Pre Feasibility Report

For
Molasses Based Fuel Ethanol Plant of
45 KLD
Along with 14 TPH Incineration
Boiler
At
Village – Mendrana
Tehsil- Pansemal
Distt – Badwani (MP)

Proposed By
M/S Shree Durga Khandsari Sugar Mills
(SDKSM)
Village- Mendrana, Tehsil- Pansemal, Dist.
Barwani, MP

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1. Identification of project and project proponent
M/s Shree Durga Khansari Sugar Mill (SDKSM) is as partnership firm registered
with State Govt and located at Village- Mendrana, Tehsil- Pansemal Dist
Barwani (MP)
The factory was established originally as Khandsari Sugar unit of 300 TCD in
1974. Initially factory was following traditional khandsari process which was
associated with number of disadvantages such as low sugar recovery, higher
sugar loss in bagasse and final molasses, high fuel consumption. In year 2004,
the unit upgraded the crushing capacity to 800 TCD and received permission for
conversion of khandsari unit to sugar plant. Presently SDKSM is operating plant
with expanded capacity of 2500 TCD.
Brief Description of Nature of the Project
The present proposal is for setting up a 45 KLD fuel ethanol plant (Molasses
based) with 14 TPH Incineration Boiler at Village Mendrana, Tehsil- Pansemal
Dist Barwani (MP) in the State of Madhya Pradesh at an estimated cost Rs. 4682
Lacs. The proposed project will be set up adjacent to the existing sugar unit
(2500 TCD & 11 MW power plant) of M/s SDKSM.
Most of the infrastructure facility is already available with the industry as
present sugar manufacturing operation is being continued from several years.
The Company proposes to set up an integrated pollution free (Zero discharge)
fuel ethanol plant in the State with an installed capacity of 45 KLD in the State
of Madhya Pradesh. The proposed Industrial Complex shall process molasses as
its raw material to produce RS & Dehydration:
Silent feature of the project
• Provided with most efficient Fed batch Fermentation technology
 Distillation operating on Multi-Pressure Technology -a efficiently heat
integrated system, operating on fully automated PLC control system
 On line cleaning system is provided for distillation equipment's to
minimize plant shut down period.
 Process equipment's are designed as per TEMA/ ASME standards
 Imported Buhler makes Mill and efficient Grain handling system is
considered.
 Closed water recycles system and plant process is designed to minimize
fresh water requirement by recycling various effluents.
 Zero Effluent Discharge norms is applied while designing the plant

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Sr. No. Particulate Description
1. Name of the proponent M/s Shree Durga Khandsari Surgar Mills
2. Project capacity 45 KLPD Molasses Based Ethanol Plant with 14
TPH Incineration Boiler.
3. Khasara No. & Location of the Khasara No. 76/1 & 76/2, Village- Mendrana,
project Tahsil Pansemal, Dist. Barwani, MP.
4. Geographic Location 21°39'24.56" N and 74°39'14.41" E
217 m MSL
5. Land requirement Total land 8.0048 acres for proposed Distillery Unit
1.989 acre built up area
2.64 acre green belt area
6. Product Product:
Fuel Ethanol :45 KLPD With 14 TPH Incineration
Boiler.
7. Operation days 270 days
8. Molasses required Molasses 158 TPD ( Fermentable sugar 42% w/w)
9. Total water 351 KLD (After recycling)
10. Source of water Borewell
11. Electricity Operational: 847 kWh
Connected load: 1185 kWh
12. Turbine generator 1.20 MW
13. Steam 9.92 TPH
14. Fuel Concentrated spent wash: 117 TPD
Bagasse – 115 TPD
15. Source Captive & Nearby Market
16. Boiler 14 TPH Incineration Boiler
17. DG Two DG sets of capacity 250 kVA
18. Effluent treatment Condensate Polishing Unit (CPU) will treat spent
System lees, cooling tower blow down, boiler blow down
and process condensate. Spent wash will be
treated by multi effect evaporator followed by
slope fired boiler.
19. Man-power 70 skilled and unskilled
20. Total project cost 4682 Lakhs
21 Land acquired 24.19 acres
22 Land required for proposed 1.989 acres
plant
23 Proposed area for plantation 2.64 acres
24 Existing area of plantation 2 acres
25 Capital Cost for
1050 Lacs 100 Lacs ( May be changed during EIA
Environmental measures
study)
(proposed )
26 Recurring cost for
environmental monitoring etc 100 Lacs ( May be changed during EIA study)
(Proposed)

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 Existing Sugar And Cogeneration Plant Details
Sr. No Description Quantity Unit

1. Crushing capacity, TPD 2500 TCD

2. Number of crushing 125
days/year
3. Boiler used 60 TPH
(expected)
4. Power generation capacity 11 MW
5. Power consumption Season Offseason. MW
For sugar plant and cogen 4 0.001
Other In-house consumption NA NA
Power export NA NA
6. Bagasse generation 636 TPD @28.4%
7. Bagasse required for 600 TPD
8. cogeneration
Saved bagasse 36 TPD
9. Molasses generation 117 MT TPD
10. Fresh water requirement for Season Offseason. CuM/D
Sugar and cogeneration after
recycling. 465 20

11. Water storage capacity 4700 CuM/D

12. Effluent generation form Sugar manufacturing CuM/D
sugar and cogeneration Process:
plant
48 M3

From Cogeneration plant : 1

M3
13. Final disposal of treated 53 M3. -
effluent
14. Ash generation from existing 24 TPD
plant
15. Pressmud 75 TPD
16. ETP Sludge 0.001 TPD
17. Lime sludge 0.008 TPD
18. WTP Sludge 0.001 TPD
19. Final disposal of Ash Given to farmer as manure. -

20. Storage capacity of Bagasse’s 1000 MT

21. yard
Storage capacity of Molasses 3000 MT

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 22. Existing manpower 100 No.
requirement for
Sugar/Cogeneration (skilled
and unskilled)

Proposed manpower 35 No.

requirement for Distillery
(skilled and unskilled)

23. Layout plan of existing sugar factory and cogeneration unit & proposed
Distillery unit with existing green belt, parking area, storage area etc -
Attached

3. Need for the project and its importance to the country and or region

Utilization of molasses for the production of ethanol in India will not only provide
value addition to the by-product, it also ensures better price stability and price
realization of molasses for the sugar mills. This will improve the viability of the sugar
mills, which will in turn benefit to cane growers.
Industry overview
Molasses is one of byproducts of sugar industry which is used to produce rectified
spirit/alcohol for making liquor and fuel. Traditionally, molasses has been used in
India to produce rectified spirit and alcohol of higher than 95% purity for producing
liquor for human consumption and for producing various chemicals. However, with
technological developments in the recent past, molasses has been effectively used to
produce bioethanol for blending with petrol as a fuel

Global scenario
Brazil is the second largest producer of ethanol globally after U.S. While U.S.
produces ethanol from corn, Brazil manufactures ethanol from sugarcane. Brazil
has mandatory blending ratio of ethanol in gasoline ranging from 18% to 25%. The
blend rate was as high as 25% before September 2011 and was reduced to 20% due
to drop in cane output hence affecting the ethanol production. Currently, flex-fuel
cars, which can use either ethanol or blended gasoline, in Brazil account for about
53% of the total car fleet and around 90% of the new vehicles sales. The proportion of
the flex-fuel cars are expected to cross 80% by 2020. Currently, the Brazilian light
vehicle fleet has been increasing by 6.7% y-o-y since 2003 with currently 90% of
the new vehicles being flex-fuel cars. Thus, there exists an increasing demand
in Brazil for ethanol which is encouraging for the sugarcane industry.

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 Indian scenario
India has about 330 distilleries, which produce over 4 billion liters of rectified spirit
(alcohol) a year. Beyond total distilleries, about 120 distilleries have the capacity to
distillate 1.8 billion liters (an additional annual ethanol production capacity of 365
million liters was built up in the last three years) of conventional ethanol per year
which is sufficient to meet requirement for 5% ethanol blending with petrol.

Government policy
In 2006, GOI mandated 5% ethanol blending with petrol, EBP programme to directly
benefit the sugarcane farmers by assuring the sugar industry a stable and reasonable
return for the molasses and then passing a significant part of the same to the
farmers. But since then the programme has been struggling to take off despite the
fact that the Cabinet Committee on Economic Affairs (CCEA) in November 2009
directed that a financial penalty be imposed on oil marketing companies for their
failure to reach targets. In November 2012, the CCEA has made it mandatory for Oil
Marketing Companies (OMCs) - Bharat Petroleum, Hindustan Petroleum and Indian
Oil Corporation - to blend 5% ethanol with petrol. This is likely to reduce the fuel
import bill and lower India's dependence on fossil fuel as the ethanol prices are lower
than petrol. The OMCs have been blending ethanol with petrol for the past two years
but the policy was partially implemented in absence of any clear directive. The
committee, headed by the Prime Minister, has also approved market-based
pricing of the biofuel, opening the
market for ethanol producers - mostly sugar companies. This shall result in an
increased demand for ethanol by OMCs.
The national bio-fuel policy, approved by the Government of India, has plans for a
20% ethanol blending programme by 2017 from the current mandated 5% blending &
recently increased to 10%, to reduce India’s dependence on fossil fuel imports.

