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Madhucon Sugar & Power Industries Limited ENVIRONMENT MANAGEMENT PLAN 65 KLPD ENA/ETHANOL DISTILLERY
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PROJECT AT A GLANCE
Name of the Industry Madhucon Sugar & Power Industries Ltd. Project Name Amendment of Environmental Clearance by adopting Waste
Minimization Technology and Generation of 2.5 MW power from 25 TPH Spent wash incineration Boiler.
Existing EC details File No: J-11011/359/2006-IA-II(I) Existing Products as per EC order
1) 65 KLPD Molasses/ Grain based Distillery (not installed till now)
2) Operating days of distillery: 270 days 3) Sugar Unit 3500 TCD (operating) 4) Power Plant (operating) : 24.2 MW (After amendment via CFE
(expansion order no: 48/PCB/CFE/RO-KGM/HO/2009-1611 dated 05/10/2009)
Amendments Proposed 1) Operating days of Distillery: 330 days (200 days on molasses and 130 days on grain)
2) Waste Minimization technology: Addition of Incineration boiler for spent wash generating from Molasses based distillery along with existing Biocomposting and Biomethanation technology as per EC order.
3) Production of 2.5 MW additional Power from Spent Wash Incineration Boiler.
Achievement of Zero Effluent Discharge. Area availability 134 acres Area acquired by the Project
20 acres
Latitude 17 07’ 53.19” N Longitude 80 00’ 26.93” E Nearest Village Ammagudem Village, 0.5 Km (NE) Raw material requirement Molasses: 52000 MT for 200 working days.
Rice grain: 2020 Mt for 130 working days. Fuel Requirement for 25 TPH Incineration Boiler
Coal: 25600 MTPA Spent wash: 31200 MTPA
Spent Wash generation From Molasses mode: 8 KL/KL of alcohol produced: 520 KLPD From Grain mode: 6 KL/KL of alcohol produced: 390 KLPD
Water requirement 1017 KLD for Molasses mode Distillery 854 KLD for Grain mode Distillery 50 % of total water requirement will be met from recycle of effluents.
Employment 55 Total cost of project 11453.54 lakhs EMP Cost 1145 lakhs
Madhucon Sugar & Power Industries Limited ENVIRONMENT MANAGEMENT PLAN 65 KLPD ENA/ETHANOL DISTILLERY
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ENVIRONMENTAL MANAGEMENT PLAN
1.0 INTRODUCTION
Madhucon Sugar and Power Industries Limited, incorporated on 05.11.2002 as Madhucon
Sugars Limited, with an object to acquire, takeover all the assets and properties including the
licenses of The Palair Co-Operative Sugars Limited, Rajeshwarapuram, Khammam District.
(established in co-operative sector in the year 1982)? In accordance with the policy decision
by the then Government to privatize sugar industry by open auction, Madhucon Sugar &
Power Industries Ltd. bought the unit through public auction in the year Nov 2002. The
company has already taken up these programmes on free seed supply, Cash loans, Seed loans,
Development loans, Fertilizers, Pesticides, Weedicides etc., in a big way in general and
propagating new varieties in particular in the region and the response of the growers was very
positive and it is expected the existing variety will be replaced to an extent of 50% in next 2 to
3 years time very comfortably as planned. This in turn will achieve higher yield and higher
recovery and contribute to improved physical performance of the plant.
In view of the above encouragements given by the company, the cane cultivation for the
factory command area has risen to 20,000 acres. On account of these developments the
Company has expanded the crushing capacity of the mill from 1250 TCD to 3500 TCD
besides establishing 24.2 MW Co-Gen plant in the year 2008.
After successful expansion of the sugar factory and establishment of cogeneration power
plant, the company has been recording good operational and financial performances. However
to consolidate its position by improving the dependability and eliminating the uncertainty in
the long run now the company has mooted the proposal of establishing a distillery unit of 65
KLPD capacity for producing ENA/ETHANOL in the current year as demand for ethanol is
likely to increase many folds as Government of India has made blending mandatory and
further Government also have increased the procurement price for ethanol from present
Rs.27/- to Rs. 42/- per litre to encourage sugar manufacturers to take up ethanol production in
large scale.
Keeping in view of the above the company has proposed 65 KLPD capacity of alcohol/
ethanol production unit considering own source molasses as input for 100 days and out
sourced molasses for remaining 100 days in total of 200 days operation with molasses and 130
days with grain (broken rice) as raw material to improve economic viability further.
Madhucon Sugar & Power Industries Limited ENVIRONMENT MANAGEMENT PLAN 65 KLPD ENA/ETHANOL DISTILLERY
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2.0 DESCRIPTION OF PROJECT & PROJECT SITE
2.1 PROJECT PROPOSAL
The industry has proposed for the establishment of 65 KLPD molasses/grain based distillery
for producing ENA/Ethanol and is also having valid EC for the same vide File No: J-
11011/359/2006-IA-II(I) dated 27th august 2007 but as the distillery plant has not been
constructed till now and EC validity is expired the client has proposed for “Revalidation of
the Existing License with amendments like addition of waste minimization technologies
as per Rules and Regulations set by CPCB for Distilleries”. Following changes will be
made like addition of Raw Spent Wash Incineration system in addition to the existing
Biometahanaion and Biocomposting plant. Further addition of 2.5 MW power plant captive
power generation is also proposed from 25 TPH Spent wash Incineration boiler. It is also
proposed to increase the no. of operating days from 270 to 330 days (200 working days on
molasses and 130 working days on grains) as the industry has proposed for Zero water
discharge.
2.2 LOCATION OF THE PROJECT SITE
The proposed project is to be located at Nelakondapally, Rajeshwarapuram, and Khammam
District, Telangana. The promoters are already running a sugar factory with an annual
crushing of 6 Lakh tons cane and also a co-generation plant of 24.2 MW for the last 5 years.
The sugar factory is proposing to crush 8 lakh tons in the coming year there by producing
36000-37000 metric tons of molasses. In view of the existing sugar factory skilled man power
availability is not a problem.
Water is sourced from Pal air Canal and the sugar factory is having enough cushions in the
water treatment plant capacity to cater to the needs of the proposed distillery unit. Molasses
produced in the sugar factory will meet the requirements of the distillery for 100 days.
Molasses requirement for another 100 days will be procured from other sugar factories.
Broken rice will be used as raw material for the 130 days and will be procured from the nearby
grain markets.
The Details of the Project site is given in the next page followed by a preliminary site.
Madhucon Sugar & Power Industries Limited ENVIRONMENT MANAGEMENT PLAN 65 KLPD ENA/ETHANOL DISTILLERY
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2.3 SITE PARTICULARS
Table 1. The Salient Features of the proposed project
Nature of the project 65 KLPD ENA/Ethanol Distillery & 2.5 MW
electricity from Spent Wash Incineration Boiler
Size of the Project 65 KLPD Ethanol
2.5 MW Electricity
LOCATION OF PROJECT
District & State Khammam District, Telangana
Village & Mandal Rajeshwarapuram Village & Nelakondapally
Mandal
Total land area 134 acres
Area required for the proposed project 20 acres.
Topography Krishna Godavari Zone
Altitude 107 meters
Llatitude/Longitude 17 07’ 53.19” N &
Rainfall 80 00’ 26.93” E
Ambient temperature 25 C- 38 C
Relative Humidity 70%
Rainy Season June to September
Climate Condition Tropical Wet and Dry
Wind velocity 158.4 KPH
Nearest Railway station Khammam- 27 km
Nearest Highway NH-9 Kodad-20 km
Nearest airport Vijaywada-135 km
River Palair Reservoir
Soil bearing capacity 22-40 T/sqmt.
