pre - feasibility report · pre - feasibility report rsl distilleries private limited 5 after the...

Modification in existing 120 KLPD Distillery (Grain to Dual mode of operation - Grain & Molasses based) At Village Chandrao, Tehsil Indri, District Karnal, Haryana

Pre - Feasibility Report

RSL Distilleries Private Limited 1

PRE - FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY

(I) Introduction

RSL Distilleries Private Limited is presently operating 120 KLPD Grain based Distillery along

with 3.5 MW Co-generation Power Plant at Village Chandrao, Tehsil Indri, District Karnal,

Haryana. Environmental Clearance for the same had been obtained from MoEFCC, New Delhi

vide Letter No. J-11011/209/2011- 1A II (I) dated 10th September, 2013.

The company is now proposing modification in existing 120 KLPD Distillery (Grain to Dual

mode of operation - Grain & Molasses based) within their existing plant premises. After the

modification of the distillery, the company will produce Ethanol also along with ENA & RS.

With this proposed modification there will be no change in the production Capacity.

The company also has existing 4 Sugar Mills in Uttar Pradesh. Since molasses is easily available

thus the company has proposed modification in the existing distillery and proposed to

operate on dual mode (grain/ molasses). As per the availability of raw material the company

will either operate on grain or molasses based.

During molasses operation the concentrated spent wash will be completely burnt in the

incineration boiler. As a part of proposed modification, there will be no change in the existing

production capacity of alcohol (ENA/RS).No additional water, power or manpower is required

for the proposed modification. The project is/ will be completely based on Zero Liquid

Discharge.

As per EIA Notification dated 14th September, 2006 and its subsequent amendments; the

project falls in Category ‘A’, Project or Activity - 5(g).

TABLE – 1

Salient Features of the Project

S. No.

Particulars Details

A. Nature & Size of the Project Units Existing Total Capacity after Modification

Distillery 120 KLPD Grain Based Distillery

120 KLPD Grain & Molasses Based

Distillery

Co-generation Power Plant

3.5 MW 3.5 MW

B. Category of the Project As per EIA Notification dated 14th Sep., 2006 and its subsequent amendments; the project falls in Category ‘A’, Project or Activity - 5(g).

C. Location Details

Village Chandrao

Tehsil Indri

District Karnal

State Haryana




Latitude 29°55'25.70"N to 29°55'33.66"N

Longitude 76°09'31.91"E to 76°09'53.36"E

D. Area Details

Total Plant Area o Existing plant area: 22.5 acres (9.11 hectares)

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

Greenbelt / Plantation Area 7.5 acres (3.0 ha) i.e. 33% of the plant area

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

1. Nearest Village Chandrao Village (~0.5 km in SE direction)

2. Nearest Town & City o Indri Town (~11 km in SW direction)

o Karnal City (~ 30 km in SSW direction)

3. Nearest National Highway/State Highway

o SH 7 (~10.5 km in West direction)

o NH 1 (~24.0 km in West direction)

4. Nearest Railway Station o Kurukshetra Railway station (~ 30 km in WNW direction)

o Karnal Railway station (~ 30 km in SSW direction)

5. Nearest Airport Chandigarh International Airport (~90 km in NNW direction)

6. National Parks/ Wildlife Sanctuaries /

Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors / Reserved / Protected Forest within 10 km radius

No National Parks/ Wildlife Sanctuaries / Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors, Reserved / Protected Forest within 10 km radius

7. Nearest Water Bodies o Dhanaura Escape & Nala (Adjacent in South direction)

o Pran Nadi (~1.0 km in ESE direction)

o Yamuna River (~3.5 km in ESE direction)

o Budhi Nadi (~6.0 km in ENE direction)

o Western Yamuna Canal (~6.5 km in NW direction)

8. Seismic Zone Seismic Zone - IV as per IS: 1893 (Part-I): 2002.

F. Cost Details

Total Cost for modification Rs. 18.0 Crores

Cost for Environment Management Plan

o Capital Cost - Rs.18.0 Crores

o Recurring Cost - Rs. 1.80 Crores / annum.

G. Basic Requirements for the project Existing water requirement

After modification water requirement

Water Requirement (KLD) 1320 KLPD 1320 KLPD

Source: Ground Water

Power Requirement (MW) 3.0 MW 3.0 MW

Source: Co-Generation Power Plant

Man Power Requirement 184 184

Source: Unskilled / Semi-Skilled - Nearby Areas; Skilled – Within or Outside Haryana

H. Product Mix Rectified Spirit, Extra Neutral Alcohol & Ethanol

I. By-product DWGS & CO2

J. Working Days 330 Days per Annum




1.1 ENVIRONMENTAL MANAGEMENT PLAN

Particulars DETAILS

Air Quality Management

� ESP with stack of adequate height has been installed with the existing boiler to control the

particulate and gaseous emissions due to combustion of fuel.

� ESP will be installed with the proposed 30 TPH incineration boiler to keep the emissions below

permissible level after modification.

� CO2 generated during the fermentation process is being/will be collected by utilizing CO2 scrubbers

and sold to authorized vendor.

� All the roads are being / will be concreted to control the fugitive dust emissions.

� Online Stack Monitoring system is already in place and operational.

� Greenbelt is being/will be developed all around the plant boundary and the same will be maintained.