4. Demand –Supply Gap

The gap between the availability of alcohol and the requirement by the industry has
been widening. The existing requirement of alcohol by the industries is around 450
crore liters annually at 10% fuel ethanol blending, industrial alcohol and potable
alcohol and the production is around 285 crore liters. The trend is increasing as the
blending increases.

The Ministry of Petroleum recently issued gazette notification dated 11th Januray
2013 making 5% ethanol belnding with petrol mandatory across th country.

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Year Ethanol production Ethanol utilization Ethanol Petrol
Blending Demand
Molasses Cane Total Industry Potable Balance
2001- 1775 0 1175 600 648 527 5% 448 8960
02` 10% 896
20% 1792
2006- 2300 1485 3785 711 765 2309 5% 638 12672
07 10% 1276
20% 2552
2011- 2300 1485 3785 844 887 2054 5% 814 16286
12 10% 162
20% 3257
2016- 2300 1485 3785 1003 1028 1754 5% 1039 20785
17 10% 2078
20% 4157

From the above table it can be concluded that actual production of ethanol in
India has not kept pace with the demand. Also with robust growth for
chemical and potable industries it will mean greater shortage of ethanol in
the coming years ahead. The Government of India has set an indicative
target of 20% blending of ethanol with petrol and also for diesel with
biodiesel across the country by 2017.
5. Imports Vs. Indigenous Production
No import is proposed as demand in domestic market is enough to consume
the product.
World Alcohol Production and Consumption (Billion Litres)
World Regions Years
2010 2011 2012 2013 2014
Americas 23.23 27.81 30.02 33.35 37.30
Asia 6.02 6.54 6.44 6.61 7.15
European Union 2.54 2.50 2.50 2.71 3.13
Rest of Europe 1.45 1.48 1.47 1.46 1.36
Africa 0.51 0.54 0.57 0.59 0.62
Oceania 0.18 0.16 0.15 0.15 0.17
World Total 33.93 39.03 41.15 44.87 49.73
India 1.80 1.90 1.65 1.70 2.0

* Projected
Source: F. O. Lichfs World Ethanol and Biofuels Report, Vol.4, No.17,
09/05/2006. Ethyl alcohol is basically used for three purposes i.e. 1)
Industrial alcohol for production of downstream chemicals, 2) Pptable Alcohol
for mamifacture of alcoholic beverages (Country Liquor and IMFL) and 3)
Fuel ethanol or Anhydrous alcohol, which can be blended with petrol or
diesel.

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 Sr. No. Ethanol Consumption for (%)

1 Industrial 21
2 Potable 11
3 Fuel 68

Industrial Alcohol: -
Ethyl Alcohol is an Important feedstock for the manufacture of chemicals.
World ethyl alcohol consumption for the production of chemicals is
around 1%. These chemicals are primarily the basic carbon based products
like Acetic acid, Butanol, Butadiene, Acetic Anhydride, Vinyl Acetate, PVC
etc. The existing plants such as synthetic rubber requiring large
quantities of alcohol will certainly grow to a large capacity. Acetic acid &
Butanol, which are needed in pharmaceuticals, paints & in many other
areas are important industries as they are value added products. Ethylene,
Ethylene oxide & Mono-ethylene glycol are also produced from
petrochemical route. However latest technological development & taking
into account the increasing cost of petrochemical raw material, it is now
possible toproduce Ethylene oxide, Mono-ethylene glycol etc. starting from
ethanol.
During the last 5-6 years, a number of alcohol-based industries have come up&
the existing has marginally expanded. The raw material needs of the
alcohol based chemical industry have to be niet to facilitate maximum
capacity utilization of these units in order to meet the domestic demands
for the end products. These units are starving for want of raw materials. The
shortage is wide spread & it has hit a most of chemical drug & other
industries. The drug industry is also bedeviled by scarcity of industrial alcohol.
Producers of insulin, antibiotics, tonics & several other essential bulk drugs &
finished formulations are unable to obtain their quota of industrial
alcohol, which is a vital raw material for them. Thus, even in
Maharashtra, which should be a State with surplus production of
alcohol, drug & chemical units are in the group of acute shortage of
industrial alcohol. It follows that the supply of industrial alcohol to chemical
and drugs units in the country will remain below normal for some more
time. In order to maintain proper rate of growth of industries,
production of alcohol must increase.

6 Export Possibility
The company is setting up fuel ethanol plant, to supply the finish goods in the
country, at present is no export possibility at this capacity is envisaged.

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7 Domestic/Export Markets
As above

8 Employment generation (direct and indirect) due to the project

Existing employment at sugar unit : 100no.
Proposed Employment : 70 Nos. ( skilled and Direct )
Apart from that indirect employment generation is envisaged from the project.
Total manpower requirement
Sr. No Staff Nos.

1. Distillery manager 1
2. Production manager 1
3. ETP in-charge 1
4. Lab chemist 4
5. Operators 8
6. Project Engineer / Shift Engineer 8
7. Electrician 4
8. Mechanical fitters 4
9. Office Peon 3
10. Office assistant 3
11. Excise officer 1
12. Waterman/ Pump man 4
13. Other Contractual staff 28
14. Total 70

9 Project Description

i. Type of the project including interlinked and interdependent project, if any

As submitted, the Ethanol Plant is proposed with the existing sugar unit of 2500
TCD. No interlinked and interdependent project is prpposed with the proposed
Ethanol plant. Incineration Boiler of 14 TPH is also proposed for implimetation
of zero discharge concept. CO2 will also generated as by product from the
fermentation process which is turn can be utilized after further treatment at
CO2plant in industrial or food grade application. It is also proposed
Evaporation plant of effluent to provide better environment conservation and
pollution control arrangement in the unit as well as for the surrounding area.

ii. Location (map showing general location, specific location, and project
boundary & project site layout) with Coordinates:

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The unit is spreaded over 24.19 acres of land in village Mendrana Tehsil,
Pansemal Dist. - Barwani of MP. The latitude and longitude of the site is as
below : 21°39'24.56"N - 74°39'14.41"E

Satellite Image of the Project area

Topographical Base Map

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iii. Details of Alternate Site:

The site is proposed on the piece of land where sugar unit ( 2500 TCD) with
cogen plant of 11 MW is already in operation. The entire land is about 24.19
acres and out of that proposed unit will require 32392 sq mt of land. Most of
the infrastructure is already available. Therefore proposed site suitable for the
project configuration.

iv. Size or magnitude of Operation:

It is proposed to produce 45 KLD of fuel ethanol from molasses based operation

along with 14 TPH Incineration Boiler. The unit shall adopt zero discharge
technology for the effluent disposal. .

v. Project Description With Process Details:

The overall process is shown on the attached Block Flow Diagram, and Process
Flow Diagrams. The following describes the production of ENA and co-products
from grain. The process envisages use of own molasses, as well as procured molasses
from nearby sugar factories, for manufacture of ethanol during sugar mill season
and during off- season days.
 Cane crushing system
 Fermentation system
 Distillation & Fuel Ethanol
 Effluent treatment system
Following is a brief description of the process:

DETAIL PROCESS DESCRIPTION & PROCESS FLOW CHARTS

 FERMENTATION
Molasses, diluted with water to the desired concentration is metered
continuously into a single tank fermenter. Additives likes urea (in the form of
pellets or prills) and defoaming oil are also introduced in the fermenter as
required. There is an automatic foam level sensing and dosing system for
defoaming oil.
Every Kilogram of alcohol produced, generates about 290 Kcal of heat. This
excess heat is removed by continuous circulation of fermenting wash through
an external plate heat exchanger called the Fermenter Cooler. The
fermenter temperature is always maintained between 32 and 35 deg. C, the
range optimum for efficient fermentation.

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The yeast for the fermentation is initially (i.e. during start-up of the plant)
developed in the Propagation Section described further on. Once propagated, a
viable cell population of about 500 million cells/ml is maintained by yeast
recycling and continuous aeration of the fermenter. Fluctuations in the yeast
count of +/- 20% have little effect on the overall fermenter productivity. Yeast
cell vitality which is usually above 70% may, in times of stress (such as
prolonged shut-downs) drop to 50% without affecting the fermentation.
Fermented wash passes through a series of hydro cyclones (one to three or
move in number depending on plant capacity), which remove grit, iron filings
and similar heavy particulate matter. This rejected material along with some
wash, is taken to the bottom portion of the wash column for alcohol recovery.
The overflow from the first hydro cyclone is taken a wash tank, also provided
with an arrangement to facilitate removal of heavy settable particulate matter.
Overflow from the wash tank is taken to the yeast separator, which clarifies
the wash. The hydro cyclone and the wash tank protect the separator from
erosion damage by removing grit and similar hard particles.

