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Proposed installation of Unit II - Grain Based Ethanol/RS Industrial/ENA Plant {500 KLPD (2X250 KLPD)} & Co-generation Power
Plant {40 MW (2X 20 MW)} in Existing Distillery Plant
At Village Mansoorwala, Tehsil Zira, District Ferozepur, Punjab
Pre Feasibility Report
Malbros International Private Limited 1
PRE - FEASIBILITY REPORT
1.0 EXECUTIVE SUMMARY
(I) Introduction
Malbros International Private Limited is proposing installation of Unit II - Grain Based
Ethanol/RS Industrial/ENA Plant {500 KLPD (2X250 KLPD)} & Co-generation Power Plant {40
MW (2X 20 MW)} in Existing Distillery Plant at Village Mansoorwala, Tehsil Zira, District
Ferozepur, Punjab. The unit will be installed in two phases as mentioned below:
Phase 1:-
a) 250 KLPD Ethanol/ RS Industrial/ ENA Unit
b) 20 MW Co- Generation power plant
Phase 2:-
a) 250 KLPD Ethanol/ RS Industrial/ ENA Unit
b) 20 MW Co- Generation power plant
Grain will be used as a raw material which is easily available from the local market.
As per EIA Notification dated 14th Sep., 2006 as amended from time to time; the project falls in
Category ‘A’, Project or Activity - 5(g)(ii) [Non-molasses based distilleries ≥ 60 KLD].
TABLE – 1
SALIENT FEATURES OF THE PROJECT
S. NO.
PARTICULARS DETAILS
A. Nature & Size of the Project
Units Existing Capacity
Grain based Ethanol/RS Industrial/ENA Unit 500 KLPD (2X250 KLPD)
Co-Generation Power 40 MW (2X20 MW)
CO2 Plant 225 TPD (2X 112.5 TPD)
DDGS/ Cattle Feed/ Poultry Feed 300 TPH ( 2X150 TPH)
B. Category of the Project
As per EIA Notification dated 14th Sep., 2006 as amended from time to time; the project falls in Category ‘A’, Project or Activity - 5(g)(ii) [Non-
molasses based distilleries ≥ 60 KLD]. C. Location Details
Village Mansoorwala
Tehsil Zira
District Ferozepur
State Punjab
Latitude 30055’07.61’’ N to 30055.03.56”N
Longitude 74057’32.56” E to 74057’35.13’’ E
D. Area Details
Total Project Area 14.8 ha (36.5 acres)
Greenbelt/Plantation 4.9 ha (~33 % of the total project area) has been proposed as Green
Proposed installation of Unit II - Grain Based Ethanol/RS Industrial/ENA Plant {500 KLPD (2X250 KLPD)} & Co-generation Power
Plant {40 MW (2X 20 MW)} in Existing Distillery Plant
At Village Mansoorwala, Tehsil Zira, District Ferozepur, Punjab
Pre Feasibility Report
Malbros International Private Limited 2
Area (ha) belt/Plantation
E. Environmental Setting Details (with approximate aerial distance & direction from project site)
1. Nearest Village Ratol Rohi (~1 km in WSW Direction)
2. Nearest Town/City • Nearest Town:- Zira (~6 km in NNE direction)
• Nearest City:- Talwandi (~7 km in West direction) 3. Nearest National Highway
/ State Highway NH-15 (~1 km in West Direction)
4. Nearest Railway station Talwandi Bhai Railway Station (~ 7 km in SSW direction)
5. Nearest Airport Sri Guru Ram Dass Jee International Airport, Amritsar (~ 88 km in NNW direction)
6. Archaeological important site
No Archaeological important site exists within 10 km radius of project site.
7. National Parks, Wild Life Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors etc. within 10 km radius
No National Parks, Wild Life Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors etc. lies within 10 km radius of the project site.
8. Reserved Forests (RF) / Protected Forests (PF) etc. within 10 Km. radius
No Reserved Forests (RF) / Protected Forests (PF) etc. lies within 10 Km. radius of the project site.
9. River / Water Body (within 10 km radius)
No river lies in 10 km radius of the project area.
F. Cost Details
1. Total Cost of the Project
Rs. 583 Crores
2. Cost for Environment Management Plan
o Capital Cost - Rs. 58 Crores. o Recurring Cost - Rs. 10 Crores / annum.
G. Basic Requirements for the project
Water Requirement (KLD)
4110 m3/day (for first run fresh water requirement would be 10958 m3/day) Source: Canal Water & Recycled Water
Power Requirement (MW)
9.0 MW Source: Proposed 40 MW (2X20 MW) Captive Power Plant & D.G. Sets- 3 X 1000 KVA (for Back-up purpose only)
Man Power Requirement
800 persons Source: Unskilled / Semi-Skilled - Local Area; Skilled- Local & Outside
H. Working Days for Distillery
350 days/ annum
1.1 ENVIRONMENTAL MANAGEMENT PLAN
Particulars DETAILS
Air Quality Management
Possible Sources Boilers, Proposed 40 MW (2X20 MW) Co-generation Power Plant, Transportation vehicles, D.G. Sets etc.
Emissions � ESP will be installed with the proposed boilers.
� Adequate boiler stack height will be maintained.
� DG Sets will also have adequate stack of height as per CPCB Guidelines.
� Adequate measures for Fugitive Dust Emissions will be taken.
� All the internal roads will be asphalted.
Proposed installation of Unit II - Grain Based Ethanol/RS Industrial/ENA Plant {500 KLPD (2X250 KLPD)} & Co-generation Power
Plant {40 MW (2X 20 MW)} in Existing Distillery Plant
At Village Mansoorwala, Tehsil Zira, District Ferozepur, Punjab
Pre Feasibility Report
Malbros International Private Limited 3
� Development of Green Belt around the periphery & within the premises of the plant will help in attenuating the pollutants emitted by the plant.
Monitoring Ambient air quality and stack emission will be regularly monitored to ensure that ambient air quality standards and suggested limits on stack emission loads would be met honestly at all the time.
Water Management
Management � The project will be based on “Zero Effluent Discharge”.
� Fresh water requirement of the project will be met by Ground Water, Canal Water & recycled water. Efforts will be made to conserve as much water as possible by recycling and reuse.
� Record of wastewater returned back to process for utilization in Fermentation/cooling tower and to gardening will be kept.
� Process condensate from MEE will be recycled back to the process for Grain dilution and cooling tower make up.
� Spent lees generation from distillation column will be recycled partly to the columns for dilution and balance will be used for cooling tower make up.