Design Wind Pressure 660 N/M2
Madhucon Sugar & Power Industries Limited ENVIRONMENT MANAGEMENT PLAN 65 KLPD ENA/ETHANOL DISTILLERY
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Figure 1. Location map of the Proposed Project Site
PROJECT SITE
Madhucon Sugar & Power Industries Limited ENVIRONMENT MANAGEMENT PLAN 65 KLPD ENA/ETHANOL DISTILLERY
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Figure 2. Google map of 10 km radius of the Proposed Project Site
Madhucon Sugar & Power Industries Limited ENVIRONMENT MANAGEMENT PLAN 65 KLPD ENA/ETHANOL DISTILLERY
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Fig. 3 Site plan of the industry
Madhucon Sugar & Power Industries Limited ENVIRONMENT MANAGEMENT PLAN 65 KLPD ENA/ETHANOL DISTILLERY
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3.0 REQUIREMENTS FOR THR PROPOSED PROJECT
330 Working days/annum (i.e. 200 working days on molasses + 130 working days on
grain)
3.1 Steam Consumption for different modes.
Table 2. MOLASSES MODE
Steam Quantity Unit
Distillation 3.50 Kg/ltr
Integral Evaporator 0.00 Kg/ltr
Stand alone evaporation 2.70 Kg/ltr
Total 6.20 Kg/ltr
Tonnage of steam required per hour 16.79 TPH
SCAPH + de-aerator 4.00 TPH
GRAND TOTAL 20.79 TPH
Table 3. BROKEN RICE MODE
Steam Quantity Unit
Liquefaction .080 Kg/ltr
Distillation 3.50 Kg/ltr
Evaporation 0.90 Kg/ltr
Drier 1.90 Kg/ltr
Total 7.10 Kg/ltr
Tonnage of steam required per hour 19.23 TPH
SCAPH + de-aerator 4.00 TPH
GRAND TOTAL 23.23 TPH
3.2 FUEL REQUIREMENT
TABLE 4. FUEL REQUIREMENT FOR DISTILLERY UNIT
Molasses Mode ( 200 WDPA) Broken Rice Mode (130 WDPA)
Concentrated Spent Wash: 31200 MTPA -
Coal: 10000 TPA Coal: 15600 TPA
Total coal requirement for 330 days: 25600 MTPA
Madhucon Sugar & Power Industries Limited ENVIRONMENT MANAGEMENT PLAN 65 KLPD ENA/ETHANOL DISTILLERY
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3.3 RAW MATERIAL DETAILS
Total Molasses requirement: 52000 Mts for 200 Working Days / Annum.
(Own Molasses 26000 Mts for 100 working days & Bought out Molasses 26000 Mts for 100
working days)
Grains Requirement (Broken Rice/ Maize) : 2020 MT for 130 Working Days/Annum.
Total Number of operable days: 330 days/annum
3.4 MANPOWER REQUIREMENT
The plant will be continuous and automatic in operation, with necessary control
instrumentation. The steam required will be supplied for self-generation. Prior to utilizing the
steam in the process the high pressure steam is used to generate power. All the three
operations namely steam and power generation, production of Ethanol are integrated. The
personnel required for all operations are listed below with their grades.
Table 5. No. of Employees
Grade Numbers
Unit head 1
Production-in-charge 1
Manager Commercial 1
Filter 4
Electrician 4
Boiler Operator 7
Technical Operator 14
Semi & unskilled labour 14
Supervisors/ Shift-in-charge 4
Stores Assistant 1
Maintenance Engineer 1
Commercial Accountant 1
Office assistant 2
TOTAL 55
3.5 LAND & BUILDING REQUIREMENT
The plant is to be constructed in 20 acres of land at the existing facility of Madhucon Sugar &
power industries Ltd, Rajeshwarapuram Village, Nelakondapally Mandal of Khammam
District, Andhra Pradesh.
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The approximate size of the buildings required for various sections are as under:
Table 6. Size & Material for Building Construction
Section Approximate Size Description
Grain Godown 28 mtr x 22 mtr x 12 mtr AC sheet roofing, RCC & Masonry
work to side walls.
Silo & unloading Platform 30 mtr x 30 mtr Open area for silo plus small shed for
unloading platform.
Milling Section 28 mtr x 17 mtr x 20 mtr Ground + four Floors covered on all
sides RCC and masonry work.
Liquefaction & fermentation 39 mtr x 43 mtr x 15 mtr AC sheet roofing sides open.
Distillation Section with ethanol 25 mtr x 15 mtr x 40 mtr AC sheet roofing sides AC sheet
cladding.
Reciever Section 18 mtr x 18 mtr x 12 mtr Roof AC sides roofing all sides
closed with RCC and masonry work.
Storage Section 40 mtr x 24 mtr Open area with boundary and dyke
walls.
Condensate polishing Unit 60 mtr x 30 mtr Open area with RCC constructions.
Evaporation section 20 mtr x 7 mtr x 24 mtr AC sheet roofing with sides open,
Ground + four floors of RCC
construction.
Dryer 15 mtr x 40 mtr x 20 mtr AC sheet roofing all sides open.
Incineration Boiler 50 mtr x 15 mtr Structural sheet constructions, open
on all sides
Turbo-alternator set 15 mtr x 20 mtr x 8 mtr RCC building
Apart from the above buildings, civil foundations (RCC) are required for Machinery and
Tanks & chimney for Boiler. Compound wall with gates, internal roads, drainage are also
required.
4.0 PRODUCTION DETAILS WITH PROCESS DESCRIPTION
4.1 Production Capacity
Table 7. Production Details
Particulars UOM No. of days
of
operation
Per day
production
Annual
production
Operating with molasses
Madhucon Sugar & Power Industries Limited ENVIRONMENT MANAGEMENT PLAN 65 KLPD ENA/ETHANOL DISTILLERY
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Ethanol Kilo Ltr 200 60.0 12000.00
Operating with Grain
ENA Kilo Ltr 130 60.45 7858.0
Technical alcohol Kilo Ltr 4.55 455.00
DDGS MT 43.55 4355.00
Assumed that price will be increase every year by 5 %
By the time the conceived distillery unit is ready for operation, it is expected that the
availability of cane for the plant will increase to about 8 lakhs MT. and therefore expected
own molasses availability will increase which can be utilized for 100 days of distillery
operation. As proposed the bought out molasses from nearby mills and open market shall be
used for production of alcohol / ethanol for another 100 days and the remaining days as per the
needs (130 days) the grain will be procured and will be used for manufacture of alcohol. In
this connection it may be mentioned that the grain like broken rice and maize are abundantly
available in the region where plant is located at reasonable prices. In the process the factory
shall be mostly dependent on own molasses and rest of the period the bought out molasses and
grain operation will be used for achieving better economic and viable status to the project and
company. However depending on the ruling prices and availability of the different products
like molasses and grain the production plan will be designed and ensure viability of the plant
from time to time.
As a policy the Pollution Control Boards are stipulating stringent conditions like Zero
Discharge of its effluent for establishment of distilleries for ensuring protection to
environment. Therefore in the proposed project, the company is using updated technology by
putting up incineration boiler to use spent wash as a raw material to generate heat to produce
steam and power for captive use and in the process no pollutant is discharged to the open
streams etc. The effluent discharged from the Distillery Unit is known as spent wash with
molasses as feed stock and has dissolved solids of about 14-18 %. This effluent is
concentrated by evaporation to increase the solid content to 60% and after concentration the
spent wash will have a calorific value of 1700 KCal./Kg which is burnt as fuel in incinerator
boiler to produce high pressure steam. Thus the concentrated spent wash almost meets half of
the energy requirements of the incineration boiler and in the process effluent treatment and
discharge problem are totally solved. Thus zero discharge of effluent is achieved. Balance half
of the energy requirement of the incineration boiler will be met by using coal as supporting
fuel. The use of concentrated spent wash as energy source in the Incineration boiler results in
reduced fuel cost compared to conventional boilers.
Madhucon Sugar & Power Industries Limited ENVIRONMENT MANAGEMENT PLAN 65 KLPD ENA/ETHANOL DISTILLERY
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The other raw material resource is grains which include broken Rice. Maize as feed stock, the
effluent is known as thin slops. Thin slops are decanted to remove suspended solids and a part
of decanted thin slop is recycled in the process. The balance thin slops are concentrated in an
evaporator so that solid content reaches 35%. The concentrated slops and the cake from the
decanter are mixed and dried in a steam heated dryer. The dried product having a moisture
content of around 10% is known as DDGS (Distillery Dried Grains & Soluble). The DDGS is
used as cattle feed; poultry feed etc. and is having a very good market.
Molecular Sieve based alcohol Dehydration plant is included in the project. Depending on the
demand of the market the main product can be either ENA/Ethanol. The overall energy
requirements in case of Ethanol will be slightly less than the energy requirements of ENA.
Products & byproducts handling & disposal
• Main products obtained are ENA/Absolute Alcohol and are marketed
• By products namely Technical Alcohol and DDGS are marketed.
• Concentrated spent wash obtained during the process is incinerated in the boiler and
energy recovered.