Wash Preparation
For the plant mash, molasses is diluted with water to give a sugar
concentration of 14 to 18% and pumped directly into the fermenter. This mash
is usually not sterilized, although in certain cases it has been pasteurised with
a resultant slight increase in efficiency. The fermenter is issued when it is one
eighth to one fourth full with a large volume of active yeast. 2 to 4% of the
final volume to allow development of the yeast during the entire filling period,
which may amount to 8 hours and to avoid growth of contaminating
organisms during this period.
Nutrients

Blackstrap molasses usually contains enough yeast nutrients to give a fast,

efficient fermentation. In some cases, however, it is desirable to add small
quantities of ammonium salts, such as ammonium sulphate, to the mash
to increase the rate and efficiency of the fermentation. In such cases, the
amount of ammonium sulphate added varies between 0.5 liters and 3 liters per
10,000 liters of mash, depending on the molasses used, the optimum amount
being determined by laboratory in a blackstrap molasses fermentation.
Fermentation Temperatures
Fermenters are usually set at a temperature between 270 F and 300 C and are
held a 320 C by the use of water sprays on the rank internal cooling coils, or

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 by circulation of the mash through external coolers. It is desirable to
maintain the temperature of the mash below 350 C. The amount of heat
liberated during the fermentation agrees with the theoretical value.
C2H12O 2C2H5OH + 2CO2+26.0 Calories
The heat produced from a fermentation involving 100 kg of sugar is 260
cal. If the fermenters are not cooled the temperature of the mash will rise as
much as 400 C.

• Yeast Recycling:
The yeast in the fermented wash is removed as a 45 to 55 v/v slurry, and is
returned to the fermenter. This feature ensures that a high yeast cell
concentration is achieved and maintained in the fermenter. By recirculating
grown, active yeast, sugar that would have otherwise been consumed in yeast
growth, is made available for alcohol production, ensuring high process
efficiency.
• Propagation:
The propagation section is a feeder unit to the fermenter. Yeast, either
Saccharomyees cereviseae or Schizosaccharomyees (the choice being
determined by other process parameters, mainly the downstream effluent
treatment system) is grown in 3 stages. The first two stages are designed for
aseptic growth. Propagation vessel III develops the inoculum using pasteurized
molasses solution as the medium. This vessel has a dual function. During
propagation, it serves for inoculum build-up. When the fermenter enters
the continuous production mode, Propagation Vessel III is used as an
intermediate wash tank. Propagation is carried out only to start up the
process initially or after very long shut-downs during which the fermenter is
emptied.
• CO2 Scrubbing and Recovery:
The carbon-di-oxide produced during fermentation is scrubbed with water in
packed- bed scrubber, to recover alcohol. The water from the scrubber is
returned to the fermenter. About 1.0% of the total alcohol production is
saved by scrubbing the fermenter off gas. In plants where it is desired to
recover carbon-di-oxide, a part of the wash is drawn into a separate vessel
and is aerated there. This external aeration allows the recovery of CO2
uncontaminated with air. More details of this system can be supplied on
request.
• Fermentation Parameters (Typical):
The pH of the fermenter is maintained between 4.0 & 4.8 usually without
addition of any acid. The alcohol concentration is maintained between 7.0 &

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 7.5 % v/v, unless a highly concentrate effluent is to be produced. To reduce
the effluent volume, the fermenter is operated at a very high dissolved solids
level by increasing the proportion of weak wash recycle. Under these
conditions, alcohol concentration is reduced to between 5.5 to 6.0% v/v.
Conversion of sugar to alcohol is instantaneous, and the residual sugar
concentration is maintained below 0.2 % w/w as glucose. This usually
corresponds to a residual reducing substances concentration of 2.0 to 2.5 %
w/w in wash.
All the nutrient elements necessary for yeast growth exist in adequate
quantities as impurities in molasses. Occasionally, Nitrogen may have to be
supplemented. Defoaming oil (DFO), say Turkey Red Oil is added to the
fermenter by an automated DFO dosing system, to control foaming. Usually no
other additives are required.
• Flexibility:
This process accords tremendous flexibility to the operator. Process conditions
and plant design can be varied to suit individual requirements of alcohol
quality, effluent concentration and characteristics. This unit can give spent
wash suitable for use in any effluent treatment process.
2. Distillation:
Clarified or de-yeasted wash flows by gravity to the propagation vessel No. III,
which during continuous production, operates as an intermediate wash tank.
From here, fermented wash is pumped to the wash preheater, which uses
vapors from the rectifying column to preheat wash. Further heating is done in
an exchange of heat with weak wash and spent wash (see flow sheet for
primary distillation). Preheated wash then enters the degasifying column of the
distillation section.
• Primary Distillation: The CO2 and the degasifying section help remove the
CO2 and other non-condensable entrained in the wash. The wash column is
first column in the distillation section. It is also called the analyzer. Wash is
boiled in this column with steam either supplied as live steam from the
boiler (after pressure reduction and desuperheating) or from a reboiler which
generates steam by evaporating effluent wash.
Alcohol in wash vapourises and is carried, along with water vapor, to the top of
the wash column from where it goes to the rectification column. As wash
travels down the analyzer, it is progressively ‘stripped’ of its alcohol content.
At a point in the column, where the alcohol concentration is 0.5 to 1.0% v/v,
a portion of the wash is drawn off. This is called weak wash.

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• Weak Wash Recycling :
Weak wash recycling of weak wash helps maintain the desired level of
dissolved solids in the fermenter, so that an adequately high osmotic
pressure is achieved. Osmotic pressure and the concentration of alcohol in the
fermenter, together keep off infection and minimize sugar losses. Weak wash
recycling also reduces the quantity of effluent spent wash and reduces the
process water requirement of the plant.
Spent wash is the wash from which all alcohol has been removed, this emerges
from the bottom of the wash column at about 105 deg C. Some of the heat is
recovered to preheat fermented wash entering the degasifying column.
Spent wash may also be passed through a forced circulation reboiler to
generate vapors. This concentrates the effluent and reduces the volume
further.
Multi Pressure Vacuum Distillation:
After fermentation the next stage in the manufacture of alcohol is to separate
alcohol from fermented wash and to concentrate it to 95% alcohol called as
rectified spirit. For this purpose, distillation process is employed.
Distillation step consumes a considerable amount of energy and is also a
deciding factor in the quality of ENA produced. Hence, in line with the demand
of the industry, efforts have always been to minimize requirement of energy and
to improve the basic quality of alcohol produced. Ease of operation,
reliability, lower down time and flexibility of operations are other parameters
considered during the design.
Three basic types of plant are designed:
a) One is to produce primary quality of alcohol, usually referred to as 'Rectified
Spirit' (R.S.) from the fermented wash. Such plants are also referred to as
‘Primary distillation’ plants.
b) Second is to produce fine quality of spirit usually referred to as 'Extra Neutral
Alcohol' (ENA) starting from R.S. Such plants are also referred to as 'secondary
distillation' plants.
c) Third is to directly produce fine quality alcohol (ENA) from fermented wash.
Such plants are referred to as 'wash (mash) to ENA' plants, where the two
steps of primary and secondary distillation are combined. Such plants
usually have lower consumption of energy than two separate plants

Multi-pressure vacuum distillation system for production of Rectified

Spirit / ENA consists of following distillation columns namely
1. Degasifying cum analyzer column – Operation under vacuum

15
 2. Pre-rectification column – Operation under vacuum
3. Rectification cum Exhaust Column - Operated under pressure
4. Recovery column - Operated under atmospheric
5. Extractive distillation column – Operated under vacuum
6. Simmering column – Operated under atmospheric

Benefits of Pressure Vacuum Distillation: -

Following are the advantages of pressure vacuum distillation.
• Since the analyzer column operates under vacuum, the formation of byproducts
such as acetal may minimize there by improvement in quality of alcohol.
• Pre-rectification column ensure removal of sulfur compounds/mercaptans and
also reduces load of lower boiling volatile compounds passing on to Rectifier
cum exhaust column.
• The chances of scaling due to invert solubility of certain precipitating inorganic
salts are minimized in vacuum distillation.
• Vacuum distillation requires low steam consumption with re-boiler
Integrated Multi-products Concept: -
It is now possible to install a distillation system, which can produce different
products. In the proposed scheme; the production of rectified spirit have
been considered. This allows flexibility of operation and various products can
be manufactured depending on the market demand. This integrated multi-
product system involves less capital investment as compared to independent
system.
In this type of system, switching over from one product to another is quite easy
and there is no chance of contamination of one product with another. The
system can work under multi-pressure principle with few columns operating
under vacuum and few under pressure/atmospheric.
3. Dehydration of Alcohol: Molecular Sieve:
The process drives the rectified feed though a bed of desiccant beds. To allow
for bed regeneration in continuous operation, twin beds are provided of which
one is in dehydration mode while the other is regenerating. Depending on
feed and product specifications, the dehydration-regeneration process releases
the adsorbed water together with contained ethanol, it is recycled back to
regeneration column for reprocessing.
The feed is pumped to regeneration column after preheating in feed
preheater. The overhead vapor of regeneration column is superheated to the
required operating temperature and circulated to sieve bed 1 assumed in the

16
 description to be in dehydration mode. After passing though the desiccant,
the vapor is condensed, cooled and sent to storage.