� Domestic waste water generated from the plant will be treated in Septic Tank/STP and treated water will be used in green belt development.
� Effluent Treatment Plant will be installed and treated water from ETP will be recycled back to the process and remaining will be used for green belt development.
Noise Management
Management � Proper maintenance, oiling and greasing of machines at regular intervals.
� PPEs like earplugs and earmuffs to the workers exposed to high noise level.
� Development of Green Belt for 33% of the total project area.
� Regular monitoring of noise level.
� D.G sets will be provided with acoustic enclosures to control the noise level within the prescribed limit.
Monitoring � Regular monitoring of noise levels will be carried out and corrective
measures in concerned machinery will be adapted accordingly to the possible extent.
Solid Waste Management
Management � Solid waste from the Grain based operations generally comprises of Fibres and proteins in the form of DDGS, which will be ideally used as Cattle Feed.
� Ash from the Boiler will be sold to Brick manufacturers.
� Used oil & grease generated from plant machinery/Gear boxes as hazardous waste will be sold out to the CPCB authorized recycler.
Green belt Development/ Plantation
Management � 33% of total project area will be developed under green belt/plantation.
� All the barren areas will be vegetated.
� Native plant species will be planted in consultation with local horticulturist.
� Green belt development along with the road & plant boundary will attenuate noise level arrest dust and improve the environment in surrounding.
Odour Management
Management � Odour will be primarily controlled at source by good operational practices, including physical and management control measures.
� Better housekeeping will be maintained with good hygiene condition by regular steaming of all fermentation equipment.
Proposed installation of Unit II - Grain Based Ethanol/RS Industrial/ENA Plant {500 KLPD (2X250 KLPD)} & Co-generation Power
Plant {40 MW (2X 20 MW)} in Existing Distillery Plant
At Village Mansoorwala, Tehsil Zira, District Ferozepur, Punjab
Pre Feasibility Report
Malbros International Private Limited 4
� Use of efficient biocides to control bacterial contamination.
� Control of temperature during fermentation to avoid in-activation / killing of yeast.
� Avoiding staling of fermented wash.
� Regular use of bleaching powder in the drains to avoid generation of putrefying micro-organisms.
2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION
(i) Identification of Project and Project Proponent
The Oasis Group has Hotels of star category at Mussoorie and Delhi under the world known
management group Carlson and brand name Country Inn & Suites by Carlson”
The group is also in luxury goods business under the brand name of “Dillano Luxurious
Jewels” which caters to the niche business class and participates in elite jewellery exhibitions
such as Wedding Asia etc.
Oasis Group, India Based Group are well known and highly reputed in the Luxury/hospitality
liquor/ business. The Group has wide distribution network for both Indian and foreign made
liquor in number of states. They have been engaged with this activity for more than 5 decades.
At present the group owned five running Distilleries, two bottling Units and expanding and
diversifying into different business at fast pace.
The Oasis Group is a highly reputed conglomerate with diverse interests that include Distillery,
Liquor Retailing, Hotels and Constructions. The Group’s rapid growth on Indian corporate
scene rests on its strong foundation of professional management and astute collective
enterprises. Over the last 15 years, the Malhotra Group has grown into a diversified
business and industrial house with a high growth rate and a total commitment to persistent
growth.
The group was founded by Shri Om Prakash Malhotra. It is his foresight and vision that has
promoted the organization to take its present shape. Its present Chairman and Director, Mr.
Deep Malhotra, a second-generation entrepreneur, carries with him rich experience coupled
with sharp commercial acumen. The Group has a team highly qualified, experienced, trusted
persons with a right mix of technocrats, Finance Experts and management professionals.
Group Companies:-
1. Country Inn & Suites By Carlson (A Unit of Diamond Resorts Pvt. Ltd.), Mussoorie
2. Oasis Resorts Pvt. Ltd., Delhi
3. Dillano Luxurious Jewels Ltd., Delhi
4. Oasis Commercial Pvt. Ltd., Haryana
5. Oasis Overseas Pvt. Ltd., Haryana
Proposed installation of Unit II - Grain Based Ethanol/RS Industrial/ENA Plant {500 KLPD (2X250 KLPD)} & Co-generation Power
Plant {40 MW (2X 20 MW)} in Existing Distillery Plant
At Village Mansoorwala, Tehsil Zira, District Ferozepur, Punjab
Pre Feasibility Report
Malbros International Private Limited 5
6. Malbros International Pvt. Ltd, Punjab
7. Oasis Distilleries Ltd, Indore
8. Gauravh Wines Pvt. Ltd., Punjab
9. Om Sons Marketing Pvt. Ltd, Punjab
10. Malbros Enterprises Pvt. Ltd, Delhi
11. Calx Paper Pvt. Ltd, Delhi
12. Gee Emm Bros. Distributors Pvt. Ltd., Delhi
13. Vijeta Beverages Pvt. Ltd., Rajasthan
14. Gautam Wines Pvt. Ltd., Punjab
ALCOHOL MANUFACTURING:- The Alcohol Distillation Unit has been designed as per multi
pressure distillation technology which gives maximum of output which minimum of input
energy. The ENA being made at our Plant meets best industrial specifications.
TRANSPORT:- Over the past few years the company has increased the number of vehicles in its
transport division. The supply of Bottled liquor in the state and outside the state is done by the
company’s own trucks. Whereas the company has also purchased 6 numbers of Tankers out of
which 2 are of 40 KL and 4 are of 25 KL each. All the tankers are of SS 304. ENA/RS is being
supplied thru these tankers all over India.
(ii) Brief description of nature of the project
Malbros International Private Limited is proposing 500 KLPD (2X250 KLPD) Grain Based
Ethanol/RS Industrial/ENA Unit along with 40 MW (2X20 MW) Cogeneration Power Plant at
Village Mansoorwala, Tehsil Zira, District Ferozepur, Punjab. Grain will be used as a raw
material which is easily available from the local market.
As per EIA Notification dated 14th Sep., 2006 as amended from time to time; the project falls in
Category ‘A’, Project or Activity - 5(g)(ii) [Non-molasses based distilleries ≥ 60 KLD].
(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. The use of
alcohol for the purpose of potable liquor is as high as its use for industrial purposes.