4.2 Process & Technology
4.2.1 MOLASSES BASED PROCESS
Ethanol production mainly involves three main processes:
1. Fermentation
2. Primary Distillation for production of Rectified Spirit. (R.S.)/E.N.A.
Molasses Storage and Handling:
Molasses is generally stored in Steel tanks. It is proposed to install Molasses storage capacity
(26000 MT) for 100 days of its consumption in the distillery plant. This capacity has been
chosen considering the molasses storage capacity available in the sugar factory premises.
Molasses is thereafter pumped to the Molasses receiving tank in the fermentation section.
Fermentation
Fermentation is a critical step in a distillery plant. It is here that yeast converts sugar present in
molasses into ethanol.
Fermentation practices vary depending upon the raw material, ambient temperatures and end
product requirement.
The Fermentations consists of following steps:
a. Molasses weighing.
Madhucon Sugar & Power Industries Limited ENVIRONMENT MANAGEMENT PLAN 65 KLPD ENA/ETHANOL DISTILLERY
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b. Yeast propagation and Pre Fermentation
c. Fermentation
A Load cell based system is to be provided for weighing of molasses with provision for
totalizing molasses consumed in a day. This weighed molasses is distributed to yeast
propagation section, pre-fermentation and fermentation section.
Yeast Propagation:
Yeast propagation section comprises of three culture vessels, Pasteurization and cooling
facility. During fermentation start up, yeast is grown in yeast propagation section. The grown
yeast is transferred to pre-fermentation stage (Yeast activation vessel).
Fermentation of Molasses for Production of Alcohol Cane molasses by itself will not ferment
on its own without dilution, as the sugars and salts exert a very high osmotic pressure. It is
therefore necessary to dilute the molasses to below about 25° Brix. Above this point the yeast
will not start fermenting rapidly, and bacterial contamination may develop before the yeast
had a chance to get established, as molasses is laden with contaminating bacteria.
Typically, molasses is diluted and allowed to ferment using yeast. The yeast converts sugars
into alcohol under anaerobic conditions, while it multiplies itself under aerobic conditions.
Fermentation is carried out under controlled conditions such as temperature, pH, yeast cell
concentration, sugar concentration, and solid’s concentration in the fermenter. These
conditions are maintained in the fermenter so as to maximize efficiencies and obtain higher
yields and productivity. However, there are many factors that affect fermentation. These are:
Molasses composition.
Water Quality.
F/N ratio of molasses.
Bacterial count, Volatile acidity or other key influencers during fermentation
process.
The fermentation efficiency generally is in the range of 88-90% provided all the factors
influencing the fermentation process are under control.
During the last decade, interesting developments have taken place in the field of technology of
fermentation of alcohol, which promise high yield of alcohol, better efficiencies, economy in
steam consumption and better quality of spirit produced.
Process
Raw molasses from the storage tank is pumped to the molasses weighing system where exact
weighing of molasses going into the fermentation system is achieved. Weighed molasses is
Madhucon Sugar & Power Industries Limited ENVIRONMENT MANAGEMENT PLAN 65 KLPD ENA/ETHANOL DISTILLERY
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then pumped to a static molasses dilutors attached to each fermenter where it is mixed with
water / fermentation wash so as to achieve proper concentration of fermentable sugars in the
dilute molasses. Typically, this is a four fermenter system. Process water is also added to first
one or two fermenters. The fermenters are agitated using agitators and recirculation pumps.
Process water is used to scrub the total outgoing carbon dioxide so as to recover the alcohol
vapours in CO2. This water is then led to wash holding tank. Nutrients & sulfuric acid etc., are
fed to the first fermenter by metering or dosing pumps. In this manner by controlling
parameters like molasses and water flows, pH, Nutrient and temperature, alcohol
concentration between 5.5 and 8.5% v/v is maintained in first and last fermenter respectively.
Temperature of the individual fermenters is maintained in the desired range of 34 to 36ºC by
re-circulating the fermenting wash through the individual plate heat exchangers. A separate
cooling tower and pump is used for recirculation of cooling water for maintaining fermenter
temperature.
The fermented wash with 9-10 % v/v alcohol is then fed into the degasifying column top for
distillation.
Average fermentation time is about 22-24 hrs. Advantages of this system are that it could take
inferior quality of molasses and yet produces higher efficiencies, good quality of spirit. Power
requirement is lower as compared to the process with yeast recycling.
Distillation
The next stage in the production of alcohol is to separate alcohol from fermented wash and to
concentrate it to 96% alcohol called rectified spirit (RS)/Extra neutral alcohol (ENA).
Rectified spirit is industrial alcohol and ENA is more purified and is used for potable purpose
especially for manufacturing IMFL (Indian made foreign liquor).
Distillation is separation of one liquid from other liquids taking advantage of their difference
in rate of vaporization. This is achieved in alcohol distillation using seven columns. The
columns are same for RS & ENA preparation. RS requires 5 columns whereas ENA uses all
seven columns. These are described below:
(A) Wash to RS Mode: -
Following columns will be under operation
1. Analyzer Column
2. Degasifying Column
3. ED column
4. Rectifier cum Exhaust Column
5. Recovery Column
Madhucon Sugar & Power Industries Limited ENVIRONMENT MANAGEMENT PLAN 65 KLPD ENA/ETHANOL DISTILLERY
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Pre-heated fermented wash will be fed to Degasifying column. Fermented wash is stripped off
alcohol by ascending vapors in Analyser column. Rectifier vapors provide energy to Analyser
column through a Thermosyphon re-boiler. Vapors of Degasifying column are condensed and
taken to Recovery Feed Tank. Analyser vapors are condensed in the Falling Film Evaporators
in the Integrated Evaporation Section. The condensed Analyser vapors are fed to ED column.
Dilution water is added in this column for concentrating higher alcohol at the top. Top of this
column is condensed in its condensers and fed to recovery feed tank while bottoms are fed to
Rectifier cum Exhaust Column for concentration.
Rectifier column, which operates under pressure, concentrates it. Condensing steam provides
energy to Purifier and Rectifier column through a vertical Thermosyphon re-boiler. Fusel Oil
Draws are taken from appropriate trays and fed to Recovery Column.
Recovery Column concentrates the fusel oil streams and Degasifying condensate to 95% v/v
concentration. An impure spirit cut is taken out from the top of the recovery column &
rectifier column. Rectified Spirit draw of 95% to 96.1% v/v is taken out depending upon the
end customer’s requirement from the upper trays of Rectifier Column.
Rectifier cum Exhaust Column meets the energy requirement of Analyser cum Degasifying
Column. Flashing the steam condensate will provide energy to Recovery column or separate
team will be provided to meet energy requirement.
Generally the distillation efficiency is around 98.5%
(B) Wash to ENA Mode: -
Following Columns will be under operation
1. Analyser Column
2. Degasifying Column
3. Pre-Rectifier cum Exhaust Column
4. Extractive Distillation Column
5. Rectifier cum Exhaust Column
6. Recovery Column
7. Simmering Column
Pre-heated fermented wash will be fed to Degasifying column. Fermented wash is stripped off
alcohol by ascending vapors in Analyzer column. Rectifier vapors provide energy to Analyzer
column through a Thermosyphon re-boiler. Vapors of Degasifying column are condensed and
taken to Recovery Feed Tank. Analyzer vapors are condensed in the Falling Film Evaporators
in the Integrated Evaporation Section. The condensed Analyser vapors are taken to Pre-
Rectifier Feed Tank. Analyzer Condensate is concentrated in Pre-Rectifier column, which
operates under pressure. Condensing steam provides energy to pre-rectifier column through a
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vertical Thermosyphon reboiler. A Technical Alcohol cut of about 1-2% of total spirit is taken
from the Pre- Rectifier column. Concentrated alcohol drawn from Pre-Rectifier column is fed
to Extractive distillation column for purification. Dilution water in the ratio of 1:9 is added in
this column for concentrating higher alcohol at the top. Top of this column is condensed in its
condensers and fed to recovery feed tank while bottoms are fed to Rectifier cum Exhaust
Column for concentration. Rectifier Column operates under pressure and condensing steam
provides energy to this column through a vertical Thermosyphon reboiler.