Water Management

� The Grain & Molasses based distillery is being/will be based on “Zero Effluent Discharge”.

Grain based operation:

� Grain Slops (Spent Wash) is being/will be taken through Centrifuge Decanters for separation of

Suspended Solids separated as Wet Cake and which goes as cattle feed as it contains high protein.

(Also known as DWG – Distillers Wet Grains)

� Thin Slops from the Decanter Centrifuge is being/will be partly recycled back to process and balance

portions shall be taken to Thins Slops Evaporation Plant for concentration of remaining solids to

form a Syrup. This Syrup is also mixed into the Wet Cake coming out of Centrifuge and forms part of

Cattle Feed. (Also known as Soluble - Collectively known as DWGS).

� The Process condensate is being / will be cooled and sent to CPU. After treatment this process

condensate is being / will be recycled into process use.

Molasses Based Operation:

� The spent wash will be concentrated in MEE and the concentrated spent wash will be mixed with

auxiliary fuel and burnt in the incinerator boiler.

� Process Condensate will be neutralized and treated in state of art Condensate Polishing Unit (CPU)

and recycled in Fermentation process and for Cooling Tower makeup.

� Domestic waste water generated from the plant is being/will be treated in STP.

� Rain Water harvesting is being done within the existing plant premises.

Noise Management

� Personal Protective Equipment like earplugs and earmuffs is being / will be provided to the workers

exposed to high noise level.

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

prescribed limit.




� Proper maintenance, oiling and greasing of machines at regular intervals is being / will be done to

reduce generation of noise.

� Greenbelt of appropriate width inside the plant premises and at the plant boundary has been

developed.

� Regular monitoring of noise level is being / will be carried out and corrective measures in concerned

machinery are being/will be adapted accordingly to the possible extent.

Solid Waste Management

� Solid waste from the grain based operations generally comprises of Fibres and proteins in the form

of DWGS, which is ideally used as Cattle Feed. The Yeast sludge is added to the Wet Cake.

� The concentrated spent wash from molasses based distillery will be burnt in incinerator boiler along

with biomass as fuel (15% coal will also be used as auxiliary fuel).

� Ash from the boiler is being /will be given to nearby brick manufacturers/ used in land application.

� Used oil generated from the plant machinery/ gear boxes as hazardous waste is being/will be sold

out to the CPCB authorized recycler.

Odour Management

� Adequate greenbelt all around the periphery of the plant.

� Efficient CO2 scrubbing to avoid carryover of alcohol vapours & other fumes.

� Better housekeeping is being/will be maintained with good hygiene condition by regular steaming of

all fermentation equipment.

� Longer storages of any product/by-products will be avoided & use of efficient biocides to control

bacterial contamination.

� Regular use of bleaching powder/formalin in the drains to avoid generation of putrefying micro-

organisms.

Greenbelt Development/ Plantation

� Greenbelt development in and around the plant site helps to attenuate the pollution level.

� The company has already developed greenbelt/ plantation in 33% of the total plant area and the

same will be further maintained.

� Greenbelt has been developed as per Central Pollution Control Board (CPCB) guidelines.

� Native species have been planted in consultation with the local DFO.

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of Project and Project Proponent

Rana Group of Companies made a humble beginning in mid 80’s when Rana Gurjeet Singh,

group’s Founder set-up Agro Boards Limited a Kraft Paper unit in Punjab. Success of this

maiden venture was duly recognized by apex state owned industrial promotion corporations

and this led to Rana Group’s ventures with different state owned corporations.




After the success of Agro Boards; Rana Group diversified into sugar sector by setting the first

sugar manufacturing facility at Buttar Sevian, Punjab in 1993. Over the years the group has

established itself as a pioneer in the sugar industry.

Promoters:

Presently, the group is managed by Sh. Rana Inder Pratap Singh. Under his leadership, the

group at present is in to Sugar, Alcohol, Power Generation and Textile Sector. Rana Inder

Pratap Singh, M.B.A from University of Kent, United Kingdom joined the management team as

Director of Rana Sugars Limited in 2002. Rana Inder Pratap controls the daily affairs of the

group and is credited with the successful expansion projects that the group undertook since

he joined the Board. Under his management, Rana Sugars established 2 new sugar units within

a span of 2 years and tripled its crushing capacity to 15000 TCD quadruplicated its power co

generation capacity to 86 MWH from just 20 MWH.

A man of tremendous foresight, the dynamic and enterprising Rana Inder Pratap has

propelled Rana Group to be one of the top business houses in north India. He has been the

pivot for the growth of the group. He not only integrated the existing capacities but also

expanded the operations geographically by setting up manufacturing facilities in the States of

Uttar Pardesh and Haryana.

He played a vital role in acquisition of Lakshmiji Sugar Mills Co. Limited and Unn Sugar

Complex. He has been a visionary and accordingly always thrives for growth and better

prospects. It is only because of his charisma, zeal and efforts that Rana Sugars Limited has

been able to become first sugar unit in India to manufacture sugar by crushing sugar beet.