Proposed installation of Unit II - Grain Based Ethanol/RS Industrial/ENA Plant {500 KLPD (2X250 KLPD)} & Co-generation Power
Plant {40 MW (2X 20 MW)} in Existing Distillery Plant
At Village Mansoorwala, Tehsil Zira, District Ferozepur, Punjab
Pre Feasibility Report
Malbros International Private Limited 6
According to analysts, the Indian Ethanol industry is expected to witness accelerating growth
in coming years. Ethanol is an alcohol fuel that is added to petrol in some countries to lower
cost to the consumer, reduce consumption of oil, and lessen the environmental impact of
transportation. Mixed fuels are rated by the amount of ethanol contained; for example,
common blends are E10, which contains 10% ethanol, and E15, which contains 15% alcohol.
Another common blend is E85, also known as flex fuel, in which the ethanol ranges from 51% in
winters to 83% in summers.
In addition, though ethanol reduces air particulate pollution, its production results in fairly high
greenhouse gas emissions and negates any the environmental benefit of the shift from fossil
fuel.
The biggest concern with the addition of ethanol to India's fuel supply is that it will take up
scarce land set aside for grazing and other crops to grow fuel. With the demand likely to be
huge, there is bound to be a shift in land use from food crops to fuel crops. Agriculture will
become even more intensive. Without adequate reforms and education in the agricultural
sector to increase productivity, the shift to fuel crops will result in food price inflation. The
savings from reduced oil imports will be spent instead on subsidies and higher food prices.
Furthermore, technology can improve at two ends - energy efficiency at the EV end and
greater storage capacity at the EVB end. The latter would translate into better performing
vehicles without the consumer having to regularly upgrade his EV.
In the path of company’s growth and development this proposed project will serve as yet
another milestone.
(iv) Demand- Supply Gap
Not required in this Project. This depends on excise Department.
(v) Import vs. Indigenous Production
Indian market could not meet present alcohol demand. So they import alcohol 5-7% of total
demand. As far as Ethanol production is concerned, Indian market play a vital role at both
domestic & international level. So they require produce the more alcohol to meet the demand.
(vi) Export Possibility
The possibility of alcohol export is very good. So Indian industries export alcohol in African,
Europe & Asian countries which is very profitable now a days. After setup of this type of
alcohol industries government can collect more revenue.
Proposed installation of Unit II - Grain Based Ethanol/RS Industrial/ENA Plant {500 KLPD (2X250 KLPD)} & Co-generation Power
Plant {40 MW (2X 20 MW)} in Existing Distillery Plant
At Village Mansoorwala, Tehsil Zira, District Ferozepur, Punjab
Pre Feasibility Report
Malbros International Private Limited 7
(vii) Domestic / Export Markets
Presently the big Indian players in alcohol production and bottling are United Spirits Ltd, ABD
Pvt Ltd, Radico khaitan Ltd, Globus Spirits Ltd etc. So they try to fulfil the current requirement
of alcohol in domestic as well as export market.
(viii) Employment Generation (Direct and Indirect) due to the project
Direct and indirect employment will be generated due to the proposed project. During
construction phase, employment opportunity to approximately 1000 persons is estimated.
The total manpower requirement for the proposed project will be 800 persons (inclusive of on
roll employees and on contract employees).
3.0 PROJECT DESCRIPTION
(i) Type of Project including interlinked and independent projects, if any.
No, this project is not an interlinked project.
(ii) Location (map showing general location, specific location, and project boundary &
project site layout) with coordinates
Proposed installation of Unit II - Grain Based Ethanol/RS Industrial/ENA Plant {500 KLPD (2X250 KLPD)} & Co-generation Power
Plant {40 MW (2X 20 MW)} in Existing Distillery Plant
At Village Mansoorwala, Tehsil Zira, District Ferozepur, Punjab
Pre Feasibility Report
Malbros International Private Limited 8
Figure - 1: Location Map
Proposed installation of Unit II - Grain Based Ethanol/RS Industrial/ENA Plant {500 KLPD (2X250 KLPD)} & Co-generation Power Plant {40 MW (2X 20 MW)} in Existing Distillery Plant
At Village Mansoorwala, Tehsil Zira, District Ferozepur, Punjab
Pre Feasibility Report
Malbros International Private Limited 9
(iii) Key Plan
Figure - 2: Key Plan
Proposed installation of Unit II - Grain Based Ethanol/RS Industrial/ENA Plant {500 KLPD (2X250 KLPD)} & Co-generation
Power Plant {40 MW (2X 20 MW)} in Existing Distillery Plant
At Village Mansoorwala, Tehsil Zira, District Ferozepur, Punjab
Form–I / Appendix–I
Malbros International Private Limited 10
(iv) Details of alternative sites consideration and basis of selecting the proposed site,
particularly the environmental considerations gone into should be highlighted.
No alternative site has been taken into consideration.
Following factors were considered while selecting the site:-
� Suitable source of raw material.
� Location in rural area ensures adequate availability of manpower at marginally
lower rates, compared to metro cities of India.
� Nearness to NH-15 which makes it easier to transport raw materials & Products.
� There is no National Park, Biosphere Reserves, Tiger Reserves, Reserved / Protected
Forests within 10 km radius of study area.
(v) Size or magnitude of operation
The total proposed production is 500 KLPD (2X250 KLPD) Grain Based Ethanol/RS
Industrial/ENA Unit along with 40 MW (2X 20 MW) Cogeneration Power Plant at Village
Mansoorwala, Tehsil Zira, District Ferozepur, Punjab.
The process includes basic raw material requirement, sizing of equipment, utilities &
services, infrastructure facilities & sources of waste generation, their quantity, treatment
& safe disposal of the waste.
S. No. Units Capacity
1. Ethanol/RS Industrial/ENA unit 500 KLPD (2X 250 KLPD)
2. Co-Generation Power Plant 40 MW (2X 20 MW)
(vi) Project Description with Process Details (a schematic diagram/flow chart showing
the project layout, components of the project etc. Should be given)
Process Description
Distillery Unit - Production from Grain:
• Grain storage
• Grain cleaning, milling and flour handling
• Slurry preparation & liquefaction
• Multi pressure alcohol distillation
• Alcohol daily receivers & bulk storage
• MEE & Dryer
MAIN PLANT & MACHINERY
1. Grain Storage :
Grains are procured from various sources, such as FCI Storage godowns through agencies
and are unloaded into large Storage Silos after Pre-Cleaning. Storage Silos are specially
Proposed installation of Unit II - Grain Based Ethanol/RS Industrial/ENA Plant {500 KLPD (2X250 KLPD)} & Co-generation
Power Plant {40 MW (2X 20 MW)} in Existing Distillery Plant
At Village Mansoorwala, Tehsil Zira, District Ferozepur, Punjab
Form–I / Appendix–I
Malbros International Private Limited 11
designed to keep the Grains in good condition for longer durations and also avoid its
deterioration and theft, etc. It is being proposed to have 30 – 45 days of Grain Storage
facility in the Distillery.