Technical Alcohol cut is taken out from the top of this column while ENA draw is taken out
from appropriate upper trays and fed to Simmering Column after cooling. Fusel Oil build up is
avoided by taking fusel oil draws from appropriate trays. These fusel oils along with the
condensate of Degasifying & Extractive Distillation columns are fed to recovery column for
concentration. A technical alcohol cut is taken out from the top of this column.
Simmering Column is operated under high reflux for better separation of methanol and di-
acetyls. Final ENA product draw is taken from the bottom of this column.
Condensing steam through a vertical Thermosyphon re-boiler provides energy to Rectifier
cum Exhaust Column.
Rectifier cum Exhaust Column meets the energy requirement of Analyzer cum Degasifying
Column.
Supplying steam to Reboiler of the Pre Rectifier column provides energy to Pre-Rectifier
Column.
Vapours of Pre-Rectifier Column meet the energy requirement of Extractive Distillation
Column and Simmering column.
Flashing the steam condensate will provide energy to Recovery column.
Molecular Sieve Dehydration:
As ethyl alcohol and water form an azeotrope (constant boiling mixture) at 97.1% v/v it is not
possible to concentrate the ethanol above azeotropic composition by normal distillation
procedures.
To concentrate the ethanol to above azeotropic strength, the operating pressure of the system
has to be changed so that azeotrope is shifted favorably to the desired concentration. But this
procedure is only of theoretical interest and no plants have worked with this system
Another procedure to overcome the azeotrope problem is to introduce a third component such
as benzene or cyclo hexane. Water to be separated forms a ternary azeotrope with benzene and
alcohol and comes out as top product and pure ethanol is obtained as bottom product some
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more columns are used to separate the benzene and to recycle. This process is used till two
decades back in India.
The water removal or dehydrogenation by molecular sieve technology is the latest and almost
all the ethanol plants use this technology. Molecular sieves have a very porous structure and a
component with a particular molecular size can only pass through it. In ethanol purification,
water molecules are adsorbed inside the molecular sieve and pure ethanol comes out. Once the
sieve is saturated with water, it is regenerated by changing the pressure. The regenerated sieve
is again used for separation of water. Generally two sieve beds are used – one will be under
regeneration and the second one will be under absorption.
Rectified Spirit containing at least 94% v/v alcohol is pumped from RS collection tank to
dehydration section. Rectified spirit is preheated in Feed pre-heater with the help of product
vapors and then fed to top tray of Evaporator Column. The objective of the Evaporator
Column is to evaporate rectified spirit. The Evaporator Column operates under pressure.
Energy is supplied to the Evaporator Column through Evaporator Column Re-boiler with
steam condensing on shell side. The steam condensate can be recycled back to the boiler.
Overhead feed alcohol vapors from the Evaporator Column are then passed through Super-
heater where alcohol vapors are superheated. Energy for superheating is supplied by steam
condensation on shell side of the Super-heater. Superheated hydrous alcohol vapors are sent to
twin Adsorbent beds. The twin Adsorbent beds operate in cyclic manner. Twin beds are
provided to allow for bed regeneration in continuous operation. While one bed is in
dehydration mode, the other is in regeneration mode. Depending on feed and product
specifications, dehydration regeneration exchange takes place approximately every few
minutes. The feed alcohol vapors are passed through the bed under dehydration mode. The
Adsorbent bed will absorb moisture present in feed vapors and dehydrated product alcohol
vapors are obtained from bottom of the bed. The product alcohol vapors are then passed
through Regeneration Pre-heater and Feed Pre-heater for heat recovery. The product alcohol
vapors are then passed through Product Condenser where product vapors are condensed with
the help of cooling water. Condensed product alcohol is collected in product receiver. The
product alcohol from Product Receiver is pumped to Product Cooler where it is cooled with
the help of cooling water and then sent for storage.
During regeneration mode, vacuum is applied to the bed under regeneration. A small amount
of product alcohol vapors are purged through the bed in regeneration mode under high
vacuum, to prepare the desiccant for cycle changeover when this bed goes online. The purged
alcohol vapors act as carrier for removal of moisture from the bed. These alcohol vapors along
with moisture are obtained from the top of bed. These alcohol-water vapors (regeneration
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stream) are condensed in Regeneration Condenser, which is attached to Vacuum Eductor.
Vacuum is pulled in the system with the help of Vacuum Eductor. Regeneration stream is used
as motive fluid for Vacuum Eductor. The regeneration stream coming from the Regeneration
Condenser is pumped, preheated in Regeneration Pre-heater and fed to the Evaporator Column
for recovery of alcohol.
Moisture present in feed alcohol is removed from the bottom of the Evaporator Column in the
form of spent lees containing less than 500 ppm of ethanol. After one cycle is over, the beds
are interchanged, that is, the bed on dehydration mode will be switched over to regeneration
mode and the bed on regeneration mode will be switched over to dehydration mode, with the
help of automation system.
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Fig. 4 Process flow diagram for ethanol from Molasses
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4.2.2 GRAIN BASED PROCESS:
In order to produce ethanol from starchy materials such as cereal grains, the starch must first
be converted into sugars. In brewing beer, this has traditionally been accomplished by
allowing the grain to germinate, or malt, which produces the enzyme, amylase. When the
malted grain is mashed, the amylase converts the remaining starches into sugars. For fuel
ethanol, the hydrolysis of starch into glucose can be accomplished more rapidly by treatment
with dilute sulfuric acid, fugally produced amylase, or some combination of the two.
The de-polymerization or hydrolysis of starch involves addition of one water molecule per
glucose unit.
n(-C6H10O5-) + n(H2O) n(C6H12O6)
Starch (162) Water (18) Glucose (180)
Enzymes are used for converting starch into alcohol. In its natural form starch exists in a semi
crystalline state which is not easily accessible to enzyme action. Hence it is necessary to
gelatinize or cook the starch to open up the crystalline structure. This step is known as
liquefaction. With the appropriate combination of alpha and beta amylases the thick starch
slurry is liquefied and then saccharified. Alpha amylase randomly breaks up long chains of
starch in to shorter chains of glucose units called dextrins which are mostly soluble in water.
Hence this step is known as liquefaction. In the next step amylo glucosidase enzyme converts
dextrin’s to fermentable sugar glucose and is called saccharification. Usually the gelatination
and liquefaction processes are carried out in close combination and often referred as cooking.
The fermentation of the glucose obtained by saccharification is carried out by the yeast. The
fermented mash is distilled to obtain alcohol.
In the following paragraphs the process is described briefly.
Stage I: Preparation of feed for fermentation
Grain handling and milling
Grains are stored in the Silos & from there they are conveyed through Screw Conveyor to
Bucket Elevator. Bucket Elevator lifts the grains to the required height (approximately 15mtr)
and then passes the grains on to the Vibrating Screen, Destoner and Magnetic Separator to
remove dust and stones. The flow through these equipments is under gravity.
The cleaned grains are then again conveyed by bucket elevator to an intermediate hopper,
which is provided with rotary air lock system for controlled flow in Hammer Mill. In Hammer
Mill the particle size is reduced to as required by the process. From hammer mill the flour is
pneumatically conveyed to Flour Bin (Intermediate storage for flour).From the flour bin, the
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flour is carried to Pre masher unit. In Pre masher flour is mixed with addition of required
quantity of water under agitation.
Slurry preparation/partial liquefaction
Slurry from pre-masher is taken to Slurry preparation tank where slurry is further diluted by
addition of f fresh water and recycled streams. Slurry is taken to initial liquefaction tank where
liquefying enzyme is added. This slurry is then “cooked” in the jet cooker. The slurry is
continuously pumped to a steam jet cooker where high-pressure steam rapidly raises the slurry
temperature. The mixture of slurry and steam is then passed through a retention vessel having
sufficient capacity to provide the desired retention time at a given flow rate. The cooked mash
is discharged to a flash tank. The cooking process, accomplished in the above manner,
converts the slurry into a hydrated, sterilized suspension (as starch molecule is solubilized)
and is therefore susceptible to enzyme attack for liquefaction.
Final liquefaction:
The gelatinized mash from the flash tank is further liquefied in a final liquefaction tank where
liquefying enzyme is added. Then the liquefied mash is cooled in slurry cooler and transferred
to fermentation section.
Sacharification and instantaneous fermentation:
The hydrolyzed starch from the liquefaction step is further treated with enzymes to convert the
material into glucose. This is carried out in the fermenter itself. The fermentation is
instantaneous after formation of glucose.
Stage II: Fermentation
The process followed after liquefaction is same as that is followed in the Molasses route.