He manages the following Companies under the umbrella of Rana Group of Companies:

Name of the Company Manufacturing Capacities

Sugar Power Distillation Textiles

Unit of Measurement TCD MWH KLPD Spindles

Rana Sugars Limited 15000 86 60 --

Rana Polycot Limited -- -- -- 75000

RSL Distilleries Private Limited -- -- 120 --

Superior Food Grains Private Limited 5000 33 -- --

Lakshmiji Sugar Mills Co. Limited 4200 -- -- --

Rana Power Limited -- 27 -- --

24200 146 180 75000

Turnover:

During the year ended 31.03.2017 the Group achieved a total turnover of Rs. 1630.35 Crores.

Venture in to Distillation Business:

The promoters further propelled Rana Group in to Distillery business by integrating its

capacities and setting up first distillery unit at Punjab under Rana Sugars Limited having a

capacity to distil 60 KLs per day. After having ample experience from the above said distillery




management set up another independent distillery under the name and style of RSL

Distilleries (P) Limited at Karnal (Haryana) having a capacity to distil 120 KLs per day. The total

cost of setting up said distillery was Rs. 111.50 Crores. The distillery has been an example of

state of the art technology with latest technology. The Company at present is manufacturing

spirit and country liquor and offers a huge scope in to bottling with the abundant capacity in

hand.

Technical Specification of Distillery Units:

Particulars Distillery Capacities

60 KLPD 120 KLPD

Place Tarantaran (Punjab) Karnal (Haryana)

Bottling Lines 8 9

(Further expandable as per requirement)

Bottling Capacity

(Cases per month)

3 Lakh 4 Lakh

Bottling Agreement Radico Khaitan Ltd

(65000 Cases per Month)

Product Line Ethanol, ENA, Punjab Medium Liquor, IMFL

ENA, Country Liquor, IMFL

Market Penetration CSD/ Civil – Across North & East India

Civil – Entire Haryana

Storage Capacity – Finished Goods (Cases)

1.25 Lakhs 2.00 Lakhs

(ii) Brief description of nature of the project

The Government of India has approved National Policy on Biofuels – 2018 in order to promote

biofuels in the country. Biofuels in India are of strategic importance as it augers well with

ongoing initiatives of Government such as Make in India, Skill Development and Swachh

Bharat Abhiyan.

Reduce Import Dependency: The ethanol supply will help to reduce import dependency on

crude oil which will in turn result in savings of forex.

Cleaner Environment: The use of ethanol will reduce CO2 emissions. It will also reduce Green

House Gas emissions by reducing crop burning and conversion of agricultural residues and

wastes into biofuels.

Health benefits: Prolonged reuse of cooking oil for preparing food, particularly in deep-frying

causes health hazard and can lead to many diseases. By using cooking oil as a potential

feedstock for biodiesel will prevent diversion of used cooking oil in the food industry.

Municipal Solid Waste (MSW) Management: Using advance technologies waste and plastic in

MSW can be converted in use fuels.





mode of operation - Grain & Molasses based) within their existing plant premises at Village

Chandrao, Tehsil Indri, District Karnal, Haryana. After the modification of the distillery, the

company shall produce ethanol. With this proposed modification there will be no change in

the production capacity and fresh water requirement.

The company also has existing 4 Sugar Mills in Uttar Pradesh. Since molasses is easily available

thus the company has proposed modification in the existing distillery and proposed to

operate on dual mode (grain/ molasses). As per the availability of raw material the company

will either operate on grain or molasses based.





Discharge.

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

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

the quality of human life in every passing year. The human race is largely dependent on

industrialization for up gradation in quality of life. Progress of the nation is judged through its

economic growth which is largely dependent on industrial productivity. In Indian economy

(which is agro based) many industries are dependent over agricultural produce for production

of luxury and need based commodities. Alcohol has assumed a very important place in the

Country’s economy. It is a vital raw material for a number of chemicals. It has been a source of

revenue by way of excise duty levied by the State Government on alcohol liquors. It has a

potential as fuel in the form of power alcohol for blending with petrol in the ratio of 20:80.

The use of alcohol for the purpose of potable liquor is as high as its use for industrial

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

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

accelerating growth in coming years with the consumer base likely to expand amidst rising

disposable income. The domestic alcoholic drinks market is estimated around $13 billion and

has been growing at a compounded annual growth rate in excess of 10% in the past few years.

The growth rate is higher than other major Asian markets like China and South Korea, etc.

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

milestone.

(iv) Demand- Supply Gap

The total production of ENA from molasses and grain is about 300 crores litres per annum. The

total requirement of ENA for IMFL in India is around 120 crores litres (35% ENA from grain & 65

% from molasses). Next five year projection of ENA from grains is 60 % & from molasses is 40 %.

Alcohol produced from molasses is also used by oil companies and 111 crores litres has been

procured in the year of 2016-17.




Post 2017 India will require 6.30 billion litres of alcohol mainly from molasses for the use in

petrol by the oil companies. Thus the huge demand of ENA will arise.

(v) Import vs. Indigenous Production

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

was imported. As far as ENA production is concerned, Indian market plays a vital role at both

domestic & international level. So they need to produce more alcohol to meet the demand.

(vi) Export Possibility

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

(vii) Domestic / Export Markets

Market depends on Excise Department.

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

The existing man power requirement is 184 persons. The total man power requirement will be

same after modification.

3.0 PROJECT DESCRIPTION

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

There are no interlinked projects related to this project.

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

project site layout) with coordinates




Figure - 1: Location Map




(iii) Key Plan

Figure 2: Environmental Settings of 10 km radius area




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

particularly the environmental considerations gone into should be highlighted.

