis in term of economic viability of the project.





� Total cost of the Project: Rs. 150 Crores

� Cost for Environment Protection Measures:

� Capital Cost: Rs. 25 Crores

� Recurring Cost/annum: Rs. 1.5 Crores / annum.

9.0 ANALYSIS OF PROPOSAL

(i) Financial and social benefits with special emphasis on the benefit to the local people including

tribal population, if any, in the area.

Proposed expansion project will result in growth of the surrounding areas by increasing

ancillary development and supporting infrastructure. Special emphasis on financial and social

benefits will be given to the local people including tribal population, if any, in the area.

Development of social amenities will be in the form of medical facilities, education to

underprivileged and creation of self help groups.

Punjab state will get revenues in terms of taxes. Business opportunities for local community will

be available like transport of alcohol to market, fly ash transport to brick manufactures,

maintenance & house-keeping contract work etc.

pre - feasibility report -...

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