Culture yeast is grown in laboratory during plant start-up. Yeast propagation section
comprises of diluter and hygienically engineered yeast vessels equipped with heating, cooling
and air s purging facility. Cell mass from Yeast vessel is transferred to yeast activation vessel
to build up cell mass required for fermentation. Here yeast cells are multiplied and activated.
The fermentation plant consists of pre-fermenters and fermenters. The fermentation is started
in the pre-fermenters in small lot and transferred to the main fermenters. During fermentation,
sugars are broken down into alcohol land carbon –di- oxide. Significant heat release takes
place during fermentation. The fermentation temperature is maintained at around 32°C by
forced recirculation flow through plate heat exchangers.
CO2 evolved during fermentation carries along with it some entrained alcohol. This CO2 is
taken to a CO2 scrubber where it is washed with water to recover the entrained alcohol.
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Stage III: Distillation
Multi-pressure (MPR) distillation schemes with the above systems & applied along with
various heat integration methods is used for the optimal economic operation of the plant.
Multi-Pressure Distillation system chosen has seven 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 proper energy
consumption.
Depending upon the market requirements either ENA is produced or RS which is subsequently
converted to Ethanol. The distillation process is same either with molasses or broken rice. The
detailed description of distillation is provided under the molasses head.
By Product recovery/Zero Discharge
In the grain based distillery, the grain flour feed contains, starch, protein and minerals.
Normally the starch content is about 65%, and moisture of 12%. Remaining 23% (proteins and
minerals) goes through the fermentation process without change. This is recovered as bottoms
(slops) of the analyzer column.
Still age or Slops which has some nutritional value are recovered as co-product. The Still age
or slops obtained from the bottom of the still are centrifuged to increase the concentration by
separating the coarse grain from the 22oluble. Thin Still age or soluble obtained from the
centrifuge is concentrated by evaporation to 30% solids and the resulting syrupy material
obtained is known as Condensed distillers soluble (CDS) or “syrup”. The coarse grain and the
syrup are then dried together in a drier with steam or hot flue gas obtained from the boiler to
obtain dried distillers grains with soluble (DDGS), a high quality, nutritious live-stock feed.
The major problem in disposing the wet soluble is that its deterioration rate is fast i.e. less than
24 hours. This can be sold off immediately as wet cake to cattle feed, but the best method is to
dry the wet cake and concentrated slops to obtain DDGS for easy handling and increase of
shelf life, which can be stored or sold off.
The process block flow diagram starting from grain is shown below in Figure 5
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Fig. 5 Process flow diagram for ethanol from Grain
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4.2.3 POWER PRODUCTION. The industry has proposed for the production of 2.5 MW of electricity from the Spent Wash
Incineration Boiler to be installed for spent wash generated from Molasses based distillery.
As a policy the Pollution Control Boards are stipulating stringent conditions like Zero
Discharge of its effluent for establishment of distilleries for ensuring protection to
environment. Therefore in the proposed project, the company is using updated technology
by putting up incineration boiler to use spent wash as a raw material to generate heat to
produce steam and power for captive use and in the process no pollutant is discharged to
the open streams etc.
The effluent discharged from the Distillery Unit is known as spent wash with molasses
as feed stock and has dissolved solids of about 14-18 %. This effluent is concentrated by
evaporation to increase the solid content to 55-60% and after concentration the spent
wash will have a calorific value of 1700 K.Cal./Kg which is burnt as fuel in incinerator
boiler to produce high pressure steam. Thus the concentrated spent wash almost meets half
of the energy requirements of the incineration boiler and in the process effluent treatment
and discharge problem are totally solved. Thus zero discharge of effluent is achieved.
Balance half of the energy requirement of the incineration boiler will be met by using
coal as supporting fuel. The use of concentrated spent wash as energy source in the
incineration boiler results in reduced fuel cost compared to conventional boilers.
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Fig 6. Flow Chart for Power production from Spent Wash Incineration Boiler
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5.0 WATER BALANCE
5.1 Water Requirement
Table 8. Fresh Water Requirement for Distillery
5.2 Waste Water Generation
Table 9. Waste water generation form Distillery Unit
S.No. Description Generation of Waste
Water in KL/day
Disposal
1 Spent Wash (for
molasses based)
520 Biocomposting and remaining to
Incineration Boiler after concentration
Spent Wash (from grain
based)
390 Decanter and evaporation to produce
DDGS
2 Domestic Activities 5.0 Septic tank followed by soak pit
3. Cooling Towers 5.0 Recycled and reused
4 Boiler Blow Down 20.0 Recycled and reused
TOTAL 550 in case of Molasses based and 420 KLD with grain based
distillery.
Molasses Mode (With approx. 50 % from recycle of effluents after treatment)
Description Process Water DM Water Soft Water
KLD KLD KLD
Fermentation 454.00 - -
Distillation - 288.00 -
Boiler make up water - 150.00 -
Cooling water make
up
- - 125.00
TOTAL 454.00 438.00 125.00
GRAND TOTAL 1017 KLD
Broken Rice Mode (With approx. 50 % from recycle of effluents after treatment)
Fermentation 216.00 - -
Distillation - 288.0 -
Boiler make up water - 150.00 -
Cooling water make up - -
TOTAL 216.00 438.00 200.00
GRAND TOTAL 854 KLD
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NOTE: In molasses mode distillery:
Spent Wash Generation: 8 KL/KL of alcohol produced.
In grain based distillery:
Spent Wash Generation: 6 KL/KL of alcohol produced.
5.3 Disposal:
ZERO DISCHARGE TECHNOLOGY
5.3.1 For Grain Mode
Generation of Effluent:
The major effluents generated in a distillery are:
1. Spent wash: The alcohol present in the fermented wash is separated as equilibrium vapor
from the top of the analyser and the balance of fermented wash comes out of the analyser as
bottom product called spent wash. The quantity of spent wash depends upon the fermented
wash strength. It can be taken on an average to 8 liters per liter of spirit produced. For a 65
KLPD distillery the spent wash quantity will be 590 KL per day.
Distillery effluent-spent wash carries one of the highest pollution loads and is highly acidic in
nature.
Earlier the spent wash is mixed with press mud from the sugar factory and is allowed to
compost. The compost product is used as fertilizer. This process requires lot of land and There
is a possibility of odour and fly nuisance. Further the operation days are limited to 270 as the
composting cannot be worked in monsoon. The pollution control boards are not giving
permission for this process to new units.
At present zero discharge is the norm prescribed by pollution control authorities. The spent
wash with an initial solid content of 12-18% is concentrated in an evaporator to bring the solid
content to 60%. This concentrated spent wash which is having a calorific value of 1700
KCals/Kg is incinerated in a specially designed boiler. The boiler requires another fuel,
generally coal, as supporting fuel. The spent wash incineration gives energy output and at the
same time avoids the discharge on to land or water bodies.
The spent wash from grain distillery is known as thin slop. In this case also zero discharge is
achieved by decantation and evaporation to a solid content of about 35%. The concentrated
thin slop ad the cake from the decanter are mixed and dried in a specially designed drier. The
dried product is known as DDGS (Distiller’s Dried Grains and Solubles). The DDGS contains
proteins and other valuables originally present in the grains and hence is a very popular cattle
and poultry feed.
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2. Spent lees: The water carried along with the alcohol vapours from the analyser top will be
discharged from the bottom of the rectifying column after separation of alcohol and is called
spent lees. The quantity varies from 1-3 liters per liter of spirit produced. The pollution load of
spent lees is very much less as compared to spent wash. The BOD load may vary between
1500-3000. The spent lees together with the condensate from the evaporator section is treated
in condensate and spent lees treatment plant and the output from the treatment plant is
reused/recycled in fermentation section as process water and cooling towers as makeup water.
The details of the treatment are discussed below.
A distillery generates large quantity of waste water. The waste water from distilleries is also
termed as vinasse or spent wash. Spent wash contains high level of BOD/COD and is viscous
in nature. This makes spent wash treatment doubly challenging. Apart from this, distilleries
are also keen to recover some value from the spent wash.