Since the proposed modification will be done within the existing plant premises and no

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

(v) Size or magnitude of operation


mode of operation - Grain & Molasses based) within their existing plant premises at Village

Chandrao, Tehsil Indri, District Karnal, Haryana. With this proposed modification there will be

no change in the production capacity and fresh water requirement.





Discharge.

Units Existing Total Capacity after Modification

Distillery 120 KLPD Grain Based Distillery

120 KLPD Grain & Molasses Based Distillery

Co-generation Power Plant

3.5 MW 3.5 MW

(vi) Project Description with Process Details

Process Description of Grain Based Distillery Operation

A) Grain Storage Silos, Cleaning, Handling and Milling Section:

Grain is received from various sources and is pre-cleaned off stones, husk, etc. and then stored

in specially designed storage silos or in bags in storage yard. Grains are continuously lifted

from the bottom of the silos, screened and followed by removal of stones in de-stoner and

iron matters in magnetic separators. Cleaned Grains are then milled using dry milling process

in Hammer Mills. The flour is fed through the bucket elevator and conveyed to the flour silo.

B) Liquefaction Section

Grain flour is mixed with recycle streams and water in Pre-masher and slurry is fed to

Liquefaction tank. Required temperature is maintained by applying steam through steam

sparger in liquefaction 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. The liquefied mash is cooled in

slurry cooler and transferred to Fermentation section.

C) Fermentation Section

The purpose of fermentation is to convert the fermentable substrate into alcohol. To prepare

the mash for fermentation, it is diluted with water. Yeast is added in sufficient quantity to

complete fermentation to produce alcohol.




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

Activation Vessel (Pre-fermenter). Significant heat release takes place during fermentation.

This is removed by passing the mash through heat exchangers to maintain an optimum

temperature. The recirculation pumps also serve to empty the Fermenters into Beer Well. 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 remove the entrained alcohol. The scrubbed

CO2 can then be taken to CO2 plant or vented out. After emptying of Fermenter, it is cleaned

with CIP using cleaning nozzles. After CIP Fermenter is ready for next batch to be filled.

D) MPR Distillation Wash to ENA:

Multi-Pressure Distillation system has eight Distillation columns operating at various pressure

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

operating under low pressure to optimize the operation for energy consumption. Following

Columns will be under operation

� Analyser Column

� Degasifying Column

� Pre-Rectifier Column cum

� Exhaust Column

� Extractive Distillation Column

� Rectifier cum Exhaust Column

� Recovery Column

� Simmering Column

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

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

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

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

concentrated in the Pre-Rectifier column. A draw of impure alcohol is taken out from the top

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

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

Extractive Column operates on the principle of inversion of relative volatility. Low boiling

impurities are separated in the Extractive Distillation Column & bottom is sent to Rectifier cum

Exhaust column. The Rectifier/Exhaust column concentrates the alcohol to 96% v/v. The spirit

is drawn from the upper trays of the Rectification Column. Fusel oil build up is avoided in the

Rectifier cum exhaust column by withdrawing side streams (fusel oils). ED condensates, fusel

oil draw from R/E column are sent to Recovery column where these fusel oils are

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

oil rich layer is separated. Washings are sent back to the column to recover alcohol. The spirit

Draw from the Rectifier column is sent to the Simmering column where methanol is separated

in the form of a cut from the top and ENA is taken out from the bottom. ENA drawn from the

Simmering Column is taken to the receiver after cooling in ENA cooler.




E) Decantation Section Excluding Decanter Centrifuges

Decantation section comprises of a Centrifuge Decanters for separation of suspended solids

from Thick slop coming out of Grain Distillation Plant. Wet cake is removed from bottom of

Decanter. Thin slops coming out of Decanter are collected in a tank and partly recycled into

the process & balance to Evaporation for further concentration. The concentrated thin slops

called as Syrup is mixed with Wet cake and sold in wet form as cattle feed (DWGS).

F) Integrated Evaporation

The suggested treatment scheme is a Multi Effect Evaporation Plant for Thin Slop

Evaporation. Shell & Tube type Evaporators with highly efficient liquid distributor working on

the principle of Falling Film and Forced circulation Evaporation are being used.

The product at the desired concentration of 30%w/w Total Solid is obtained at the outlet of the

final effect. Each effect is provided with recirculation cum transfer pumps. The condensate

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

transferred for further treatment by using centrifugal pump. The system operates under

vacuum. Water-ring vacuum pumps are used to maintain a desired vacuum. Cooling water

from cooling tower is used in the surface condensers for condensing the vapours.

G) Process Condensate Treatment Section

The process condensate from the evaporation section is treated in this unit and this treated

condensate is then recycled back to process thus reducing the fresh water consumption.




Figure 3:- Process flow diagram of Grain based Distillery




FOR MOLASSES BASED OPERATION

i) Molasses Unloading and Storage

Molasses from tankers will be unloaded at unloading point and transferred in to molasses

storage tank.

ii) Fermentation:

Yeast Activation: Yeast seed material will be prepared in water-cooled Yeast Activation Vessel

by inoculating sterilized mash with Active Dry Yeast. Optimum temperature will be maintained

by cooling water. The contents of the Yeast Activation Vessel will then transferred to Pre -

Fermenter.