2. Grain Cleaning, Milling and Flour Handling :
The grain is lifted in bucket elevators, screened followed by removal of stones and iron
matter. Cleaned Grains are then milled using dry milling process in Hammer Mills. The
flour is fed through the bucket elevator and conveyed to the Batch Tipping Machine
through a Screw Conveyor. The flour addition is metered through the Batch Tipping
Machine with load cell arrangement, before transferring the flour to the Slurry Tank
through another Screw Conveyor (pre-masher) for slurry preparation process. It is being
proposed to have 4 x 16 TPH as milling paraphernalia for this Distillery.
3. Slurry Preparation & Liquefaction :
Grain flour and process water is fed at controlled rate to Initial Liquefaction tank. Mixed
slurry is taken to the Initial Liquefaction Tank where additional quantity of water is added
as per requirement. Viscosity reduction Enzyme and stabilizing chemicals and a portion of
liquefying enzyme are also added at this stage. 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 the Retention Vessel. The retention vessel has 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 and is therefore susceptible to enzyme attack for
liquefaction.
The gelatinized mash from the Flash Tank is liquefied in the Final Liquefaction Tank where
liquefying enzyme (alpha-amylase) is added. The liquefied mash is cooled in Mash Cooler
and transferred to Saccharification cum fermentation section. This process initiates the
formation of sugar.
The gelatinized mash from the Flash Tank is liquefied in the Final Liquefaction Tank where
liquefying enzyme (alpha-amylase) is added. The liquefied mash is cooled in Mash Cooler
and transferred to Saccharification cum Fermentation section.
Proposed installation of Unit II - Grain Based Ethanol/RS Industrial/ENA Plant {500 KLPD (2X250 KLPD)} & Co-generation
Power Plant {40 MW (2X 20 MW)} in Existing Distillery Plant
At Village Mansoorwala, Tehsil Zira, District Ferozepur, Punjab
Form–I / Appendix–I
Malbros International Private Limited 12
4. Hiferm-Nm Saccharification and Instantaneous Fermentation:
Yeast Activation:
Yeast seed material is prepared in water-cooled Yeast Activation Vessel by inoculating
sterilized mash with Active Dry Yeast. Optimum temperature is maintained by cooling
water. The contents of the Yeast Activation Vessel are then transferred to Fermenter.
Saccharification & Instantaneous Fermentation:
The Liquefied starch slurry comprising Dextrins is partly taken for Yeast development in
Yeast Activation vessel and majorly transferred into the Fermenter. Amyloglucozydase
and other nutrient Enzymes are first added to Saccharify the Starch Slurry causing
formation of Sugars. Immediately, the Active Yeast is introduced in the system for
simultaneous Fermentation. The process of fermentation is to convert the fermentable
substrate into alcohol. To prepare the mash for fermentation, it may have to be diluted
with water. The pH of the mash is adjusted by the addition of acid. Yeast is available in
sufficient quantity to initiate fermentation rapidly and complete it within the cycle time.
At the start of the cycle, the fermenter is charged with mash and contents of the Yeast
Activation Vessel. Significant heat release takes place during fermentation. This is
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 are emptied, they are cleaned with water and caustic solutions and
sterilized for the next batch. The carbon dioxide evolved during the process is vented to
atmosphere after recovery of alcohol in a scrubber.
5. Ethannol Distillation :
Fermented wash from wash holding tank T-01 is pumped by wash feed pump P-01 to the
top of degassing column (C-2) after preheating the same in beer heater E-02 and spent
wash heat exchanger E-01. The vapors along with non-condensable gases from the top of
degassing column (C-02) are rectified in Heads column (C-03), to expel the high volatiles,
technically known as heads. Bottom liquid from the degasser flows into analyzer column
(C-01) where alcohol is stripped from the liquid. The liquid from bottom of analyzer
column (C-01) is completely stripped of alcohol and is pumped out by thick slop discharge
pump P-02 through heat exchanger E-01 where it preheats the fermented wash before it
enters degassing column. The slop from the analyser column will be feed in to
decanter.The dilute alcohol vapors from near the top of analyzer column (C-01) are
condensed first in beer heater (E-02) while exchanging heat with wash feed and then in
analyzer condenser (E-03). Degasser and analyzer operate under vacuum. The
Proposed installation of Unit II - Grain Based Ethanol/RS Industrial/ENA Plant {500 KLPD (2X250 KLPD)} & Co-generation
Power Plant {40 MW (2X 20 MW)} in Existing Distillery Plant
At Village Mansoorwala, Tehsil Zira, District Ferozepur, Punjab
Form–I / Appendix–I
Malbros International Private Limited 13
condensate from E-02 and E-03 is collected in Rectifier Feed Tank V-02. The vapors for
stripping alcohol are generated from analyzer column bottom liquid in the analyzer
column re-boiler (E-04) by using the rectified column top vapors, as discussed
subsequently.
Vapors from the top of heads column (C-03) are condensed in heads column condenser
(E-06) and then in head column vent condenser (E-07). Part of the condensate is returned
to column C-03 as reflux while a small portion is taken out as an impure spirit cut. Liquid
from bottom of C-03 is also taken into Rectified feed tank V-02.
Dilute alcohol water mixture from rectifier feed tank (V-02) are pumped by rectifier feed
pump (P-04) through rectifier feed pre-heater E-11 in to rectifying column (C-04). Rectifier
and its associated equipment work under pressure so that these vapors can supply the
necessary heat for generating the vapors.
The condensate from E-04 is then pumped as Reflux to rectifying column C-04. Rich
alcohol vapors at a concentration of 95.5% v/v from top of rectifying column (C-04) are
condensed first in Analyzer (E-04) and then in Reflux Vent Condenser (E-05). The liquid
from E04 and E-05 are collected in Rectifier Reflux Tank (V-01). Part of the liquid from E-
05 may be drawn off as impure spirit. The impure spirit cut will be maintained as little as
possible to maintain aldehyde levels to meet the required limits in Absolute Alcohol.