A small portion of the product vapor is sent, under high vacuum, through
bed 2, in regeneration mode, to prepare the desiccant for cycle changeover when
bed 2 goes online. The regeneration operation forces the release of the moisture
from the desiccant, making the bed 2 ready for the next cycle. The recovered
low strength vapors are condensed and recycled back to the Regeneration
column.
4. Evaporation for Spent wash Treatment
As per recent Environmental Protection Norms from Ministry of
Environment and Forests (MoEF), it is Corporates Responsibility to achieve
Zero Discharge in Inland Surface Water. For 45 KLPD distillery plant nearly
about 117 M3/Day spent wash will produced. Considering the large volume of
spent and achieve Zero liquid discharge plant operation following three stage
process is proposed.
Multi pressure distillation – In this steam is utilized in direct way for heating.
Hence, spent wash quantity generated is less as compared to traditional
distillation technology. Integrated and Standalone Multi effect evaporation -
The spent wash evaporation technology is a multiple effect evaporator system in
which heat recovered from one effect is used to concentrate spent wash in
second effect evaporator with continuous recirculation of concentrated spent
wash within the system until desired concentration is obtained. This entire
concentration process is carried out under vacuum leading to less
consumption of steam and maximum concentration of spent wash with in less
period of time. This is the 3rd stage of effluent treatment wherein spent
wash after integrated evaporation is concentrated and used in incineration
boiler.

5. Spent wash Incineration Technology:

After spent wash evaporation, concentrated spent wash with desired
concentration is obtained is feed to incineration type of boiler. The
concentrated spent wash generated after entire process of evaporation is then
sprayed in a furnace with auxiliary fuel such as coal and is then burnt in a
boiler.
6. Process Condensate Treatment and Recycle:
The condensate polishing unit is also envisaged to take care of spent lees,
cooling tower blow down, washing and process condensate from evaporation
plant. After treatment all the stream at CPU, treated condensate can be
recycled to process for dilution and as cooling tower make up and will

17
 achieve zero liquid discharge (ZLD) Due to recycle of process condensate back
to process, fresh water demand can be reduced at large extent.

Quantity of Raw Materials Required;

Raw material requirement

Sr. No. Name of raw Quantity Storage Transportation

material
Distillery
1. Molasses 158 TPD Tank Tanker
2. Coal NA NA NA
3. Sulfuric Acid 0.25kg/KL FRP Tank Tanker

4. Anti-foam reagent 0.25 Drum Truck

Sugar unit
2500TCD Open Area Truck & Tractor
1. Sugarcane
2. Lime 658 MT/Year Bags Truck
3. Sulphur 158 MT/Year Bags Truck
4. Caustic soda (50%) 5.45MT/year Bags Truck
5. Caustic soda 5.45 MT/Year Bags Truck

SDKSM will generate about 14,688 MT of molasses from expected / sustained

cane crushing of 3.125 lakh MT / year, with minimum 4.7% molasses recovery.
The total requirement of molasses for the 270 days operation of the proposed
distillery plant at optimum level of operation will be around 45,000 MT and the
balance 28062 MT of molasses will be sourced from group units sugar factories.
The fuel ethanol yield from cane molasses will be at 270 lit/ton. The per day
requirement of molasses will be about 166 MT per day for 45 KLPD ethanol
production per day. The total requirement of molasses for the 270 days
operation of the proposed ethanol plant will be about 42,750 MT (at maximum
95% utilization level from 4th year onwards). At the projected average cane
crushing of 2500 TCD for 125 days or 3.125 lakh MT per year, 14,688 MT
molasses will be generated from the cane crushing. The balance quantity of
28,062 MT will be sourced from other units. In house molasses should be
adequate to run the ethanol plant for at least 270 days. All four unit in-house
molasses will be sufficient to run the 45 KLPD of distillery plant for 270 days
at 9500 TCD combined Crushing Capacity of all four units.

18
 As the sugar plant is expected to crush about 3.125 lakh MT of sugarcane in
future, molasses of around 14,688 MT will be produced at 4.7 % molasses
generation on cane. The own molasses will be utilized by the fuel ethanol plant,
leaving 28,062 MT as other unit molasses, as the total molasses requirement is
42,750 MT for optimum level of operation.
The balance quantity of molasses will be sourced as procured molasses from
nearby sugar factories.

vii. Resource optimization/ recycling and reuse

 Multi Pressure Distillation system has lower steam consumption as it is
designed for maximum heat integration to conserve energy.
 Energy efficient Multi-Pressure Distillation system with a Steam Consumption
9.92 TPH of Total Spirit (depending on mode of operation).
 Vacuum operation nearly eliminates scaling problem in Analyzer Column and
ensures better separation of impurities, which results into better quality
product.
 Well-engineered Plants with high efficiency trays to ensure elaborate separation
and removal of impurities ensuring superior quality of Extra Neutral Alcohol.
 Analyzer Column with Hyper-stat Rh-Grid trays ensure high turbulence on tray,
this minimizes chances of scaling. Also, this special construction of trays and
access to each tray helps in easier cleaning column internals.
 Condensers are designed with multiple passes to ensure high velocity and to
minimize scaling inside tubes.

Alcohol is well known as an industrial raw material for manufacture of a variety

of organic chemicals including pharmaceuticals, cosmetics, polymers etc. A
large demand is anticipated for alcohol as a fuel. Alcohol is an eco-friendly
product
and is a substitute to the imported petroleum. Indeed fuel ethanol production
has been promoted for a variety of reasons as mentioned below,
 It has less severe impact on the environment than conventional gasoline and
less dangerous to health. As oxygenates are compounds such as alcohols or
ethers which contain oxygen in their molecular structure. Oxygenated fuels tend
to give a more complete combustion of its carbon to carbon dioxide (rather than
monoxide) which leads to reduced air pollution from exhaust emissions. It
reduces the dependence on oil imports.
 It helps to maintain rural economy.
 Factory proposes zero liquid discharge method for waste water treatment.
Maximum waste water will be recycled back into the system.

19
  Factory proposes to install Multiple Effect evaporator followed by Incineration
boiler. Advantages are as follows
 Production of steam and power generation
 Reduction in air pollution as compared to coal based boiler.
 Reduction in water pollution and achieve zero discharge in inland surface water.

viii.: Availability of Water its source, energy / power requirement and source:
Water requirement:
Construction Phase – 20 kld
Operational Phase – Net fresh water requirement will be 351 KL per day
Source : Borewells

Water Balance
. Water inputs (In KLD)
1. Process water for fermentation section and CO2 scrubber 414
2. DM water for RS dilution 50
3. Water for vacuum pump, pump sealing, air blower & 6
others
4. Soft water makeup for cooling towers 340
5. Other domestic usage, laboratory uses, cleaning 5
6. Boiler 15
7. Total water input at start-up 830
Water Out Put (In KLD)
1. Spent Lees (PR & Rect.) 120
2. Process condensate 395
3. CT Evaporation & Drift Losses 272
4. Water losses from vacuum pump, pump sealing, Air blower 0.2
5. Cooling tower and boiler blow down 67
6. Total Water Output 854.2
Recycled water (In KLD)
1. Lees recycle for cooling tower make up 120
2. Process condensate fermentation 120
3. Process condensate to cooling tower, CIP, Fermentation 233
4. Pumps Sealing Water Recycle cooling tower 5
5. CO2 scrubber beer well to process water for fermentation 1

6. Total Recycling water per day 479

Daily fresh water input 351

20
 Water requirement for existing sugar and cogeneration
Sr. Particulars For sugar in For During Off
No KLD Cogeneration Season
in KLD
1. Total water requirement 350 150 3 M3
2. Water recovered 135 25 -
3. Total daily fresh water 215 125 -
required after recycling

Wastewater generation of sugar and cogeneration

Sr. Source Process KLD Treatment Final Disposal
No.
1. Sugar Sugar ETP Treatment Units: Bar screen For ferti
Plant manufacturi and grit chamber, oil and grease irrigation.
ng Process 200 traps, reaction tank, equalization
M3 tank, anaerobic tank, aeration
Tank I, aeration Tank II,
secondary clarifier, sludge drying
bed and polishing pond.
2. Co Cooling 15 For polishing pond for For Ferti-
generati Tower dilution with other effluent Irrigation
on 11 Boiler Blow 5 M3 For polishing pond for For Ferti-
MW down dilution with other effluent Irrigation
D.M. 50 Neutralization followed For Ferti-
Regeneration M3 bydisposal to polishing pond for Irrigation
dilution with other waste water
stream.
3. Total - 270 - -
M3

