Pre-Feasibility Report

for
Grain Based 60 KLD Distillery
Along With Cogeneration Power
Plant of 1.8 MW
At
Village – Aliganj
Tehsil - Bareli
Distt - Raisen (MP)

Proposed By
M/s KP Biofuels Pvt Ltd
50 Nishant Colony
Link Road TT Nagar
Bhopal (MP) -462011
1. Identification of project and project proponent

M/s KP Biofuels Private Limited is proposing green field grain based distillery in the
Dist of Raisen . The management has proposed to install 60 KLD fuel ethanol unit
based on grain feed unit to meet out the requirement of Fuel Ethanol in the market.

The company will have well defined managerial and technical team looking after entire
operation. Shri Vivek sarang will be director of the unit and shall be look after entire
project under his supervision.
Following are the directors of the Company
1. Shri Atul Vaidya Ward no 06 Balaghat MP
2. Shri Arpit Vaidya Ward no 06 Balaghat MP
3. Shri Ankit Bothra Ward no 06 Balaghat MP

4. Brief Description of Nature of The Project

The present proposal is for setting up a grain based 60 K.L. of fuel ethanol unit with
cogeneration of power (1.8 MW) at Village –Aliganj Tehsil Bareli & Dist Raisen (MP) in
the State of Madhya Pradesh at an estimated cost Rs. 60.30 Crores.
The Products will have specified as 60 KLPD of fuel ethanol. The by product is
identified as CO2 which will generate at about 30 TPD (70%of total generation).
DDGS 26-28 TPD) shall also be recovered from the proposed unit
The Company proposes to set up an integrated pollution free (Zero discharge) Distillery
Complex in the State. The proposed Industrial Complex shall process waste and
coarse grains as its raw material to produce fuel ethanol, CO2 etc. :

Silent feature of the project

Liquefaction:
1. Maximum conversion of starch to sugar
2. Recycle of lees thus minimizing the fresh water requirement.
Fermentation:
1. High alcohol productivity with high efficiency of fermentation of up to 92%.
2. Higher alcohol content in the fermented mash, thus lower steam requirement.
3. High ease of operation
4. Design of equipment, piping and provision of cleaning in place ensures minimum
bacterial activity.
5. Mash coolers designed to reduce the possibilities of choking.
6. Water recycle and reuse system reducing fresh water requirement.

Distillation:
1. Plant with maximum heat integration to produce alcohol with lowest energy
consumption.
2. Energy efficient integrated system Distillation efficiency up to 99.5% whilst
producing AA
3. Well-engineered plants with high efficiency trays to ensure elaborate separation
and removal of impurities ensuring superior quality of Spirit.
Proper care in design of calming zone on trays, large area of down-comers, gas-
liquid separators with tangential entry and vapor bottles ensures proper gas-liquid
disengagement and eliminates chances of liquid carryover
4. Mash column with hyper stat Rh Grid trays ensure high turbulence on tray, this
minimizes chances of scaling. Also, this special construction of trays and access to
each tray helps in easier cleaning of column internals.
5. Condensers are designed with multiple passes to ensure high velocity and to
minimize scaling inside tubes.
6. Water recycle and reuse system reducing fresh water requirement.

Integrated Evaporation:
1. Concentrated spent wash up to 40 % w/w solids with low steam.
2. The process condensate after the condensate treatment used as cooling tower
make up thus reducing the fresh water requirement.
3. Possibility of Higher value realization obtained from mixing of syrup with wet cake
in the dryer.
4. Water recycle and reuse system reducing fresh water requirement.