Liquid from the reflux tank (V-01) is pumped by Product Pump (P-03) partly as product
and partly as reflux to the top of the Rectifying Column (C-04). The necessary rectifying
vapors to C-04 are generated by boiling the C-04 bottom liquid in Rectifier Column Re-
boiler E-08 using medium pressure steam. Some side streams are drawn from rectifier
column as light and heavy fractions of higher alcohols called fusel oils and cooled in fusel
oil coolers E-09 and E-10 and are mixed with water and allowed to separate out in fuel oil
separator F-01. All vents from E-03, E-07, V-02 and E-05 are connected to Vent Gas
Absorber (C-05) where the vent gases are scrubbed with water to recover entrained
alcohol. The scrubber water is used for washing the fuel oils in fuel oil separator to
recover alcohol from the fuel oil fractions. The absorber vent is connected to vacuum
pump (G-01) which is used to create vacuum in the analyzer and degasser.
Absolute alcohol is manufactured by dehydration of Rectified Spirit. The process adopted
here is based on Pressure Swing Adsorption (PSA) system using Molecular Sieves (3-A).
The flow scheme is shown in above referred flow diagram.
Rectified spirit, after preheating by waste hot streams, is vaporized and superheated in E-
03 and E-04 by using medium pressure steam at 6 Kg/cm2g pressure. Hot vapors at
Proposed installation of Unit II - Grain Based Ethanol/RS Industrial/ENA Plant {500 KLPD (2X250 KLPD)} & Co-generation
Power Plant {40 MW (2X 20 MW)} in Existing Distillery Plant
At Village Mansoorwala, Tehsil Zira, District Ferozepur, Punjab
Form–I / Appendix–I
Malbros International Private Limited 14
kg/cm² g pressure and 130° C temperature pass through PSA column S-01A/S-01B where
the water vapors are retained while water free alcohol is released as vapors. The vapors
are condensed in E-07 and E-08 and collected as Absolute Alcohol. When the molecular
sieve bed is saturated with water the alcohol vapors are shifted to the other tower and
the first tower is taken for regeneration. Regeneration is done first by pressure releasing
and creating vacuum and then by elutriating with dehydrated alcohol vapors from the
tower in dehydration operation. The vapors are condensed in E-06 and E-05 and the vent
vapors are recovered through scrubber C-02. Vacuum can be created vacuum by P-04.
(Eductor may also be considered for this duty). Product is cooled in E-09 and transferred
to Absolute Alcohol receiving tank and then on to storage tank.
6. Alcohol Daily Receivers & Bulk Storage :
Alcohol is first taken to Daily receiver storage tanks, which is based on the State Excise
laws, storage for three days considering the weekly holidays of two days. Thereafter, the
alcohol is transferred to Bulk Storage Tanks after taking the daily receiver Dip. This is
transferred using flameproof pumps. Final dispatch of alcohol is metered and again is
carried out using special flameproof pumps. The Bulk Spirit Storage is proposed to be set
up for 30 days.
EFFLUENT HANDLING SECTION
1. Decantation Section:
Decantation section comprises of Centrifuge Decanters, operating at high rpm which are
used for separation of suspended solids from Spent Slops coming out of Distillation
section. The Wet cake thus separated has 30-35% w/w solids, as removed from bottom of
Decanters. This is directly loaded on the trolleys parked below. Thin slops coming out of
Decanter are collected in a tank and are transferred for part recycle & further for
Evaporation into thick syrup.
2. Integrated Evaporation Section:
The suggested treatment scheme is a 2 FF + Finisher Evaporation Plant for Thin Slops
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 Evaporation have been used, with Plate type Preheaters for
preheating of FEED stream which serves the purpose of energy conservation.
� Analyzer vapour is fed to the first effect evaporator shell side at the given pressure
and temperature as the heating medium.
Proposed installation of Unit II - Grain Based Ethanol/RS Industrial/ENA Plant {500 KLPD (2X250 KLPD)} & Co-generation
Power Plant {40 MW (2X 20 MW)} in Existing Distillery Plant
At Village Mansoorwala, Tehsil Zira, District Ferozepur, Punjab
Form–I / Appendix–I
Malbros International Private Limited 15
� The Feed from the Feed balance tank is taken to the PHCOND to make the best
heat recovery.
� The Feed after getting heated to the predetermined temperature in preheater is
fed from the first effect evaporator which is Falling Film Evaporator -1
� The flow path is given below.
INLET FEED - pH cond – E1 – E2 – OUTLET PRODUCT
� Vapours generated in 1st effect VLS (Vapour Liquid Separator) are used as heat
source in the 2nd effect.
� The product at the desired concentration of TS is obtained at the outlet of the
second effect, which is a Falling Film evaporator.
� 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.
� 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.
CONCLUSION
The thick syrup thus obtained is mixed with the Wet Cake obtained from Decanter
Centrifuges using specially designed Ribbon type mixer and this enriches the protein
content in the fibrous suspended solids separated earlier in Decanter. This Protein & Fibre
rich DWGS is directly sellable as Cattle / Poultry Feed. However, in order to increase the
shelf life of such by-product, it is necessary to dry the product, with minimum possible
moisture content.
SYSTEM DESCRIPTION FOR DWGS DRYER
Wet distiller’s grains shall be fed into the dryer housing at controlled rate through a
suitable feeding system. The Rotary Tube Bundle is enclosed in an insulated dryer housing
and on its outer flights are fixed. Dry saturated steam is to be supplied to the tube bundle
Proposed installation of Unit II - Grain Based Ethanol/RS Industrial/ENA Plant {500 KLPD (2X250 KLPD)} & Co-generation
Power Plant {40 MW (2X 20 MW)} in Existing Distillery Plant
At Village Mansoorwala, Tehsil Zira, District Ferozepur, Punjab
Form–I / Appendix–I
Malbros International Private Limited 16
through rotary joint at one end & the condensate is discharged through rotary joint
mounted at other end.
During the course of rotation, these flights pick up the material and shower them on to
the tube bundles. The heat transfer is primarily by conduction. The water vapours are
exhausted through an Exhaust Blower & passed through a cyclone separator for
separating fines.
Dry product partially recycled back to Feed conditioner for feed conditioning through
Product Screw & Recycle Conveyor.
Entire operation of the Dryer is controlled through Control panel.
SYSTEM DESCRIPTION FOR COOLING & CONVEYING
� DWGS below product screw is discharged into charging hopper of pneumatic
conveying system.
� Rotary feeder feeds it into the conveying line.
� Ambient air is used for conveying.
� The material gets conveyed to product collector & discharged from rotary
discharge valve.