Summary of effluent generation from proposed distillery, existing sugar and

cogeneration unit
Source Effluent Quantity Disposal
Proposed Distiller Spent wash Raw spent wash Conc. Spent Wash
generation 450 KLD Feed in Incineration
concentrated spent Boiler.
wash 117 KLD
Sugar Molasses 117 TPD
Effluent 200 KLD
Co generation Blow down from the 70 KLD
cooling tower &

21
 boilers
Domestic Waste Sewage generation 20 KLD
water

ix. Power Requirement:

Construction Phase – 30 kw

Electricity consumption bifurcation

Sr. No Section Operating load
Connected load (kWh)
(kWh)
1. Fermentation
2. Distillation
3. MSDH
4. Integrated RSW evaporation
1185 KWH 847 KWH
5. Process condensate
treatment plant
6. Alcohol storage
7. Utility (Cooling tower)
8. Instrument air compressor

9. Total 1185 KWH 847 KWH

During operation phase , the required power will be taken from cogeneration
power plant. One DG set of 1010 KVA shall be kept as standby arrangement

Fuel consumption
Sr. No Fuel Quantity
1. Concentrated spent wash 117.84 TPD
2. Spent wash concentrate, GCV 1600 kcal/kg
3. Coal GCV NA
4 Bagasse 115.20 TPD
5 Bagasse GCV 2250 kcal/kg

22
 Steam Requirement
Sr. No. Section Quantity (TPH)

Steam utilization for

Distillery
1. Steam for Distillation (Wash to ENA mode) NA
Or Steam for Distillation (Wash to EQRS) 4.82 TPH
2. Steam for Integrated Evaporation 4 TPH
3. Steam for MSDH 1.10 TPH
4. Total 9.92 TPH
Steam utilization for sugar factory
5. Crushing rate 2500 TCD
6. Steam Generation 1440 MTD
7. Steam Requirement 1161 MTD
8. Steam Condensate 113 MTD

Steam Requirement
S no Purpose Quantity
1 Ethanol Fuel 3.5 kg/lit
2 Evaporation 1.8 kg/lit

X. Quantity of wastes to be generated (liquid and solid) and Scheme for their
management/ disposal

For Liquid Waste

The total water requirement at the startup will be around 830 m3/day, and
after recycling daily fresh water requirement will be 479 CMD. Source of water
will be Bore well. Water storage facility is available with the sugar factory.
Detail water breakup is given in Table

Water requirement for existing sugar

Sr. Particulars For sugar During Off
No Season
1. Total water requirement 350 M3 3 M3
2. Water recovered 135 M3 NA
3. Total daily fresh water 215 kld NA
required after recycling

23
 Wastewater Generation Of Sugar And Cogeneration
Sr. Source Process KLD Treatment Final Disposal
No.
1. Sugar Plant Sugar 200 ETP Treatment Units: Bar screen For ferti
manufactur M3 and grit chamber, oil and grease irrigation.
ing Process traps, reaction tank, equalization
tank, anaerobic tank,
aeration Tank I, aeration Tank II,
secondary clarifier, sludge drying
bed and polishing pond.
2 CO Gen Cooling 15 For polishing pond for For Ferti-
Plant Tower dilution with other effluent Irrigation

Boiler Blow 5 For polishing pond for For Ferti-

down dilution with other effluent Irrigation

D.M. 50 Neutralization followed For Ferti-

Regeneration bydisposal to polishing pond for Irrigation
dilution with other waste water
stream.
2. Total - 270 - -
M3

Summary of effluent generation from proposed distillery, existing sugar and

cogeneration unit
Source Effluent Quantity Disposal
Proposed Distillery Spent wast Raw spent wash Conc. Spent Wash
generation 450 KLD Feed in Incineration
concentrated spent Boiler.
wash 117 KLD
Sugar Molasses 117 TPD ETP
Effluent 200 KLD
Co generation Blow down from the 70 KLD
cooling tower &
boilers
Domestic Waste Sewage generation 20 KLD Septic tank and
water soak pit

Solid And Hazardous Waste Management

 Yeast sludge mixed with spent wash and incinerated in the boiler or used as
manure.
 Ash generated will be given to brick manufacturers.
 Sludge from ETP will be used as manure.

24
 Solid Waste Details
Sn Type of waste Quantity Disposal
From existing sugar &- Proposed Distillery
cogeneration plant
Yeast Sludge NA 0.2 Kg/day Fertilizer
Lime Sludge 0.008 MT/day NA Fertilizer
WTP Sludge 0.001 MT/day NA Fertilizer
ETP Sludge 0.001 MT/day - Fertilizer
Ash Bagasse ash: Coal Ash : NA
24 MT/day Spent wash Ash ; 1.73 MT/day
Domestic waste 0.01 MT/day NA
Waste Oil 0.0001 Ltr/day NA

4.0 Site Analysis:

i. Connectivity
Location : Own land at Village Mendrana
Tehsil –Pansemal, District- Barwani (MP)

Place : Tehsil –Pansemal

District : District- Barwani (MP)

S. Particulars Details
No.
1 Co-ordinate 1. 21°39'24.56"N - 74°39'14.41"E

2
3 Height above mean sea 217 m MSL
level
4 Nearest Town Pansemal – 4.50km
5 Nearest Railway Dondaicha – 37.25km
Station/Town
6 Nearest Airport Shirpur – 48.00km
7 Nearest Highway/Road Khetia- Sendhwa Road SH 36 - 0.17 km
- S
8 Hills/Valley Toramal Hill – NEE – 8.75km
9 Ecological Sensitive Zone None
10 Reserve Forest RF- NNE – 8.75km
RF- ENE – 9.75km
11 Nearest Village Mendrana – E – 0.90km
12 Nearest River/ Nalla Bandbhara Buzurg nadi – N- 0.09km
Gomai River – SE – 1.25km
Umri Nadi – W – 3.25km
14 Surrounding Features

25
ii. Land Form, Land use and Land Ownership
Project Proponent is having 24.19 acres of land which is possession and
diverted for industrial purposes.

iii. Topography
Topography of the area is almost plain. Map is given in point No. 3.2

iv. Existing Land use pattern

The land use of the project area is pertaining to industrial activity only. Out of
project area is predominantly being used or agricultural purposes.
Land use Break-Up for Existing and proposed unit
Area in Sq Mt
Particular Existing Sugar Unit Proposed
Distillery unit
Built up Area of main plant and 20245 8049
machineries
Road area 2024 2024
Raw Material storage area 8098 100
Fuel Storage Area 4049 2024
Roof Area 2025 NA
Parking area 2025 Common
Green Belt 20245 8098
Open Land 39235 12097
Total area 97946 Sq. Mtr. (24.19 Acre) 32392

Land Bifurcation Of Proposed Distillery Unit

No. Units Area (sq. m.)
1. Molasses Storage Tanks 1020
2. Fermentation Section 1040
3. Distillation Section 700
4. Evaporation Section 710
5. Product Storage & Receiver Section 1020
6. Cooling Tower for Fermentation 200
7. Cooling Tower for Disti. + Int. Evaporation 300
8. Cooling Tower for MSDH Section 200
9. PCTP Section 50
10. WTP & Raw Water Storage Tank 729
11. Weigh Bridge 30
12. Administration Office 80
13. Excise Office 20

26
 14. Security Cabin 20
15. Time Office 20
16. Boiler House 900
17. Coal Yard NA
18. Lagoon & Settling Pit 1000
19. Fire Water Pump House 10
Total area of Plant & Machineries 8049 Sq. Meter
In Acres 1.98 Acres
Total area earmarked for project 8.0048 acres

v. Existing Infrastructure
The required infrastructure is already in place as proposed site is in operation.
State Highway is passing at 170 mtrs from the industry.

vi. Soil Classification

The soils in the area are generally of sedimentary type soil .

vii. Climate data from Secondary Source:

Meteorological data month of 1 st March to 31 st May 2017

Relative Humidity Cloudiness

Temperature OC Morning (8.00) Evening (15.00)
% Octas
Wind Wind
Date Wind Wind
Max Min Avg. Max Min Avg. Speed Speed Mor. Eve.
Dir. Dir.
km/h km/h
1 35 17 26 64 14 31 E 5 SW 15 2 0
2 33 16 24 53 15 33 NW 7 WSW 18 3 2
3 32 15 23 60 12 35 NW 6 WSW 19 4 1
4 31 14 22 73 17 43 ESE 7 W 14 0 0
5 29 16 23 64 24 44 NE 10 NNW 7 0 3
6 30 16 23 68 19 36 ENE 13 SE 4 0 0
7 33 16 24 49 9 25 ESE 11 SW 13 6 3
8 31 16 23 49 15 31 WNW 14 W 20 6 10
9 31 16 23 52 14 31 WNW 14 WSW 22 7 9
10 29 16 22 53 26 40 W 21 WNW 21 8 43
11 28 15 21 77 11 33 W 21 WNW 23 10 2
12 27 9 18 47 9 26 NNE 11 N 8 0 0
13 30 14 22 42 9 25 ENE 7 W 5 2 0
14 31 13 22 42 5 24 E 12 ESE 6 0 51
15 32 16 24 35 7 18 ESE 17 SSW 9 14 1
16 34 18 26 74 9 22 SE 15 WSW 13 4 2
17 33 15 24 40 9 21 NNW 12 NW 18 0 0
18 33 18 26 49 15 28 WNW 21 WNW 23 15 10
19 33 17 25 52 16 34 ESE 10 WNW 27 7 6
20 33 17 24 60 15 34 NE 12 NE 8 1 1
21 34 19 27 52 8 28 E 9 SE 4 0 0
22 37 18 28 46 10 25 SSE 6 SW 10 0 0
23 37 19 28 38 10 23 NW 5 WSW 7 0 0