Table 10. Typical Composition of spent wash:
Parameters Description
Colour Dark brown
Odour Smell of burnt sugar
Temperature 50 C
Ph 4.5-5.4
BOD, mg/l 50,000-55,000
COD, mg/l 1,00,000-1,20,000
Total Solids, mg/l 65,000-85,000
Volatile solids , mg/l 15,000-35,000
Total Nitrogen, mg/l 1000-2500
Total Sulphide, mg/l 300-1000
Chloride, mg/l 3000-6000
Potassium as K, mg/l, 6000-10,000
Sodium, mg/l 150-2000
Sulphate, mg/l 2000-12,000
Calcium, mg/l 400-1500
Magnesium as Mg, mg/l 800-2700
Silica as SO2, mg/l 300-1300
Iron, mg/l 50-187
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After effects of unprocessed effluent:
The disposal of the spent wash on the land creates the following problems namely: -
Pollution of ground water.
Charring of crops.
Accumulation of salts.
Increase in the cropping period.
Increase in the electrical conductivity of the soil.
Bad smell.
On the other hand, if the effluent is let out in a river or canal, the oxygen content of the water
is depleted because of high organic content of the effluent.
The high BOD of the effluent consumes lots of oxygen present in the water. On account of
this, as mentioned earlier, the water living organisms are deprived of the oxygen, leading to
their death, in many cases, it is reported that the fish in the river die and float.
It is for these reasons the distillery effluent will be treated before it is disposed off. The
properties of the effluent that can be let out have been specified. The same as per the Indian
Standards Specifications I.S. 3307-1965 and 5061-1968 are given below:
Table 11. Tolerance Limits for the Effluent to be Disposed on the Land
S.No. Item Quantity
1 pH 5.5 to 9.0
2 TDS (mg/l) 2100 max.
3 Suphates as SO4, (mg/l) 1000 max.
4 Chloride (mg/l) 600 max.
5 BOD 30 max.
6 Oil & Grease (mg/l) 10 max.
7 Boron as B (mg/l) 2 max.
8 Sodium as Na (mg/l) 60 max.
The general characteristic of spent wash indicates that it is highly colored with low pH and
high BOD and COD, total solids, volatile solids etc.
The wastes from distillery industry are highly polluting. It is highly acidic and normal micro
fauna and flora cannot survive in it except a few fungi, which also can grow slowly. The spent
wash is having temperature in the range 95-105ºC. When it is discharged it can affect D.O.
concentration in the stream and other temperature dependent reactions-physical, chemical and
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biological. Since it contains high BOD, it putrefies rapidly giving rise to offensive odour. The
brown colour is esthetically objectionable and affects photosynthesis. Prolonged land
irrigation using spent wash if not sufficiently diluted may cause soil sickness.
5.3.2 For Molasses Mode:
The Central Pollution Control Board (CPCB) has recently issued guidelines for treatment and
disposal of effluent by molasses based distilleries. The guidelines have a theme of ZERO
discharge of liquid effluent. They have also recommended effluent treatment schemes and
technologies to be adopted by molasses based distillery effluent to achieve Zero discharge.
They are:
1. Bio-methanation followed by composting.
2. Concentration of Spent Wash and Incineration.
3. Direct Composting.
4. Bio-methanation followed by ferti-irrigation.
Bio-Methanation Followed By Composting: Existing Proposal
Waste water plant comprises of the primary treatment section followed by the secondary
treatment section.
Primary treatment is an anaerobic treatment, which leads to biogas formation to be fired in a
boiler for raising steam.
The secondary treatment of Bio Composting is an aerobic treatment. The spent wash of
distillery poses a very serious problem by way of threat to the environment. The volume
generated from a distillery is around 10 to 12 ltrs. per ltrs. of spirit produced. Reviewing the
work on treatment of distillery effluent and its disposal already done in India, it may be
mentioned that most of the distilleries in India have adopted open anaerobic lagooning for the
last 20 years. This of course reduces the organic pollution load up to 70% but has created its
own problems due to process limitation as briefly described below.
Percolation through sub-soil If soil is sub-standard or porous strata, pollutes drinking
water. However, lining lagoons with polythene sheet can take care of this, though the
investment is high.
Surrounding atmosphere prevails with foul smell
Sludge formation is very high, and reduces the capacity of lagoons.
De-sludging process is laborious and involves heavy expenses.
Area requirement for treatment of effluent is very high.
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It will be pertinent at this stage to discuss related legislative aspects on environmental
pollution control measures formulated by the government. The Government of India by an Act
in 1974 & 1981 respectively, and by amendments made from time to time brought in force
several legislations to keep the environment clean. The delineation of objectives, functions,
duties, responsibilities and institutional forms constitute the first part of legislation. Till
recently, Government had made limited intervention for environmental management. Prior to
1980, the two main Central Government Acts – relating to environmental protection were not
vigorously applied. However, these acts have been recently subjected to detailed review by the
committees appointed by the Government. The same committee is also asked to recommend
the measures for environmental protection. It is only after 1980 that the Government has come
out with well-defined environmental policies as given below in brief.
1. Conservation and development of safe, healthy, productive and aesthetically satisfying
environment.
2. Planning of development on sound ecological principals with environmental input,
analysis and incorporation of appropriate environmental safeguards.
3. Promotion of environmental safety, technology for recycling of resources and utilization
of wastes.
4. Evaluation of environmental norms and establishment of effective mechanisms for
monitoring surveillance and dissemination of information.
Concentration of Spent Wash and Incineration: Current Proposal
Concentrated Spent Wash contains approximately 60 % solids. Distilleries across the world
are increasingly coming under pressure from governments and society for the polluting
effluents (spent wash) from their core process. ‘Zero effluent discharge’ (ZED) norm for
distilleries is already in place in number of countries including India. Since existing disposal
methods – bio-methanation and bio-composting are unable to meet the ZED norms, distilleries
are increasingly looking to an alternate solution of concentrating the spent wash and then
firing it in a specially designed boiler.
Concentration and using as fuel is successfully proven on a commercial scale in terms of
technical scheme, costs, suitability of material of construction of equipment. Hence the same
has been considered as the effluent treatment method for the plant
The process of using concentrated spent wash as a fuel for incinerator boiler along with coal is
now well established and hence the industry has also proposed to use a commercial-scale
incinerator boiler technology for firing spent wash. The twin benefits of the incinerator boiler
include:
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1. Ability to dispose effluent discharge of distilleries in a safe and environmentally sound
way
2. Steam generation for meeting the process steam and electricity requirements of distillery.
Benefits:
1. By generating steam from spent wash, industry can significantly reduce the energy costs.
2. Every kilogram of concentrated spent wash replaces nearly 0.33 kg of Indian Coal.
3. Community life around the distillery site shall not be plagued by pollution, as the discharge
of spent wash is almost entirely eliminated.
4. Distillery meets zero liquid effluent discharge norms.
5. Effective solution for power and process steam requirements of distillery.
6. Ash generated from the boiler has high potash content used in bio-composting and, surplus
ash shall be sold to the brick manufacturers.
5.4 CONDENSATE AND SPENT LEES TREATMENT PLANT
The condensate from the evaporation and drier plants and the spent lees should be treated such
that they are suitable for recycling.
The plant consists of an equalization tank, an anaerobic digester, degassifier, filters, R.O plant,
necessary transfer pumps, instrumentation etc.
The capacity of the plant considered is 25% more than the requirement at full capacity
utilization.
BOD, COD, SS, TDS, pH, Volatile acidity and SDI at each stage is to be monitored.
Description
The proposed wastewater treatment plant shall consist of following units.
PRIMARY & SECONDARY TREATMENT
Equalization / Buffer Tank
Nutrient Dosing Assembly
Anaerobic Reactor
Aeration Tank
Secondary Clarifier
Sludge Drying Beds
TERTIARY TREATMENT
Flash Mixer
Flocculator
Lamella Clarifier - II
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Chlorine contact Chamber
Pressure Sand Filter
Activated Carbon Filter
Softener
Process Description:
Equalization Tank
Equalization tank constructed in RCC is provided for mixing the two streams and dampening
the fluctuations in wastewater quality and quantity. The Equalization tank also helps in
reducing the temperature of wastewater. Equalization tank is provided with mixer for mixing
the effluent. Effluent from Equalization tank will then be pumped to anaerobic Reactor.
Nutrient Preparation Tank:
Nutrient preparation tank is constructed in RCC. This tank is used for Nutrient solution
preparation and continuous mixing of nutrient. Nutrient is fed to equalization tank for pH
correction in required proportion. An agitator is provided for mixing of contents in the tank.
Dosing Pumps are provided for transferring the nutrient solution.