� Exhaust air is vented to atmosphere.
� The conveying system is lean phase suction type, using centrifugal blower as prime
mover. The conveying air quantity is designed considering cooling requirement & to
cool the product before discharge.
Figure - 3: Process flow chart For Grain Based Distillery
Proposed installation of Unit II - Grain Based Ethanol/RS Industrial/ENA Plant {500 KLPD (2X250 KLPD)} & Co-generation
Power Plant {40 MW (2X 20 MW)} in Existing Distillery Plant
At Village Mansoorwala, Tehsil Zira, District Ferozepur, Punjab
Form–I / Appendix–I
Malbros International Private Limited 17
B) Power Co-generation 40 MW (2X20 MW)
OPERATIONS
The unit proposes to set-up boiler and power turbine.
2 Nos. X 100 TPH boiler will be installed and based on Coal/Rice Husk/Pet Coke/
Biomass/Natural Gas etc. as available fuel options. This Boiler will operate mainly to
feed steam to grain based operations and 40.0 MW (2X20 MW) power generations
from Turbine.
Proposed 40.0 MW (2X20 MW) co-generation plant consists of a high pressure
water tube steam boiler extraction cum condensing steam turbine. Fuel in the
steam boiler will be burnt with the help of air in the boiler furnace. Water will be
circulated in the boiler drum and tubes thus getting heated by the flame burning in
the boiler furnace. Water comes out of the boiler drum located at the top of the
boiler as steam. Flue gases rise in the boiler furnace and come in contact with the
steam coming out of boiler drum. Steam after coming in contact with flue gases
gets heated up further thus getting superheated. Super heated steam leaves the
boiler in a pipe. Flue gases after super heating the steam pass through economizer
where they pre-heat the boiler feed water before it enters the boiler drum. After
economizer, flue gases pass through air pre-heaters where they heat the air which
is fed to the boiler furnace for burning the fuel. After air pre heaters flue gases pass
through Bag Filter where the dust particles are collected. The dust is collected from
here.
High pressure superheated steam from boiler is passed through a steam turbine,
which is used for distillery process operations. While passing through the turbine,
the high pressure and temperature steam rotates the turbine rotor and an electric
alternator mounted on the same shaft. Electric power is generated by the
alternator. This electric power generated is consumed in house i.e. for running the
distillery and utilities like boilers auxiliaries etc.
Proposed installation of Unit II - Grain Based Ethanol/RS Industrial/ENA Plant {500 KLPD (2X250 KLPD)} & Co-generation
Power Plant {40 MW (2X 20 MW)} in Existing Distillery Plant
At Village Mansoorwala, Tehsil Zira, District Ferozepur, Punjab
Form–I / Appendix–I
Malbros International Private Limited 18
FIGURE 4: PROCESS FLOW CHART FOR COGENERATION 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 Requirements
The raw materials required for the distillery can be broadly categorized as follows:
• Grain
• Enzymes & Chemicals
• Steam
• Fuel
• Power, etc.
The basic raw material for the manufacturing will be Grain. In the present scenario, grains
with different starch content are used like damaged grain feed stock, nakku kinki, maize,
bajra, sorghum, barley etc. The process requires the above grains to be milled into
specific flour size. Small quantity of sulphuric acid is sometimes required. The raw
material for the boiler fuel will be Coal, Rice Husk , Pet Coke , Bio Mass, Natural Gas etc .
Table 2
RAW MATERIAL REQUIREMENT FOR GRAIN BASED DISTILLERY
S. No.
Particular Requirements Source of the Raw Material & Mode of
Transportation
1. Grain (Damaged grain feed stock, nakku kinki, maize, bajra, sorghum, barley etc.)
1100-1300 TPD Nearby area and states , by road or
Railway
2. Chemicals Quantity (kg/d)
Sodium Hydroxide (Caustic) 2000 KGS
Enzymes 800-1000 KGS
Proposed installation of Unit II - Grain Based Ethanol/RS Industrial/ENA Plant {500 KLPD (2X250 KLPD)} & Co-generation
Power Plant {40 MW (2X 20 MW)} in Existing Distillery Plant
At Village Mansoorwala, Tehsil Zira, District Ferozepur, Punjab
Form–I / Appendix–I
Malbros International Private Limited 19
NH2-CO- NH2 (Nutrients) 2000-3000 KGS
Antifoam Agent 500-600 KGS
Yeast (Active Dry Yeast/Distiller’s Yeast 250-350 KGS
(a) Fuel Requirement
Name of Raw
Material
Quantity (MT per
day) Mode of transportation
Coal, Pet Coke 500-750 TPD By Railway
Rice Husk, Bio Mass 1000-1200 TPD Nearby Road
Natural Gas 500-600 TPD Pipeline
(b) Marketing Area and Mode of transportation of Final Product
The company has explored National and International markets for their products
from proposed unit. The final product will be sold in domestic market as well as it
will be exported. The mode of transportation for domestic market will be by road
and ship for export.
(viii) Resources optimization/ recycling and reuse envisaged in the project, if any,
should be briefly outlined.
Water as a resource will be recycled at each possible step of the process and latest
technology and methodology will be adopted to conserve and reuse the resources.
Waste water will be generated from the process goes to ETP and treated water
after pH corrections is used back again into the various processes and remaining is
used for the horticulture purposes.
(ix) Availability of water it’s source, energy /power requirement and source should be
given.
(a) Water Requirement and Source
The total water requirement for the first run for the proposed project will be 10958
m3/day and after recycling it will be 4110 m3/day.
Source of Water: Canal Water & Recycled Water.