Dryer:

1. Multiple working references

2. Low Temperature drying – No product degradation
3. 100 % syrup can be consumed
4. Robust construction

Process Condensate Treatment Plant:

Designed to treat process condensate + Cooling Tower Blow down + Dryer vapour
condensate thus enhancing recycle and reducing fresh water requirement to up to
3.8 lit/lit for Distillery process
1. Technology available indigenously with successful plants running based on the
technology with focus on reducing water ,energy and carbon footprint
2. Provided with most efficient Fed batch Fermentation technology
3. Distillation operating on Multi-Pressure Technology – an efficiently heat
integrated system, operating on fully automated PLC control system
4. Most efficient process technologies for liquefaction, fermentation ,MPR
distillation , dehydration and evaporation to attain maximum and sustainable
plant outputs
5. Extensively process and heat integrated system to reduce energy consumption
6. Water management design based upon three principles of reduce, reuse and
 recycle water to minimize fresh water requirement.
7. Zero effluent and liquid discharge norms applied while designing the plant.
8. Ethanol produced from the proposed 1G ethanol facility will be as per Indian
specifications (IS 15464:2004) of anhydrous ethanol for use of blending in
automobile fuel.

Salient Features of The proposed Proect

Site Address Khasara No. 134/3/1/1,134/6/2/1,
153/5/1/2,154/3/155/1,/155/2/1/1,
155/2/1/2
Village- Aliganj, Tehsil- Bareli Dist Raisen (MP)
Production Capacity Grain base fuel ethanol unit of 60 KLPD along
with 1.8 MW Power Plant and 30 TPD CO2
generation
Cost of Project 6030 Lacs
Grain Requirement 140-145 TPD
Boiler capacity at MCR (100% Load) 18 TPH
Steam Requirement 10-12 TPH @ 3.5 kg/cm2
Fuel 100 TPD as rice husk or Coal ( ---- TPD)
Total water Requirement 1200 KLD
Total Recycling of Water 715 KLD
Net Fresh Water Requirement 485 KLD
Spent Wash Generation 484 TPD
DDGS Generation 27 TPD
Ash Generation from Boiler 20 TPD
Power Requirement 1500 KW
Power Requirement Max 29925 KWHR
Capital Cost for Environmental measures 18.83
MEE, Dryer, Bag filter for boiler (
proposed )
Recurring cost for environmental 10.5
Management etc ( Proposed )

Total Acquired Land 4.359 Hact

Total Built Up area of Plant 16500 sq mtrs
Proposed area for plantation 14500 Sq mtrs)
Alternative Source of Power DG set of 500 KVA
Direct Employment Generation 50+90
3. Need for the project and its importance to the country and or region

Reducing import dependency: The proposed 1G ethanol project will produce

around ~1.92 – 1.98 Crore litres of Fuel Ethanol. This project is a step in
utilizing renewable and environment-friendly sources of energy like ethanol to
supplement fossil fuels.
Cleaner Environment : As per the ministry of petroleum notification on new
biofuel policy, the proposed 1G ethanol project of K P Biofuels will produce around
~1.92 – 1.98 Crore litres of Bio-Fuel Ethanol which has the potential to save
around 45% – 50% of CO2 emissions per year by replacing gasoline with bio-
ethanol if biomass is considered as possible fuel source
Employment Generation: The proposed 60 KLPD 1G ethanol project will create
around 100+ direct jobs in plant operations, and about thousands of indirect jobs
for personnel related to various supply chain & selling of by-product; village level
entrepreneurs and Grain and DDGS supply chain. DDGS as a protein rich feed for
animals will boost animal husbandry development in rural India. This will provide
boost to rural economy in India.
Income to Farmers: Farmers will get sustainable income source by growing
feedstock and there will be assured offtake and utilization of grains for biofuel
production. This will help to increase farmer’s income.
Infrastructural Investment in Rural Areas: Proposed 1G ethanol plant will
require Capital Investment of ~ INR 70 Crores. Investment in proposed 1G
ethanol plant will spur infrastructural investment in rural areas.