Fermentation: The Molasses from storage tank will be pumped to Dilutor installed in

Fermentation section and diluted with water. The diluted Molasses called Wort will be fed into

Pre Fermenter for activation of Yeast. The activated yeast from the Yeast activation vessel will

be transferred into pre fermenter.

Once the yeast will be activated in Pre fermenters it will be transferred in to fermenters and

diluted molasses is to be add. The process of fermentation is to convert the fermentable

substrate into alcohol. The pH of the wort will be adjusted by the addition of acid. Yeast is

available in sufficient quantity to initiate fermentation rapidly and complete it within the cycle

time.

Significant heat release takes place during fermentation. This will be removed by passing

cooling water through the Fermenter PHE’s to maintain an optimum temperature. The

recirculating pumps also serve to empty the fermenters into Beer Well. After the fermenters

will be emptied, cleaned with water and sterilized for the next batch. The carbon dioxide

evolved during the process will be vented to atmosphere after recovery of alcohol in a

scrubber.

iii) Distillation:

Fermented wash from wash holding tank / beer well will be pumped by wash feed pump to

the top of degassing column after preheating the same in beer heater and spent wash heat

exchanger. The vapours along with non-condensable gases from the top of degassing column

will be rectified in Heads column, to expel the high volatiles, technically known as heads.

Bottom liquid from the degasser flows into analyzer column where alcohol is stripped from

the liquid. The liquid from bottom of analyzer column will be completely stripped of alcohol

and is pumped out by thick slop discharge pump through heat exchanger where it preheats

the fermented wash before it enters degassing column. The slop from the analyser column

will be feed in to MEE. The dilute alcohol vapours from near the top of analyzer column are

condensed first in beer heater while exchanging heat with wash feed and then in analyzer

condenser. Degasser and analyzer operate under vacuum. The condensate from beer heater

and analyser condenser will be collected in Rectifier Feed Tank. The vapours for stripping




alcohol will be generated from analyzer column bottom liquid in the analyzer column re-boiler

by using the rectified column top vapours, as discussed subsequently.

Vapours from the top of heads column will be condensed in heads column condenser and

then in head column vent condenser. Part of the condensate will be returned to column as

reflux while a small portion is taken out as an impure spirit cut. Liquid from bottom of heads

column will be also taken into Rectifier feed tank.

Dilute alcohol water mixture from rectifier feed tank will be pumped by rectifier feed pump

through rectifier feed pre-heater in to rectifying column. Rectifier and its associated

equipment work under pressure so that these vapours can supply the necessary heat for

generating the vapours.

The condensate from analyser column reboiler will be then pumped as Reflux to rectifying

column. Rich alcohol vapors at a concentration of 95.5% v/v from top of rectifying column will

be condensed first in Analyzer reboiler and then in Reflux Vent Condenser. The liquid will be

then collected in Rectifier Reflux Tank. Part of the liquid from vent condenser may be drawn

off as impure spirit. The impure spirit cut will be maintained as little as possible to maintain

aldehyde levels to meet the required limits in Absolute Alcohol.

Liquid from the rectifier reflux tank will be pumped by Product Pump partly as product and

partly as reflux to the top of the Rectifying Column. The necessary rectifying vapours to

rectifying column are generated by boiling the bottom liquid in Rectifier Column Re-boiler by

using medium pressure steam. Some side streams are drawn from rectifier column as light and

heavy fractions of higher alcohols called fusel oils and cooled in fusel oil coolers. These are

mixed with water and allowed to separate out in fuel oil separator. All vents from condensers

are connected to Vent Gas Absorber where the vent gases are scrubbed with water to recover

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

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

which is used to create vacuum in the respective columns.

The remaining process is same as mentioned under grain based distillation and the product

ENA will be sent for storage.

iv) Alcohol Daily Receivers & Bulk Storage:

Alcohol is first taken to Daily receiver storage a tank is thereafter transferred to Bulk Storage

Tanks after taking the daily receiver Dip. This is transferred using flameproof pumps. Final

dispatch of alcohol is again carried out using special flameproof pumps.

EFFLUENT HANDLING SECTION

i) Evaporation Section:

The spent wash coming from Distillation section will be fed in to first calendria of the

evaporator section. The multi effect evaporator (MEE) shall be designed to concentrate the




dissolved solids. Suggested treatment scheme is FF + Finisher Evaporation Plant for spent

wash Evaporation. The following points will elucidate the basic working principle:

� Shell & Tube type Evaporators with highly efficient liquid distributor working on the

principle of Falling Film & Forced Evaporation have been used, with Preheaters for

preheating of FEED stream which serves the purpose of energy conservation.

� Vapours generated in 1st effect VLS (Vapour Liquid Separator) are used as heat source

in the 2nd effect and from 2nd to third and so on.

� The product at the desired concentration of TS is obtained at the outlet from the final

effect,

� A Shell & tube type Multi-pass Surface condenser is employed for condensing the shell

side vapours.

� The Pure and the process condensate are collected in receiving vessels.

� Highly efficient operating pumps will be provided for pumping the required fluid.

� The operation of the plant will be under vacuum. Vacuum is created with the help of a

water ring vacuum pump.

� The plant will have high level of automation to get consistent output at required

concentration.