Water Requirement for Grain Based Operation
The total water requirement for the Grain based process is estimated at 4110
m3/day, worked out as per details given below:
Proposed installation of Unit II - Grain Based Ethanol/RS Industrial/ENA Plant {500 KLPD (2X250 KLPD)} & Co-generation
Power Plant {40 MW (2X 20 MW)} in Existing Distillery Plant
At Village Mansoorwala, Tehsil Zira, District Ferozepur, Punjab
Form–I / Appendix–I
Malbros International Private Limited 20
TABLE - 3 (A)
Total Water Input
S. No. Section Water Consumption (KLPD)
1. PROCESS WATER IN LIQN 1635
2. BOILER FEED WATER 3678
3. DM WATER for DISTILLATION 625
4. SOFT WATER for COOLING TOWER 3750
5. SOFT WATER DISTILLATION 675
6. SOFT WATER PUMPS SEALING 250
7. FERMENTER WASHING 94
8. FLOOR WASHING 219
9. DOMESTIC CONSUMPTION 32
TOTAL 10958
TABLE -3(B)
Total Water Output
S. No. Section Water Consumption (KLPD)
1. STEAM CONDENSATE 2582
2. SPENT LEES PR 625
3. SPENT LEES RECTIFER 625
4. SPENT WASH (GRAIN SLOPS) 265
5. WATER IN DDGS DRYER 810
6. CT EVAPORATION & DRIFT LOSSES 3750
7. PUMP SEALING 250
8. PROCESS CONDENSATE 2001
9. BOILER BLOWDOWN 50
TOTAL 10958
TABLE - 3 (C)
Recycle & Utilization Streams
S. No. Section Water Consumption (KLPD)
1 STEAM CONDENSATE 2582
2 THIN SLOPS 265
3 R/E to DISTILLATION 531
4 PR LEES TO FERMETATION 94
5 PUMP SEALING 250
6 BOILER BLOWDOWN 50
7 PROCESS CONDENSATE 2001
8 FLOOR WASHING 219
9 PREC LEES TO CT 391
10 R/E to Less to CT 94
11 CT BLOWDOWN 371
Total Recycling / Reutilasation of water per day 6848
TOTAL FRESH WATER INPUT 4110
Hence, fresh water Requirement is 4110 KLPD. Water requirement for first run
would be 10958 KLPD.
Proposed installation of Unit II - Grain Based Ethanol/RS Industrial/ENA Plant {500 KLPD (2X250 KLPD)} & Co-generation Power Plant {40 MW (2X 20 MW)} in Existing Distillery Plant
At Village Mansoorwala, Tehsil Zira, District Ferozepur, Punjab
Form–I / Appendix–I
Malbros International Private Limited 21
Figure 5: Water balance Diagram
Proposed installation of Unit II - Grain Based Ethanol/RS Industrial/ENA Plant {500 KLPD (2X250 KLPD)} & Co-generation
Power Plant {40 MW (2X 20 MW)} in Existing Distillery Plant
At Village Mansoorwala, Tehsil Zira, District Ferozepur, Punjab
Form–I / Appendix–I
Malbros International Private Limited 22
(b) Power Requirement and Source
The total power requirement for proposed project will be 9 MW, which will be
sourced from own 40 MW ( 2X20 MW), cogeneration power plant.
(c) Steam Requirement
Steam requirement is 149.74 TPH, which will be sourced from proposed Boilers (100
TPH X 2 nos).
TABLE 4
STEAM REQUIREMENT FOR GRAIN BASED DISTILLERY
S. No. Purpose Steam Requirement (TPH)
1. Cooking & Liquefaction 15.79
2. Multi-pressure Distillation 65.20
3. Evaporation (Integrated) 6.25
4. DWGS Drier (DDGS) 52.08
5. Boiler Deaeration 10.41
Total 149.74
Boiler Details
Two Boilers of 100 TPH capacity each with ESP as APCE is sufficient to meet the
requirements. Others details regarding this are mentioned in the table given below:
TABLE – 5
BOILER DETAILS
S.
No.
Details
1. Type of Fuel Coal , Rice Husk , Pet Coke , Bio Mass,
Natural Gas etc
2. Capacity of Boiler 100 TPH X 2 NOS
3. Stack Height 63 MTS
4. Pollution Control
Equipment Measures
ESP
Details regarding the D.G. Sets
3 D.G. sets of 1000 KVA will be installed for the power backup. Details regarding the D.G.
Sets are mentioned in the table given below:
Proposed installation of Unit II - Grain Based Ethanol/RS Industrial/ENA Plant {500 KLPD (2X250 KLPD)} & Co-generation
Power Plant {40 MW (2X 20 MW)} in Existing Distillery Plant
At Village Mansoorwala, Tehsil Zira, District Ferozepur, Punjab
Form–I / Appendix–I
Malbros International Private Limited 23
TABLE – 6
DETAILS REGARDING THE D.G.SETS
S. No. Details
1. Type of Fuel HSD
2. Capacity 3 X 1000 KVA
3. Stack Height (above roof level) As per CPCB/SPCB norms
4. Pollution Control Equipment Measures Adequate stack height/ Acoustic
(x) Quantity of waste to be generated (liquid and solid) and scheme for their
management/disposal
o The proposed project is based on “ZERO EFFLUENT DISCHARGE”.
o Grain Slops (Spent Wash) will be taken through Centrifuge Decanters for separation
of Suspended Solids separated as Wet Cake.
o Thin Slops from the Decanter Centrifuge will be partly recycled back to process (30-
35%) and partly taken to Thins Slops Evaporation Plant for concentration of
remaining solids to form a Syrup. This Syrup is mixed with the Wet Cake coming out
of Decanter Centrifuge and forms part of Cattle Feed. (Also known as Distillers Wet
Grain Solubles - Collectively known as DWGS).
o DWGS is taken to a dryer operating on steam and is dried to make it DDGS –
Distillers Dried Grain Solubles.
o The process condensate is cooled and collected into a neutralization tank with
sufficient residence time. After Neutralization, this process condensate will be
recycled into process and is used for green belt development within the complex.
o Two streams of low BOD lees (White Effluent) comes out is partly used as
fermenter washing and then sent for Cooling, treatment and utilized for RS
dilution. The second part requires only cooling and can be used as Cooling Tower
water makes up directly.
o Solid waste from the Grain based operations generally comprises of Fibres and
proteins in the form of DDGS, which will be ideally used as Cattle Feed.
o Ash from the Boiler will be sold to Brick manufacturers.
o Yeast sludge will be sent to the Sludge Drying Beds or may be added to the Wet
Cake.
o Used oil & grease generated from plant machinery / Gear boxes & D.G. Set will be
partly used in oiling & greasing as lubrication of external parts of machinery &
partly will be sold to the CPCB authorized recycler.
Proposed installation of Unit II - Grain Based Ethanol/RS Industrial/ENA Plant {500 KLPD (2X250 KLPD)} & Co-generation
Power Plant {40 MW (2X 20 MW)} in Existing Distillery Plant
At Village Mansoorwala, Tehsil Zira, District Ferozepur, Punjab
Form–I / Appendix–I
Malbros International Private Limited 24
4.0 SITE ANALYSIS
(i) Connectivity
The project site is well connected to National Highway NH-15 (~1.0 km in West
direction). The nearest railway station is Talwandi Bhai Railway Station (~ 7 km in
SSW direction) and nearest airport is Sri Guru Ram Dass Jee International Airport,
Amritsar (~ 88 km in North direction).