Anaerobic Reactor:
Up-flow Anaerobic Sludge Blanket reactor is provided for anaerobic treatment of effluent.
The anaerobic reactor is constructed in MS. The reactor consists of three zones viz. Influent
distribution zone, Reaction zone, Gas, Solid, & Liquid separation zone.
Influent Distribution Zone:
The raw waste water enters the bottom through influent distribution zone. A sophistically
designed piping network is provided for uniform distribution of effluent in the tank. Effluent
then travels upward in the reactor.
Reaction Zone:
In reaction zone, anaerobic bacteria are maintained in the form of sludge blanket. Organic
matter in waste water comes in contact with bacterial population and is degraded anaerobically
to methane rich biogas, which is the end product. Anaerobic digestion is to be provided with
central driven clarifier mechanism and sludge recirculation pumps. Part of the settled sludge at
the bottom of the settling tank will be pumped to the aeration tank and part of it will be
discharged on sludge drying beds as per operational requirement. This sludge being fully
mineralized is suitable for sun drying on sand drying beds.
Drying Beds:
In aeration system the sludge is sufficiently mineralized and does not need any further
treatment before dewatering and disposal. Sand filtration drying beds will be provided, where
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sludge will be dewatered by filtration through sand bed and sun drying of the dewatered
sludge is scraped & used as manure after composting.
Tertiary Treatment:
Flash Mixer:
The effluent coming from clarifier has certain amount of suspended materials. If not removed
this suspended material damage the equipment provided down the line & further process. This
material is made settle-able with the help of alum dosed in flash mixer. Static Baffled wall
type flash mixer is provided for this purpose.
Flocculator:
The water from flash mixer is then taken to flocculator where the suspended material will be
converted in flocs using flocculator mechanism and transferred to the lamella clarifier - II.
Clarifier-II:
A Lamella Clarifier in the form of rectangular or square tank will be provided for settlement
of flocculated Effluent from the flocculator. The tank will be provided with lamella PVC
plates. The settled sludge at the bottom of the settling tank will be discharged on sludge drying
beds as per operational requirement. This sludge being fully mineralized is suitable for sun
drying on sand drying beds.
Chlorine Contact Chamber:
The treated Effluent will further be subjected to chlorination for denitrification of the treated
effluent. Chlorine solution will be added to the treated Effluent. A baffled wall channel
constructed in RCC M-20 will be provided. Chlorine dose will be adjusted to maintain the
residual chlorine concentration of 0.5-1.0 ppm.
Pressure Sand Filter:
Chlorinated effluent will then be pumped to pressure sand filter for removal of suspended
solids. Pressure sand filter will consist of a cylindrical mild steel vessel with dished ends.
Filter media in the form of sand and gravel will be provided.
Softener:
A softener fabricated in MSRL is provided for removal of the Hardness of the treated effluent.
The softener will be provided with exchange resin for the removal of cations. Regeneration
system consists of brine tank, brine ejector and dosing arrangement. The treated water from
the above plant is reused and recycled as process water and cooling tower makeup water.
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6.0 ENVIRONMENT MANAGEMENT PLAN The major objective and benefit of utilizing Environmental Management Plan in project
planning stage itself, is to prevent avoidable losses of environmental resources and values as a
result of Environmental Management Plan. Environmental Management Plan includes
protection/mitigation/enhancement measures as well as suggesting post project monitoring
programme. It may often suggest additional project operations that have to be incorporated in
the conventional operation.
The industrial development in the study area needs to be with judicious utilization of non-
renewable resources of the study area and within the limits of permissible assimilative
capacity. The assimilative capacity of the study area is the maximum amount of pollution load
that can be discharged in the environment without affecting the designated use and is
governed by dilution, dispersion, and removal due to Physio-chemical and biological
processes. The EMP is required to ensure sustainable development in the study area of the
proposed plant site, hence it needs to be all encompassive plan for which the proposed
industry. Government, regulating agencies like pollution control board working in the region
and more importantly the affected population of the study area need to extend their
cooperation and contribution.
It has been evaluated that the study area has not been affected adversely as there are no major
polluting industries in the study area and likely to get economical fillip. The affected
environmental attributes in the region are air quality, water quality, soil, land use, ecology and
public health
The management action plan aims at controlling pollution at the source level to the possible
extent with the available and affordable technology followed by treatment measures before
they are discharged. Environmental management plan aims at the preservation of ecosystem
by considering the pollution abatement facilities at the plant inception.
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Table 12. Pollution Prevention and Abatement Plan
S.NO. AREA OF CONCERN SOURCE POLLUTION CONTROL MEASURES
1. AIR POLLUTION Particulate Matter, SO2,
NO2 & Hydrocarbons
Proposed Boiler: 25 TPH
Bag Filter will be provided Stack height will be kept at 45 m.
Fugitive Emissions Vehicular emission Grain receipt and
Storage
Roads are paved/asphalted Water Sprinklers (2 Nos.) Cyclones and aspiration systems
are to be provided of capacity 25.0 MT/hr at grain receipt and storage section.
Online Ambient Air Quality Monitoring stations will be installed.
2. NOISE POLLUTION Due to plant facilities Pumps /
compressors /Plant Machinery
Provision of silencers Sound-proofing the pump and compressor
Green belt development Usage of modern technologies & machineries
Due to Power Back up Facility
DG Sets Acoustic enclosures
Due to Transportation of materials & Construction Activities
Vehicles & Machinery
Provision of PPE to workers, Maintenance of machinery & vehicles
3. WATER Plant Facilities Floor Washing,
Fermenter wash, Boiler blow down, cooling water
ETP Green Belt Development Ferti-Irrigation
Domestic Canteen, toilets etc Septic Tank followed by soak pit. 4. SOIL
Plant Facilities Yeast Sludge DDGS
Dried & Disposed off as per norms Sold as Cattle Feed
6.1 AIR POLLUTION CONTROL
Bag filters will be provided to spent wash incineration boiler for pollution control to
control particulate matter concentration within the CPCB prescribed limits. Stack
height of 45 m will be provided.
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Ambient air quality and stack emission is regularly monitored to keep check on
emissions. Same will be continued in future.
Green belt has already developed and the industry is continuing developing green belt
which will help in attenuating the pollutants emitted by the plant.
Action plan to control fugitive emissions
The roads within the premises are concreted / paved to avoid vehicular emissions.
Roads & ash storing yards are sprinkled with water to reduce fugitive emissions
All transportation vehicles carry a valid PUC (Pollution under Control) Certificate
Proper servicing & maintenance of vehicles is carried out
Regular sweeping of all the roads & floors is being done.
Adequate green belt has already been developed. Green belt act as surface for settling
of dust particle and thus will reduce the particulate matter in air.
Ambient air quality is regularly monitored and effective control exercised, so as to
keep emission within the limits.
6.2 WATER POLLUTION CONTROL
No water is withdrawn from nearby surface water body/river.
Proposed unit is based on Zero Liquid Discharge so will not pose any threat to ground
or surface water.
ETP is present in plant and will be used to treat the waste water generated from floor
washing, boiler blow down etc.
Water is conserved at every stage of process. Large quantity of water is reused &
recycled.
Domestic waste is treated in septic tank followed by soak pit.
Rainwater harvesting system is installed at plant. These helps in augmentation of
ground water level of the area.
Water Conservation Measures
The following measures shall be adopted to conserve water-
Recycle of Water
Reuse of wastewater after treatment for green belt development
Periodic preventive maintenance of water distribution systems
Training and awareness on water conservation measures
Madhucon Sugar & Power Industries Limited ENVIRONMENT MANAGEMENT PLAN 65 KLPD ENA/ETHANOL DISTILLERY
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6.3 SOLID WASTE
Solid waste generated from the industry is as follows:
Table 13. Solid Waste generated
Type
Quantity Storage Utilization/disposal
Grain based distillery
DDGS 4355 MTPA Covered shed Sold as cattle feed directly
Fly ash
15 TPD
Covered shed Brick manufacturing units
Molasses based distillery
Fly ash
15 TPD
Covered shed Brick manufacturing units
6.4 NOISE ENVIRONMENT
Various components of industrial operations will cause some amount of noise, which will be
controlled by proper maintenance and compact technology.
Time to time oiling and servicing of machineries will be done
Acoustic enclosure for Turbine & D.G. sets would be used
Green belt development (plantation of dense trees across the boundary) will help in
reducing noise levels in the plant as a result of attenuation of noise generated due to
plant operations, and transportation.