� Cooling water from cooling tower is used in the surface condensers for condensing the

vapours.

ii) Incinerator boiler:

The concentrated molasses based effluent will be burnt in Incinerator boiler along with other

Biomass or coal fuels to generate high pressure steam.




Figure 4:- Process flow diagram of Molasses based Distillery




B) Power Co-Generation (3.5 MW)

OPERATIONS

Presently, with the approved capacity 3.5 MW, the Co-generation section is operating on coal

or various biomasses such as Rice Husk/ paddy straw/ cow dung/ poultry waste etc.

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

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

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

the flame burning in the boiler furnace. Water comes out of the boiler drum located at the top

of the boiler as steam. Flue gases rise in the boiler furnace and come in contact with the steam

coming out of boiler drum. Steam after coming in contact with flue gases gets heated up

further thus getting superheated. Super heated steam leaves the boiler in a pipe. Flue gases

after super heating the steam pass through economizer where they pre-heat the boiler feed

water before it enters the boiler drum. After economizer, flue gases pass through air pre-

heaters where they heat the air which is fed to the boiler furnace for burning the fuel. After air

pre heaters flue gases pass through an ESP where the dust particles are collected on charged

electrodes. The dust is collected from the bottom of the ESP.

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

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

temperature steam rotates the turbine rotor and an electric alternator mounted on the same

shaft. Electric power is generated by the alternator. This electric power generated is

consumed in house i.e. for running the distillery and utilities like boilers auxiliaries etc.

Figure 5: Process flow chart for Proposed Co-generation Power Plant




vii) Raw material required along with estimated quantity, likely source, marketing area of

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

(a) Raw Material Requirement

The basic raw material for the manufacturing of ENA/RS will be Grain and Molasses. In the

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

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

Small quantities of micro-nutrients & other chemicals are required.

Molasses from sugar mills containing sugar shall also be used.

The raw material for the boiler fuel is coal or various biomasses such as Rice Husk/ paddy

straw/ cow dung/ poultry waste etc and concentrated spent wash with coal/biomass for

incineration when the distillery is operated on molasses.

Table - 2

Raw Material Requirement

S. No.

Particulars Requirement Source & Mode of

Transportation Existing After modification

1 Grain - Broken Rice, Sorghum, Bajra, Maize etc.

270 MT/day 270 MT/day

or

545 MT/day

Through Grain suppliers By road/Rail

2. Molasses Nil From suppliers by tankers (road)

3. Chemicals (kg/day) Near-by Markets by road

Sodium Hydroxide 150 kg/day 150 kg/day

Liquefying Enzyme 60 kg/day --

Saccharifying Enzyme 140 kg/day ---

Liquor Ammonia 500 kg/day --

Antifoam Agent 50 kg/day 50 kg/day

Yeast (Active Dry Yeast/Distiller’s Yeast

60 kg/day 60 kg/day

(b) Fuel Requirement

TABLE – 3

Fuel Requirement

Fuel Source & Mode of Transportation

During Grain based operation

Biomass - 190 T/Day From suppliers by truck

During Molasses based operation

Conc. Spent wash - 265 T/Day and Coal 60 MT/Day or Biomass 90 T/Day




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

briefly outlined.

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

technology and methodology is being/will be adopted to conserve and reuse the resources.

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

given.

(a) Water Requirement and Source

Existing fresh water requirement is 1320 KLPD which will remain the same after modification

as there is no additional water requirement.

Source: Ground water (For which permission has been obtained).

Existing Water balance for 120 KLPD Grain based Distillery along with 3.5 MW Co-generation

power Plant

Total fresh water requirement for 120 KLPD Grain based Distillery is 1320 m3/day. Water

requirement for the proposed project will be met from ground water as well as recycled

water. Permission for ground water extraction has already been granted.

The details worked out are given below:

TABLE – 4 (A)

Total Water Input

S. No. Section Water Consumption (KLD)

1. PROCESS WATER IN LIQN & FERMENTATION 851

2. DM WATER FOR RS DILUTION 1080

3. DM WATER FOR BOILER FEED 1080

4. SOFT WATER FOR ANALYSER FLASH TANK 119

5. SOFT WATER FOR VACUUM PUMP & OTHERS 50

6. BLENDING ( 6000 CASES ) 30

7. BOTTLE WASHINGS 30

8. SOFT WATER MAKEUP FOR COOLING TOWER 819

9. MISC. WASHING WATER 20

10. OTHER DOMESTIC USAGE 20

TOTAL 4099




TABLE – 4 (B)

TOTAL WATER OUTPUT


1. STEAM CONDENSATE 890

2. SPENT LEES PR 168

3. SPENT LEES RECTIFER 1080

4. SPENT WASH (GRAIN SLOPS) 992

5. SOFT WATER FOR VACUUM PUMP & OTHERS 50

6. WATER IN PRODUCT 30

7. BOTTLE WASHING 30

8. CT EVAPORATION & DRIFT LOSSES 819

9. WASHING WATER 20

10. DOMESTIC CONSUMPTION 20

11. STEAM CONDENSATE 890

TOTAL 4099

TABLE – 4 (C)

Recycling & Utilization Stream


1. LEES RECYCLE FOR RS DILUTION 864

2. STEAM CONDENSATE RECYCLE FOR BOILER 890

3. SPENT LEES (RECT) - COOLING TOWER MAKEUP 144

4. THIN SLOPS RECYCLE TO LIQN PROCESS 347

5. PROCESS CONDENSATE TO PROCESS 534

Total Recycling /Re-utilization of water per day 2779

TOTAL FRESH WATER INPUT 1320

Water balance for 120 KLPD Molasses based Distillery along with 3.5 MW Co-generation

power Plant

Total fresh water requirement for 120 KLPD Molasses based Distillery is 1320 m3/day. Water

requirement for the proposed project will be met from ground water as well as recycled

water. Permission for ground water extraction has already been granted.