27
 24 37 21 29 47 11 25 NNW 14 WNW 15 1 0
25 38 19 29 49 11 26 NW 10 WNW 18 0 0
26 39 18 29 53 12 29 E 5 WNW 10 0 0
27 38 23 31 47 14 27 NE 10 NNE 11 0 0
28 40 20 30 35 12 24 NW 6 NW 6 0 0
29 41 23 32 36 12 21 N 15 NW 8 0 0
30 40 22 31 28 12 19 N 15 WNW 17 0 0
31 39 23 31 39 13 26 NW 10 W 15 0 0

Table no. 3.2 (B)

Meteorological data month of 1 st April to 30 th April

Relative Humidity Cloudiness

Temperature OC Morning (8.00) Evening (17.00)
% Octas
Wind Wind
Date Wind Wind
Max Min Avg. Max Min Avg Speed Speed Mor. Eve.
Dir. Dir.
km/h km/h
1 39 23 31 39 6 20 NW 17 W 24 0 0
2 38 22 30 38 6 16 WNW 21 W 21 0 0
3 38 18 28 34 7 20 W 18 WSW 18 0 0
4 38 19 29 60 8 29 W 19 WSW 24 0 0
5 37 20 29 48 13 32 W 17 W 21 0 0
6 38 22 30 53 7 26 W 23 WSW 24 0 0
7 36 19 28 57 5 25 WNW 19 W 22 0 0
8 36 16 26 33 4 15 NNE 12 NNW 6 0 0
9 36 20 28 31 4 13 NE 13 NNW 7 0 0
10 36 20 28 26 4 13 NE 19 NNE 13 0 0
11 38 18 28 23 4 12 SE 9 WSW 17 0 0
12 39 19 29 33 5 14 NNW 7 N 14 0 0
13 41 21 31 33 5 16 NNW 10 NNW 15 0 0
14 41 22 31 38 5 15 NNW 22 NNW 15 0 0
15 41 22 32 26 5 14 NW 23 NNW 19 0 0
16 41 22 32 29 7 15 NW 21 NNW 15 0 0
17 41 24 33 25 8 15 NNW 18 NW 14 0 0
18 41 23 32 32 8 17 NW 21 WNW 17 0 0
19 41 23 32 29 5 14 W 20 W 26 0 0
20 40 22 31 27 5 14 W 26 WNW 27 0 0
21 39 23 31 42 7 20 W 24 WSW 22 0 0
22 37 21 29 58 10 28 W 22 WSW 21 0 0
23 37 21 29 54 9 26 WNW 19 W 19 0 0
24 36 19 28 53 8 28 W 22 WSW 23 0 0
25 36 21 29 51 12 30 W 20 W 20 0 0
26 37 20 28 60 6 25 WNW 17 W 18 0 0

28
27 38 19 29 39 4 17 NW 12 WSW 11 0 0
28 39 21 30 27 5 14 WNW 15 WSW 24 0 0

29 39 24 31 37 10 23 W 17 W 17 0 0

30 37 21 29 41 15 28 W 18 WSW 18 0 0
Table No. 3.2 (C)
Meteorological Data Month Of 1 st May To 31 st May 2017

Relative Humidity Cloudiness

Temperature OC Morning (8.00) Evening (17.00)
% Octas
Wind Wind
Date Wind Wind
Max Min Avg Max Min Avg Speed Speed Mor. Eve.
Dir. Dir.
km/h km/h
1 39 23 31 50 6 25 WNW 16 W 14 0 0
2 40 25 32 25 6 16 NE 11 SW 11 0 0
3 40 24 32 37 9 19 WNW 14 WSW 16 0 0
4 41 24 32 41 6 18 NW 14 WNW 10 0 0
5 41 25 33 35 6 18 NW 16 WSW 13 0 0
6 41 24 33 30 6 16 NW 19 WNW 15 0 0
7 40 24 32 29 9 20 WNW 8 WSW 13 0 0
8 41 25 33 51 12 30 WNW 13 W 6 0 4
9 39 24 32 51 13 29 W 15 WSW 13 0 0
10 40 23 32 45 11 27 W 14 WSW 13 0 0
11 41 23 32 43 12 24 WNW 9 WNW 10 0 2
12 42 26 33 42 13 26 NNW 13 NNW 10 0 0
13 42 27 34 34 12 20 NNW 15 NNW 10 0 0
14 42 28 35 28 13 20 NNW 14 NW 14 0 0
15 41 26 33 35 12 22 WNW 18 W 17 0 0
16 40 26 33 51 10 24 WNW 19 W 19 0 0
17 40 27 33 36 9 23 WNW 19 W 20 0 0
18 41 26 33 55 11 27 WNW 16 WNW 18 0 0
19 41 26 33 51 10 26 WNW 21 W 19 0 0
20 41 26 33 43 9 24 WNW 20 WSW 18 0 0
21 39 26 32 61 16 33 W 22 W 15 0 0
22 40 24 32 54 14 31 W 14 WNW 18 0 0
23 40 25 32 49 19 40 NW 18 WNW 12 0 0
24 42 24 33 61 18 32 NW 18 WSW 9 0 0
25 42 24 33 83 17 44 NW 15 WNW 9 0 5
26 41 23 32 65 22 44 WNW 15 W 10 0 0
27 42 27 34 66 20 40 WNW 12 W 17 0 0
28 39 26 32 70 27 44 W 20 WSW 24 0 0

29
 29 37 25 31 65 27 47 W 18 WSW 25 0 0
30 36 22 29 78 26 55 W 16 W 13 1 5
31 40 25 32 69 26 51 WSW 12 SSW 9 0 2

viii. Social Infrastructure available

Social infrastructure like community center, hospital and electricity is available
in Pansemal as well as in Barwani (MP)

5.0 Planning Brief:

i. Planning Concept :
The grain base unit shall be installed after receiving environment clearance and
consent under air and water act from the MPPCB. 14 Months has been
considered for the same.
ii. Population Projection:
The project is small in magnitude. No influx of population is expected as labour
shall be deployed from the local villages.

iii Land use planning

As above

Amenities / facilities

 First aid facility has already been provided at site.

 The area shall not being used at all by general public.
 A rest shelter is there for workers.
 Guards during day & night has already been deputed at site to prevent
unauthorized entry.
 In case of natural hazards such as earthquake we will take assistance from the
local competent authority of Govt.

6.0 Proposed Infrastructure

The major plant & machinery required for the proposed project is as given
under.
Outline Technical Specifications For 45 Klpd Ethanol
Storage & Handling:

30
 Sr. Equipment Technical Specification Qty. MOC
No.
1 Raw Molasses Type- Screw/Gear 1+1 CI
transfer pump type Capacity- 20
2 Day Molasses Tank MT/hr
Capacity- 250 MT 1 MS
3 Molasses Transfer Pump Type- Screw/Gear 1+1 CI
type Capacity-
20MT/hr
4 Molasses Filter Type- Basket Strainer 1+1 MS
5 Molasses Receiving Tank Type- Cyl/Vert. Shell with 1 MS
Open Top & Conical
Bottom, Capacity- 3 MT
6 Molasses Type- Load Cell 1 MS
Weighing System Capacity 4 MT Per
Trip
7 Weighed Molasses Tank Type- Cyl/Vert. Shell with 1 MS
Conical Top & Sloping
Bottom, Capacity- 20 MT
8 Weighed Molasses Type- Screw/Gear 1+1 CI
Transfer Pump with Motor type Capacity- 15
MT/hr
9 Molasses Diluter For Type- Static Mixer 1 AISI304
Yeast Vessel

Fermentation Section:

Sr. Equipment Technical Specification Qty. MOC

No.
1 CO2 Scrubber Type: Sieve 1 AISI 304
Trays Dia: 500
2 Culture Vessel-I with mm
Type - Cyl/Vert 1 AISI 304
Air Sparger Shell, Jacketed with
Dished Ends.
3 Culture Vessel-II with Type - Cyl/Vert 1 AISI 304
Air Sparger Shell, Jacketed with
Dished Ends.
4 Culture Vessel-III with Type - Cyl/Vert Shell, 1 AISI 304
Air Sparger Jacketed with Dished
Ends. Capacity- 12 m3
5 Cell Mass Transfer Pump Type- Centrifugal with 1
with Motor Trolley Capacity- 10 m 3
6 Fermenter with Agitator, Type- Cyl/Vert. Shell 4 AISI 304
SG, LG with Conical Top &
Sloping Bottom, Capacity-
7 Molasses Broth Mixer Type- 3
300 mStatic Mixer 3 SS 304
for Fermenter