The site is suitably located with respect to availability of raw material, water, road
network, skilled/semi skilled/unskilled and professional manpower etc. All
communication facilities such as telephone, telefax & internet are available in the
vicinity of the project site.
(ii) Land from Land use and Land ownership
Total land requirement for the proposed project is 14.8 ha (36.5 acres) and has been
completely acquired by Malbros International Pvt. Ltd.
(iii) Topography
Topography of the core zone for the proposed project 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 – 7
Environmental Settings of the Area
S. NO.
PARTICULARS DETAILS
(with approximate aerial distance & direction from project site)
1. Nearest Village Ratol Rohi (~1 km in West Direction)
2. Nearest Town/City Zira (~6 km in NNE direction)
3. Nearest National Highway / State Highway
NH-15 (~1 km in West Direction)
4. Nearest Railway station Talwandi Bhai Railway Station (~ 7km in SSW direction)
5. Nearest Airport Sri Guru Ram Dass Jee International Airport, Amritsar (~ 88 km in NNW direction)
6. Archaeological important site None within 10 km radius
7. National Parks, Wild Life Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors etc. within 10 km radius
No National Parks, Wild Life Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors etc. lies within 10 km radius of the project site.
8. Reserved Forests (RF) / No Reserved Forests (RF) / Protected Forests (PF) etc. lies
Proposed installation of Unit II - Grain Based Ethanol/RS Industrial/ENA Plant {500 KLPD (2X250 KLPD)} & Co-generation
Power Plant {40 MW (2X 20 MW)} in Existing Distillery Plant
At Village Mansoorwala, Tehsil Zira, District Ferozepur, Punjab
Form–I / Appendix–I
Malbros International Private Limited 25
Protected Forests (PF) etc. within 10 Km. radius
within 10 Km. radius of the project site.
9. River / Water Body (within 10 km radius)
No river lies in 10 km radius of the project site.
10 Soil Type Sierozem & Desert soil
11 Seismic Zone Seismic Zone - III as per IS: 1893 (Part-I): 2002.
(v) Existing Infrastructure
Proposed project is new project. There are no existing infrastructures.
(vi) Soil classification
The soil is of Sierozem & Desert soil type.
(vii) Climatic data from secondary sources
The climate of the district can be classified as tropical desert, arid and hot. The area
receives about 389 mm annual normal rainfalls which is unevenly distributed over
the area in 23 days, out of which about 79% occurs during south west monsoon.
Rain fall in the district decreases from north east to south west.
(viii) Social Infrastructure available
There are primary schools, dispensaries, small hospitals, 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 project is installation of ethanol/RS Industrial/ENA unit within existing distillery.
Facilities required for the proposed project will be provided as per requirement.
Transportation of raw material and final product will be done via existing road
network and cement concrete road will be developed within the proposed project
area.
(ii) Population Projection
Temporary influx of people will be there as the managerial and supervisory staff
will generally be outsider. A projection may be made by a governmental
organization, or by those unaffiliated with a government.
(iii) Land use planning
Total area required for the proposed project will be 14.8 ha (36.5 acres), out of
which ~33 % of the total project area will be covered under green belt & plantation
in order to reduce noise pollution levels & to increase aesthetic beauty of the area.
Proposed installation of Unit II - Grain Based Ethanol/RS Industrial/ENA Plant {500 KLPD (2X250 KLPD)} & Co-generation
Power Plant {40 MW (2X 20 MW)} in Existing Distillery Plant
At Village Mansoorwala, Tehsil Zira, District Ferozepur, Punjab
Form–I / Appendix–I
Malbros International Private Limited 26
(iv) Assessment of infrastructure demand (Physical & Social)
The Company will assess the demand of infrastructure (Physical & Social) in nearby
area of the proposed site and will be developed in under corporate social
responsibilities programs
(v) Amenities/Facilities
The Company will develop the Amenities/Facilities in nearby area of the proposed
project 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)
Approx. 14.8 ha (36.5 acres) areas will be required for proposed unit.
(ii) Residential area (Non Processing area)
Residential colony is not proposed for the project. The local labor will be preferred to
provide employment opportunities.
(iii) Green Belt
Out of the total project area i.e. 14.8 ha, 4.9 ha (~33 % of the total plant area) will be
developed under greenbelt area & plantation in order to reduce noise pollution levels
& to increase aesthetic beauty of the area.
(iv) Social Infrastructure
Proposed 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 proposed project is well connected with Rail and Road.
(vi) Drinking Water
32 m3/day of water will be required for drinking & domestic purpose in the
proposed project which will be sourced from Canal Water.
(vii) Sewerage System
The waste water generated from the sanitary blocks will be disposed off in soak
pit/STP.
(viii) Industrial Waste management
The proposed unit would be based on “ZERO DISCHARGE”.
Proposed installation of Unit II - Grain Based Ethanol/RS Industrial/ENA Plant {500 KLPD (2X250 KLPD)} & Co-generation
Power Plant {40 MW (2X 20 MW)} in Existing Distillery Plant
At Village Mansoorwala, Tehsil Zira, District Ferozepur, Punjab
Form–I / Appendix–I
Malbros International Private Limited 27
(ix) Solid Waste Management
� Solid waste from the Grain based operations generally comprises of Fibres and
proteins in the form of DDGS, which will be ideally used as Cattle Feed.
� Ash from the Boiler will be sold to Brick manufacturers.
� Yeast sludge will be sent to the Sludge Drying Beds or may be added to the Wet
Cake.
(x) Power requirement and source
The total power requirement for the proposed project will be 9.0 MW, which will be
sourced from Co generation power plant of 40 MW (2X 20 MW) & D.G Sets (for
emergency).
7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN
(i) Policy to be adopted (Central/State) in respect of the project affected persons
including home oustees, land oustees and landless labourers.
Any rehabilitation and resettlement plan is not applicable in this case since there is no
habitation on the proposed site location.
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 all other
required clearance and will complete after two years of commencement.
(ii) Estimated project cost
� Total cost of the Project: Rs. 583 Crores
� Cost for Environment Protection Measues:
� Capital Cost: Rs. 58 Crores
� Recurring Cost/annum: Rs. 10 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.
The project activity and the management will support local administration and provide
other form of assistance for the development of public amenities in the region. Plantation
will be developed in and around the project area. The project will help in improving the
overall status of the area.