TABLE – 5

Fresh water requirement for Molasses based operation

Fresh Water Requirement Quantity in KLPD

DM water 530

Process water 690

Soft water 50

Bottle Washing 30

Domestic 20

Total 1320




Figure 6: Water Balance flow chart for 120 KLPD Molasses based operation




(b) Power Requirement and Source

Existing power requirement is 3.0 MW. No additional power required for modification.

Source: Existing 3.5 MW Co-generation Power Plant & D.G Sets (for back-up).

(c) Steam Requirement

Existing steam requirement for 30 TPD for Grain based operation is being met by existing

boiler capacity of 35 TPH and after modification steam requirement will be same. After

modification for molasses operation additional boiler of 30 TPH capacity shall be installed

which be suitable for incineration of molasses spent wash and coal /biomasses.

(d) Boiler Details

Existing and proposed boiler details are mentioned in the table given below:

TABLE – 6

Boiler Details

S. No.

Boiler Details Existing Proposed

1. Boiler Capacity 35 TPH 30 TPH

2. Type of Fuel Coal /Biomass

Conc. spent wash and Coal/Biomass

3. Stack Height 50 metres 50 meter

4. Pollution Control Equipment Measures

ESP ESP

(e) Details regarding the D.G. Sets

One D.G. sets of 1100 KVA have already been installed for the power backup. No additional

D.G. Sets will be required.

Details regarding the D.G. Sets are mentioned in the table given below:

TABLE – 7

Details Regarding The D.G. Sets

S. No. Details Existing

1. Type of Fuel Diesel

2. Capacity 1 x 1100 KVA

3. Stack Height (above roof level) 2.5 m

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

management/disposal

� The distillery project is being/will be based on “ZERO EFFLUENT DISCHARGE”.

� Grain Slops (Spent Wash) is being/will be taken through Centrifuge Decanters for

separation of Suspended Solids separated as Wet Cake.

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

process and balance taken to Thins Slops Evaporation Plant for concentration of

remaining solids to form Syrup. This Syrup is mixed with the Wet Cake coming out of




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

Solubles - Collectively known as DWGS)

� The process condensate is being/will be cooled and taken to CPU. The treated water is

then recycled into process and/ or used for greenbelt development within the complex.

� Molasses slops (spent wash) shall be concentrated in evaporators and incinerated in

boiler.

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

in the form of DWGS, which are being / will be ideally used as Cattle Feed.

� Fly Ash from the boiler is being / will be sold to brick/cement manufacturers/used in land

application.

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

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

is being / will be sold to the CPCB authorized recycler.

4.0 SITE ANALYSIS

(i) Connectivity

The project site is located at Village Chandrao, Tehsil Indri, District Karnal, Haryana and is well

connected with state highway and National Highway from the plant site. Nearest Railway

Station is Karnal & Kurukshetra. Nearest Airport is at Chandigarh. It has an easy access to raw

material availability and other infrastructural facilities e.g. land, power, water, transport and

communication, approach through road & access distances from the nearest highway, railway

station etc.

(ii) Land from Land use and Land ownership

Total plant area is 22.5 Acres. Since, the proposed modification will be done within the existing

plant premises, thus, no additional land is required for the same.

(iii) Topography

The topography of the area is almost flat.

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

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

the forests, national park, wild life sanctuary, eco sensitive areas, water bodies

(distance from the HFL of the river), CRZ. In case of notified industrial area, a copy of

the Gazette notification should be given




TABLE – 8

Environmental Settings of the Area

S. NO.

PARTICULARS DETAILS

1. Nearest Village Chandrao Village (~0.5 km in SE direction)

2. Nearest Town & City o Indri Town (~11 km in SW direction)

o Karnal City (~ 30 km in SSW direction)

3. Nearest National Highway/State Highway

o SH 7 (~10.5 km in West direction)

o NH 1 (~24.0 km in West direction)

4. Nearest Railway Station o Kurukshetra Railway station (~ 30 km in WNW direction)

o Karnal Railway station (~ 30 km in SSW direction)

5. Nearest Airport Chandigarh International Airport (~90 km in NNW direction)

6. National Parks/ Wildlife Sanctuaries /

Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors / Reserved / Protected Forest within 10 km radius

No National Parks/ Wildlife Sanctuaries / Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors, Reserved / Protected Forest within 10 km radius

7. Nearest Water Bodies o Dhanaura Escape & Nala (Adjacent in South direction)

o Pran Nadi (~1.0 km in ESE direction)

o Yamuna River (~3.5 km in ESE direction)

o Budhi Nadi (~6.0 km in ENE direction)

o Western Yamuna Canal (~6.5 km in NW direction)

8. Seismic Zone Seismic Zone - IV as per IS: 1893 (Part-I): 2002.

(v) Existing Infrastructure

Total plant area is about 22.5 Acres. Proposed modification will be done within the existing

plant premises. Existing infrastructure comprises of Grain based Distillation & Fermentation

unit and basic utilities such as water, power, etc.