31
8 Fermenter Type- 4+1 CF8
Recirculatio Centrifugal
n Pump with Motor Capacity-
9 Fermenter Wash Cooler Type- 3PHE 4 Plates
250m /hr AISI
10 Pre fermenter Type- Cyl/Vert. Shell with 2 316
AISI 304
/Yeast Activation Conical Top & Sloping
Vessel with SG,LG Bottom, Capacity- 40m3
11 Molasses Broth Mixer Type- Static Mixer 2 AISI 304
for Yeast
Activation Vessel
12 Yeast Activation Type- 1+1 CF8
Vessel Transfer Centrifugal
Pump with Motor Capacity- 30
3
m /hr
13 Yeast Activation Type- PHE 1 Plates
Vesse AISI 316
l Cooler Frame
14 Wash Holding Tank Type – Cyl/Vert. Shell 1 MS
MS Epoxy
with Conical Top &
Sloping Bottom, Capacity –
15 Wash Transfer Pump 200 m3
Type- Centrifugal Capacity- 1+1 CF8
3
25 m /hr (Wetted
Parts
16 Air Filter Type- HEPA 1+1 Only)
MS Frame
17 Air Blower with Motor Type- Watering Capacity- 1+1 CI
220 Am3/hr
18 Nutrient Dosing Tank Capacity- 1 m3 1 AISI 304
with Agitator
19 Nutrient Dosing Pump Type- Centrifugal 1+1 CI
3
Capacity- 1 m /hr
20 Acid Dosing Tank Type- Cylindrical, 1 MS
Vertical Capacity- 1 m3
21 Acid Dosing Pump Type- Centrifugal 1+1 Wetted
3
Capacity- 1 m /hr Parts
Alloy 20
22 Antifoam Dosing Tank Type- Cylindrical, 1 MS
Vertical Capacity- 1 m3
23 Antifoam Dosing Pump Type: Gear Capacity- 1 m3/hr 1+1 CI
24 CIP tank Type- Cylindrical, 1 AISI304
Vertical Capacity- 25
25 CIP Pump m3
Type- Centrifugal Capacity- 1+1 Wetted
Parts
12 m3/hr
Alloy 20

32
 26 Piping, Valves As Per Standards Lot
Instrumentati
on

DISTILLATION SECTION:

Sr.
No. Description MOC Tech. Specs. Qty.

Analyser Column (Rh Dia: 1200 mm

1 Grid Trays) AISI 304 No. of Trays : 1
19
Degasifying Column Dia: 700mm
2 (Seive Trays) AISI 304 No. of Trays : 1
5
Pre-Rectifier Column Dia: 800 mm
3 (Bubble Cap Trays) AISI 304 No. of Trays : 1
56
Extractive Column Dia: 600 mm
4 (Bubble Cap Trays) AISI 304 No. of Trays : 1
45
Rectifier Cum
5 Exhaust Column Shell : AISI Dia: 1000 mm 1
(Bubble Cap Trays) 304 Trays No. of Trays :
AISI 304 72
Recovery Column Dia: 500 mm
6 AISI 304 No. of Trays :
(Bubble Cap) 1
50
7 Alcohol Scrubber AISI 304
1

Re boilers
1 Analyzer Column Reboiler Shell & Tube Type AISI 304 1
2 ED Column Reboiler Shell & Tube Type AISI 304 1
3 Rectifier Cum Exhaust Column Reboiler Shell & Tube Type AISI 304 1
4 Pre Rectifier Column Reboiler Shell & Tube Type AISI 304 1
Co ndensers & Coolers
5 DG Condenser I Shell & Tube Type AISI 304 1
6 DG Condenser II Shell & Tube Type AISI 304 1
7 Analyser Condenser I & II Shell & Tube Type AISI 304 3
8 ED Condenser I & II Shell & Tube Type AISI 304 2
9 Recovery Condenser Shell & Tube Type AISI 304 1
10 Vent Condenser for Analyzer Shell & Tube Type AISI 304 2

11 PCV Condenser Shell & Tube Type AISI 304 2

12 Product Alcohol Cooler Shell & Tube Type DOW Cu 1

33
13 Product (RS) Cooler Shell & Tube Type AISI 304 1
14 TA Cooler Shell & Tube Type AISI 304 1
15 FO Cooler Shell & Tube Type AISI 304 4
16 R/E Alcohol Cooler Shell & Tube Type AISI 304 1
17 ED Feed Cooler Shell & Tube Type AISI 304 1
OUTLINE TECHNICAL SPECIFICATIONS FOR 45 KLPD ETHANOL
PHE's, Pumps
19 DM Water Preheater PHE SS 316 Plates /MS 1
Frame
20 Rectifier Feed Preheater PHE SS 316 Plates /MS 1
Frame
21 PR Feed Preheater PHE SS 316 Plates /MS 1
Frame
22 Analyser Bottom Centrifugal Type CF8 (Wetted Parts Only) 1+1
Transfer Pump
23 Rectifier Lees Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1
24 PR Lees Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1
25 Pre Rectifier Feed Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1
26 PR Refux Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1
27 Rectifier Reflux Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1
28 FO Washing Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1
29 ED Bottom Transfer Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1
30 Alcohol Transfer Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1
31 Recovery Feed Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1
32 Steam Condensate Pump Centrifugal Type CI 1+1

33 Vacuum Pump Water Ring Type CI 1+1

34 Emergency Water Supply Set Standard 1

Others

Sr. Description Tech. Specs. Qty.

No.
1 FO Decanters As Per Standard 2
2 Mixing Bottle (For ED/Purifier As Per Standard 1
3 Column)
Vapour Bottles As Per Standard Lot
4 Manometer Bottles As Per Standard 2
5 Seal Pot As Per Standard 1
6 Siphon For Recovery Column As Per Standard 1

34
7 TA Mixing Bottle As Per Standard 1
8 Pipes & Fittings, Valves and As Per Standard Lot
Instrument

ABSOLUTE ALCOHOL PLANT:

Sr. Description MOC Qty. Tech. Specs.

No.
1 Absorber Bed AISI 304 2 Diameter : 900 mm
2 Evaporator Column AISI 304 1 Diameter : 900
mm with Trays
3 Evaporator Column Re boiler AISI 304 1 Suitable
4 Feed Preheater AISI 304 1 Suitable

5 Regeneration Preheater AISI 304 1 Suitable

6 Product Condenser AISI 304 1 Suitable
7 Product Cooler AISI 304 1 Suitable
8 Regeneration Condenser AISI 304 1 Suitable

9 Regeneration Cooler Plates: 1 PHE

SS
10 Super heater 316
AISI 304 1 Suitable

11 Regeneration Receiver AISI 304 1 Suitable

12 Product Receiver AISI 304 1 Suitable

13 Vacuum Educator AISI 304 1 Suitable

14 Feed Pump with Motor AISI 304 1+1 Suitable
15 Regeneration Pump with Motor AISI 304 1+1 Suitable
16 Product Pump with Motor AISI 304 1+1 Suitable

17 Filters CS 3
18 RS Feed Tank MS 1 Capacity : 50 m3
19 Instrumentation Standard Lot
20 Piping and Valves Standard Lot
21 Electricals Standard Lot

Sr. Equipment Technical MOC Qty.

No. Specification
1 RS Receivers Capacity: 50 m3 MS 3
2 IS Receivers Capacity: 10 m3 MS 1

35
 3 Ethanol Receiver Capacity: 50 m3 MS 3
4 RS Storage Tank with Vent Capacity: 900 m3 MS 2
Condenser & Flame
Arrestors
5 Ethanol Storage Tank with Capacity: 900 m3 MS 1
Vent Condenser & Flame
6 IS Bulk Storage Tank with Capacity: 400m3
Arrestors MS 1
Vent Condenser & Flame
7 Arrestors
FO Storage Capacity: 8 m3 MS 1
8 Alcohol Pumps with Centrifugal Wetted Parts Suitable
Flameproof Motor CF 8
9 Issue Measures PD Flowmeters Standard 3
10 Piping & Fittings Standard Standard 1 Lot

INTEGRATED EVAPORATOR:

Sr. Description Qty. Technical data M.O.C.