High standard of maintenance is practiced for plant machinery and equipments which
helps to avert potential noise problems.
Future expansion and installation of the plant machinery will be done after due
consideration to design noise levels and noise mitigation measures.
Workers are provided with personal protective equipments
Periodical monitoring is being carried out on regular basis
6.5 ODOUR MANAGEMENT PLAN Odour Management Plan outlines the methods by which odorous emissions will systematically
assess, reduce and prevent potentially from the distillery unit.
Better housekeeping by regular steaming of all fermentation equipments.
Regular steaming of all fermentation equipment.
Use of efficient bio-cides to control bacterial contamination.
Madhucon Sugar & Power Industries Limited ENVIRONMENT MANAGEMENT PLAN 65 KLPD ENA/ETHANOL DISTILLERY
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Control of temperature during fermentation to avoid in-activation / killing of yeast.
Regular use of bleaching powder in the drains to avoid generation of putrefying micro-
organisms.
Any processes or chambers where an unacceptable level of odour could be generated
or released to atmosphere will be covered or enclosed.
To minimize odour risk the site shall be kept tidy at all times and any spillages cleaned
up promptly.
6.6 OCCUPATIONAL HEALTH AND SAFETY
Production of ethanol involves storage handling and use of several chemicals. Some of these
chemicals are toxic and hazardous in nature. Information about these chemicals is therefore
important for the safety of the employees and the plant. Besides, the health status of the
employees is also important which may be affected due to exposure to these chemicals. The
exposures may be sudden and accidental or for a long period. In both of the cases there will be
different health effects. Therefore safety measures dealing with these chemicals are of vital
importance and will be followed judiciously.
In order to ensure good health of workers, regular health check-up of the plant workers
will be carried out.
Occupational health surveillance programme will be taken as a regular exercise for all
the employees and their records maintained.
Proper storage and handling precautions will be taken. The storage area will be cool,
dry and well ventilated away from any source of heat, flame or oxidizers.
Use of Personal Protective Equipment (PPEs) will be encouraged. Proper training on
use of PPEs, characteristics of the material handled and safety precautions to be
adopted will be given to the workers.
Fire safety measures will be incorporated within the factory premises. All the fire
extinguishing media such as water, dry chemicals, CO2, sand, dolomite, etc. will be
kept in vital locations.
Fire Fighting and Safety Instruments
A hydrant line ring surrounding the entire distillery complex is to be provided with
following equipment.
Electric water pump, Diesel Engine driven pump and jack pump (1+1).
Hydrant outlet valves at 20/25 meter distance.
Swiveling type water monitor with nozzles.
Hose reels with hose boxes and G.M nozzles.
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Portable DCP extinguishers and/or CO2 extinguishers-- one /25 M2 plant area.
Fire buckets with stands.
The system should generally comply with F.I /TAC recommendations
Safety precautions will be displayed in the premises on the banners, boards etc
6.7 SOCIO-ECONOMIC ENVIRONMENT
The plant has provided direct and indirect employment and improved infrastructure
facilities and will provide the same in coming future as per the requirements.
Company has been provided assistance to the nearby villagers for their development
related to education, hospital, postal, transportation, medical services etc.
The industry would help in promoting the activities related to environmental awareness
in the nearby villages.
Activities related to awareness for sanitation in schools & nearby villages, Distribution
of essentials in the schools and environment awareness camps will also be organized.
6.8 POST PROJECT ENVIRONMENTAL QUALITY MONITORING SYSTEM
The quality of air, water and noise levels will be monitored at site as per APPCB requirements
and the reports will be submitted to the board on regular basis.
TABLE 14. IMPLEMENTATION SCHEDULE
S.NO Recommendations Time requirement 1 Air pollution control measures Before commissioning of respective unit 2 Water pollution control measures One month before commissioning of plant 3 Noise pollution control measures Along with construction 4 Solid waste management Stage wise implementation before
commissioning
Table 15. Monitoring Schedule for Environmental Parameters
S.NO
PARTICULARS MONITORING FREQUENCY
PARAMETERS
1 Stack gases monitoring- Furnace chimney
Every fortnight SPM, SO2 and NOX
2 Ambient air quality monitoring- Four stations as per prevailing wind directions
Weekly - 24 hours monitoring
SPM, SO2 and NOX
3 Noise monitoring Every fort night - 4 Waste water and effluents Every fort night PH,TDS,SS,COD,BOD,CHLORIDE,
SULPHATES, OIL & GREASE
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6.9 GREEN BELT
The industry has developed green belt of 40 acres around the premises and is constantly
making efforts for further development. The philosophy behind the green belt development is
to improve the ecology and environment of the surrounding of the plant by extensive
afforestation.
PLANT DETAILS
Trees particularly having compact branching closely arranged leaves of simple elliptical and
hairy structure, shiny or waxy leaves and hairy twigs are efficient filters of dust. The following
species have been planted to arrest the dust
Alstonias scholaris
Leucaena luecocephala
Delonia regia
Aeschenomene indica
Ficus benjamina
Coccus nucifera
Lagerstreemia indica
Tabubia rosea
Bauhinia purpurea
Cassia siamea
Peltophorum pterocarpum
Butea monosperma
Tamarindus indica
Azadirachta indica
Greenbelt is a set of rows of trees planted in such a fashion, to create effective barrier between
the plant and surroundings. The greenbelt helps to capture the fugitive emissions, attenuate the
noise levels in the plant and simultaneously improving aesthetics of the plant site. The
greenbelt around the factory compound wall and in the reserve site will be developed in
keeping view of the following objectives.
1. Planting of trees in each row will be in staggered pattern.
2. The short trees will be planted in the first two rows and the tall trees in the outer rows
around the purview of the project site.
3. Since the trunks of the trees are generally devoid of foliage, it will be useful to have
shrubs in front of the tress so as to give coverage to this portion.
4. Sufficient spacing will be maintained between the trees to facilitate effective height of
the greenbelt.
5. Plants of native origin, fast growing type with canopy and large leaf index shall be
preferred.
Madhucon Sugar & Power Industries Limited ENVIRONMENT MANAGEMENT PLAN 65 KLPD ENA/ETHANOL DISTILLERY
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Fig. 7. Green Belt Photographs
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6.10 COST OF THE PROJECT
Table 16. Cost of the Project
S.No. Particulars Molasses
mode alone
Grain
mode
alone
Total
cost in
lakhs
1. SITE DEVELOPMENT COSTS 200.00 50.00 250.00
2. CIVIL AND STRUCTURAL BUILDINGS
INCLUDING EQUIPMENT FOUNDATIONS
1500.00 300.00 1800.00
3. PLANT & MACHINERY INCLUDING
ELECTRIFICATION, ERECTION &
COMMISSIONING OF WHOLE PLANT
6158.75 1332.50 7491.25
4. MACHINERY CONTINGENCIES 296.44 66.53 363.06
5. CONTINGENCY ON BUILDINGS 85.00 15.00 100.00
6. TECHNICAL KNOW-HOW FEE 59.29 13.33 72.61
7. VEHICLES 50.00 25.00 75.00
8. OFFICE FURNITURE & EQUIPMENT 50.00 25.00 75.00
9. DEPOSITS 35.00 15.00 50.00
10. PRE-OPERATIVE EXPENSES 651.31 67.56 718.87
11. MARGIN FOR WORKING CAPITAL 274.65 183.10 457.75
12. Total 9360.43 2093.11 11453.54
Total cost allocated towards EMP and Pollution Control Measures is 1145 lakhs.
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7.0 CONCLUSION
The techno –commercial viability of the proposed distillery is proved as the following factors
significantly favour setting up the unit.
Assured supply of Molasses from the Group Company and availability of grain in
abundance around the factory.
Establishment of Plant & Machinery to handle either molasses or broken rice to
manufacture all or any of the three finished products RS/ENA/Ethanol
Viability of the project is established beyond doubt with Molasses or Broken rice as
input raw materials.
Capital cost considered is low compared to the general trend in the market.
The proposed process and plant and machinery makes the project environmental
friendly.
The proposed manufacture of fuel ethanol makes the country that much less dependent
on imports of petroleum product (fuel).
To the extent of its installed capacity, production of fuel ethanol improves energy
security & self-sufficiency and saving of foreign exchange for the country.
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