(vi) Soil classification

The Chantang Nala is the other drainage line and flows from north to southwest in the

western part of the district and disappears near Assandh. The soils in Gharaunda and SE half of

Karnal blocks are young, stratified with no profile development. They are sandy to fine sandy

loams. The soils in SE half of Nilokheri, SW extremity of Karnal block touching Nilokheri,

eastern portion of Nissang, Western half of Gharaunda block are heavily textured varying from

sandy loam at the surface to clayey loam at about one meter depth.

(vii) Climatic data from secondary sources

The climate of the district is characterized by the dryness of the air with an intensely hot

summer and a cold winter. The year may be divided in to four seasons. The cold season starts

by late November and extends to the middle of March. It is followed by hot season which

continues to the end of June when the southwest monsoon arrives over the district. July to

September is the southwest monsoon season. The post monsoon season period is from

October to December.




The normal annual rainfall of the district is 582mm recorded in 32 rainy days in a year. About

82.39% of the annual rainfall is recorded during the southwest monsoon from July to

September. August is the wettest month of the year with an average of 9.0 rainy days and

221.5 mm rainfall. Maximum rainfall of 1404mm and minimum rainfall of 255mm were

observed in the years 1998 and 1987 respectively.

(viii) Social Infrastructure available

There are schools, College, dispensaries, hospitals, Post offices, Banks, Market and places of

worship in nearby area of the project site.

5.0 PLANNING BRIEF

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

Planning/Development authority classification.

The existing unit is Distillery industry and proposed modification will be done within the

existing plant premises. Facilities required for the proposed modification & installation

project will be provided as per requirement. Transportation of raw material and final product

is being / will be done by road.

(ii) Population Projection

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

be from outside the area.

(iii) Land use planning (breakup along with greenbelt etc)

Total Plant area is 22.5 Acres. Proposed modification will be set up in the existing plant

premises. No additional land will be required. About 33 % of the total plant area is being/will

be covered under greenbelt & plantation in order to reduce dust & noise pollution levels & to

increase aesthetic beauty of the area.

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

RSL Distilleries Private Limited has assessed the demand of infrastructure (Physical & Social)

in nearby area of the plant site and development activities are being undertaken under

corporate social responsibilities program for rural development initiatives for the upliftment

of the nearby communities from time to time.

(v) Amenities/ Facilities

RSL Distilleries Private Limited has developed and will further develop the Amenities/Facilities

in nearby area of the Plant site as per requirement of local people of the nearby area under

corporate social responsibilities programs.

6.0 PROPOSED INFRASTRUCTURE

(i) Industrial Area (Processing Area)

Existing plant area is 22.5 acres. No additional land is required for modification of the distillery

plant as the same will be done within the existing plant area.




(ii) Residential area (Non Processing area)

No residential area is envisaged.

(iii) Greenbelt

The company has already developed greenbelt/ plantation in 33% of the total plant area and

the same will be further maintained.

(iv) Social Infrastructure

The project will result in growth of the surrounding areas by increased direct and indirect

employment opportunities in the region including ancillary development and supporting

infrastructure.

(v) Connectivity

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

such no constraints are envisaged in this aspect.

(vi) Drinking Water

5 m3/ day water will be required for drinking purpose after proposed modification &

installation project which will be sourced from Ground Water.

(vii) Sewage Treatment System

Domestic waste water generated from the plant is being/will be treated in STP.

(viii) Industrial Waste management

The distillery project is being / will be based on “ZERO DISCHARGE”.

(ix) Solid Waste Management

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

in the form of DWGS, which are being / will be ideally used as Cattle Feed.

� Ash from the Boiler is being / will be sold to Cement & Brick manufacturers/used in land

application.

(x) Power requirement and source

Existing power requirement is 3.0 MW. No additional power required for modification.

Source: Existing 3.5 MW Co-generation Power Plant & D.G Sets (for back-up).

7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

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

including home oustees, land oustees and landless labourers (a brief outline to be

given).

Proposed modification will be done within the existing plant premises. No additional land is

required for the same and hence, Rehabilitation & Resettlement is not applicable.

8.0 PROJECT SCHEDULE AND COST ESTIMATES

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

the project to be given).

The project will start only after obtaining Environmental Clearance and other statutory

permissions. Project will be completed in 12 months after getting all the regulatory approvals.




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

� Total cost of the Project: Rs. 18.0 Crores

� Cost for Environment Protection Measures:

� Capital Cost: Rs. 18.0 Crores

� Recurring Cost/ annum: Rs. 1.80 Crores / annum.

9.0 ANALYSIS OF PROPOSAL

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

including tribal population, if any, in the area.

Project will result in growth of the surrounding areas by increasing ancillary development and

supporting infrastructure. Special emphasis on Financial and Social benefits will be given to

the local people including tribal population, if any, in the area.

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

underprivileged and creation of self help groups.

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

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

maintenance & house-keeping contract work etc.

pre - feasibility report · pre - feasibility report rsl distilleries private limited 5 after the...

Documents