No.
1 Multiple effect Suitable Shell & Tube SS304
evaporator type, Falling
Film
2 Vapor Separator Suitable Cylindrical SS304
3 Surface condenser 1 Sheet & Tube type SS304
4 Circulation pump Suitable Double Mech Shaft Contact Part SS 304
5 Process 1+1 Contact Part SS 304
Condensate
6 pump
Concentrated Spent 1+1 Contact Part SS 304
wash transfer pump
7 Condensate Pump 1+1 Contact Part SS 304
8 Vacuum pump 1+1 Contact Part SS 304
9 Piping & Valves Lot Suitable
10 Electrical & Lot With Std.
Instrumentatio Specificatio
n n

INDEPENDENT EVAPORATOR:

Sr. Description Qty. Technical data M.O.C.

No
1 Feed and Product Tank 2 Type:- Rectangular SS304

36
 2 Feed Pump & Spent 1 + 1 each Type - Centrifugal type SS 316
wash pump Suitable
3 Evaporators Suitable Type : Forced circulation SS304
4 Vapor Liquid Separators Suitable Type : Gas SS304
liquid separator
5 Evaporation Pump Suitable type
Recirculation pump SS 316
6 Surface Condenser 1 Type : shell & tube; SS 304
9 Vacuum Pump 1+1 Type - Water ring type SS 316
10 Condensate Tank 1 Capacity – Suitable SS 304
11 Condensate Pump 1+1 Type - Centrifugal type SS 316
12 Piping and Valve, Electrical and Instruments

UTILITIEs: COOLING TOWER:

Sr. Equipment Description Specifications Qty. (Nos)

No.
1 Cooling tower for Fermentation plant 1000 M Kcal/hr 1
2 Cooling tower for Distillation 2000 M Kcal/hr 1
3 Cooling tower for Ethanol 600 M Kcal/hr 1
4 Cooling tower for evaporation 3000 M Kcal/hr 1
5 CW Recirculation pump for Suitable. Centrifugal, 1+1
Fermentation
6 CW Recirculation pump for Distillation Suitable. Centrifugal, 1+1
7 CW Recirculation pump for evaporation Suitable. Centrifugal, 1+1
8 CW Recirculation pump for Ethanol Suitable. Centrifugal, 1+1
9 PRDS Suitable. 2
10 Instrument Air compressor & dryer Suitable capacity 1+1
11 Piping, Valves standard Lot
12 Instrumentation standard Lot

Slop Fired Incinerator Boiler & Turbine

Sr. Particulars Specification

No.
1 Slop fired incinerator boiler 14 TPH, 45 Kg/Cm2 (g) Pressure
with coal as supporting fuel
2 Turbine Suitable capacity of 1.2 MW back
pressure with exhaust pressure of
4.5 Kg/Cm2(g)

37
 Water Treatment Area Filtration Plant

1. Multi grade Sand Filter 1 No.

Pressure vessel internally painted with black1 No.MS with epoxy coating
bituminous and externally with red oxide primer
:MOC
Piping works with valves 1 No.
Graded filtering sand specifically selected and 1 No.
graded
2. Activated Carbon Filter 1 No.
Pressure vessel internally painted with 1 black
No. MS with epoxy coating
bituminous and externally with red oxide primer
:MOC
Piping works with valves 1 No.
3. Softener 1 No.
Pressure with rubber lining from inside and 1 No.
externally with red oxide primer
Piping works with valves 1 set
Cation Exchange resign 1 set
Hardness test kit 1 set
Brine saturated tank of MS construction 1 No.
Brine distribution system 1 Lot
4. D.M. PLANT ( 1 No.)
1 Strong acid cation 1 No.
2 Degasser tower & pump 1 No.
3 Strong acid anion 1 No.
4 Mixed bed exchanger 1No.

Fire Fighting & Protection

Fire protection system to be offered based on site plan. The system is designed
as per International rules (NFPA) & equivalent standards.

Molasses Bulk Storage Section.

Sr. Equipment Technical Qty. M.O.C.

No. Specification
1 Molasses Storage Tank 4000 MT storage 2 Mild steel,
capacity. Nos. painted

38
 2 Raw molasses Transfer Gear type positive 2+2 C.S.
pumps. displacement pumps Nos.
3 Interconnecting piping. Carbon steel pipes. LOT MS

ii Residential area (Non Processing area)

As the local people from nearby villages shall be engaged in project activity.
Therefore no housing / building is proposed.

iii Greenbelt
 Approx 2 acres area has been covered with the good green belt. Further it is
proposed to cover 2.64 acres in next 05 years of time.

iv Social Infrastructure
Company shall evaluate the need base program under CSR and shall execute as
per the given plan.

v Connectivity
Site is well connected with by State Highway Khetia- Sendhwa road. .

vi Drinking water management

Drinking water will be supplied through bore well with proper RO system.

vii Sewerage System

The domestic waste shall be taken to soak pit and septic tank.

viii Industrial waste management

As described earlier.

ix Solid waste management

As described earlier.

x Power Requirement and supply / source

As described earlier.

7.0 Rehabilitation & Resettlement Plan

No R & R plan is required.

8.0 Project Schedule and Cost estimate

39
i. Likely date of start of construction and likely date of completion
After obtaining environmental clearance and water / air consent the company
shall start the project. Proposed date shall be July 2018 (subject to clearances)

ii. Estimated project cost along with analysis in terms of economic viability
of the project
a. Land & Site Development (Refer Annexure – 1)

SDKSM has already earmarked 8 acres of land for the proposed fuel ethanol plant.
The site development expenses is estimated at Rs. 49 lakh which include leveling,
fencing, gates, internal roads, green belt development, etc
Civil Works
The main civil works for the fuel ethanol plant and their estimated costs are
indicated in the following table.
Item Cost, Rs.
Lakh
Main plant building, admin building, lab, Excise Office, 450.00
stores Weigh bridge, storage, distillery machinery
foundations, Structural for evaporation, distillation &
fermentation, Pipe Racks, Cooling tower civil works (Basin
Only), Raw water tank, Treated Water storage tanks, Fire
water storage tank, Raw & Concentrated Spent wash holding
tank, Condensate Polishing Unit civil work, Boiler
foundations & Axillaries, Turbine foundations DG set
foundation, structural work for Boiler & Turbine, Ash & Fuel
Architect
handling fees
system foundations etc., staging structure and 9.00
Total
foundations 459.00

Based on the actual civil costs incurred for similar capacity fuel ethanol
plant and preliminary estimates from the project architect, the civil estimates
have been worked out at Rs. 459 lakh, including Architect’s fees. The
appointed architect for the project will work out detailed estimates and civil
drawings (based on the inputs received by the equipment suppliers and labour
/ material rates at the site location).
Equipment
The main items of equipment for the fuel ethanol plant and their estimated
erected costs are given in the following table:
Item and brief specifications Estimated
Erected
Cost, Rs.
lakh

40
 1) 45 KLPD Capacity distillery plant, including incl.
Molasses storage & handling, Fermentation, Multi-Pressure
Distillation & Ethanol, Integrated & Independent
Evaporation for spent wash concentration, Utility Equipment 1525.00
- Cooling Towers, Condensate Polishing Unit, Blower, Alcohol
Storage & auxiliaries, interface piping, electrical &
instrumentation, Air compressor, structural work, Erection
& Commissioning etc.

2) 14 TPH Capacity, 45 kg/cm2 pressure slop fired 1050.00

Boiler & auxiliaries
3) 1.2 MW Capacity matching back pressure TG set & 150.00
auxiliaries
4) Balance of Plant equipment incl. PRDS, DCS, etc. 175.00
Sub-total including erection & commissioning, packing
forwarding, insurance, etc. 2900.00
Avg. Taxes & Duties (18 %) 522.00
Total 3422.00

Based on the budgetary offers received from reputed machinery suppliers &
possible negotiation margins, the estimated erected cost of plant and equipment
for the proposed fuel ethanol plant including Boiler & Turbine has been worked
out at Rs.3422.00 lakh

Item Year
1 2 3 4 5
Installed Capacity-KLPD 45 45 45 45 45
Number of shift/day 3 3 3 3 3
 No. of days 180 270 270 270 270
 No. of hrs. 24 24 24 24 24
 Annual Installed Capacity 8100 12150 12150 12150 12150
Capacity utilization, % 80 90 95 95 100
Net Production Fuel Ethanol, 6480 10935 10935 11543 12150
KL

Cost Summary
Based on the capital cost break up worked out, the project cost summary for
the entire integrated project is given in the following table
Distillery Plant
Particulars
(Rs. Lakh)
Land and Site Development 49

41
 Buildings 459
Indigenous Plant and Machinery 3422
Miscellaneous Fixed Assets 248
Prelim. & Preoperative Expenses 308
Contingencies 68
Working capital margin 128
Total 4682

9.0 Analysis of Proposal (Final Recommendation)

Financial and social benefits with special emphasis on the benefit to the
local people including tribal population, if any, in the area.
From the foregoing analysis, it is observed that proposal is environmental
compatible and will helps to people improving their financial status,
performance and repayment capability. This also helps the company in
venturing into production of niche specialty products which will eventually
better their profits and also their ranking in the industry. CSR programme
shall be executed through the group discussion and need base programme will
be proposed for the area, by which people of the area will be benefitted.

42