Indian Outlook for Bioethanol

 Progressive Vision and Strong Policy Support
 The Government of India in January 2003 launched its Ethanol Blended Petrol
(EBP) Programme for 5% ethanol blended petrol in 9 states. India’s EBP
Programme sought to improve fuel efficiency and ensure protection from the price
shocks of the global crude market.
 In 2006, Government of India announced 5 % mandate for ethanol blending Pan
India excluding the entire north-eastern region, Jammu and Kashmir, and
Andaman and Nicobar Islands which were left out of the EBP Programme (source:
Ministry of Petroleum & Natural Gas, 2015)
 In 2009, the Government of India introduced a National Policy on Biofuels. The
Policy focused on further encouraging biofuel usage and reducing the prevailing
dependence on fossil fuels, while it sought to mitigate environmental and fuel
efficiency concerns. The Policy also recognized the significant opportunity that
biofuels offer to India’s agricultural and industrial sectors. This policy also
mandated a phased implementation of ethanol blending in petrol in various states.
 In 2012, the CCEA decided that a stable EBP Programme would ensure sustainable
benefits for sugarcane farmers across the nation, and the 5% mandatory ethanol
blending with petrol should be implemented across the country and that the
purchase price of ethanol would be decided between OMCs and the suppliers of
ethanol. A Gazette Notification was issued, directing OMCs to sell ethanol blended
petrol with percentage of ethanol up to 10% and as per the Bureau of Indian
Standard (BIS) specifications (Ministry of Petroleum and Natural Gas, 2015).
 In 2014, in order to offer OMCs and suppliers clear signals, the CCEA fixed
ethanol prices based on the distance of the mill/distillery from the OMC
depot/installation (Cabinet Committee on Economic Affairs (CCEA), 2014).
 These policy measures and strong support the Indian EBP Programme managed to
achieve an average blending ration of around 4.5 %
 To give a further boost to the EBP Programme the Union Cabinet, chaired by the
Prime Minister Shri Nagendra Modi approved National Policy on Biofuels – 2018.

Highlights of national biofuels policy -

 Targets to achieve these key outcomes through the EBP Programme
 Ensuring energy security and self-reliance by enhancing biofuels production.
 Reducing import bill and conserving foreign exchange.
 Reduction in carbon emission
 Strengthening rural economy, Enhanced and sustainable income for farmers by
providing boost to agricultural sector
 Retain employment and additional employment generation in rural India.
 Targets 10% ethanol blending by 2022 and 20% blending by 2030
 Allowing additional feedstock for 1st Generation like sugarcane juice/syrup,
surplus/damaged grains for production of ethanol
 Use of lingo cellulosic biomass such as agricultural crop residue, energy crops
,etc. for production of 2nd Generation Bioethanol
 Other major policy measures to support the EBP
 Interest subvention schemes introduced for sugar cane and molasses based
distilleries
 Remunerative ethanol pricing for various feed stocks independent of crude oil
pricing
 Assurance of OMCs to purchase ethanol for 10 years
 OMCs have modified there tender terms like
‐ reduction in penalties from 5% to 1%,
‐ reduction in security deposit from 5% to 1 %,
‐ flexibility in supply
KEY DRIVERS

 AATMA-NIRBHAR BHARAT ABHIYAN to promote local Energy resource.

 Aggressive Biofuel policy and Ethanol Blending Program
 Target to reduce GHG emission by 30 to 35% by 2030
 Enhance Energy self-reliance.
 Availability of plenty of agro based feedstock.
 Advancements in Ethanol production (enhanced feedstock basket) and
application (Flex Fuel Vehicles) technologies.
 YoY increase in Potable and Industrial ethanol consumption.

GOI is planning to reduce crude import up to 10% by 2022. EBP is one of the
key facilitator of reducing import bill by blending ethanol in gasoline thereby
reducing gasoline requirement and providing sustainable income to farmers.
The above table also depicts the ethanol available and shortfall in M.P and
potential demand going ahead

The following point’s highlight the advantages of establishing such plants in

order to bring sustainability to ethanol blending program –
1. In the current scenario Ethanol supply is dependent on Sugar sector.
2. Major Sugar Cane Crop Production is limited within Maharashtra, Uttar
Pradesh, Bihar and Karnataka. Due to this the major Alcohol Production is
also from these four states only, making imbalance for demand and supply
of other states.
3. Shortage in supply of fuel ethanol post diverting excess sugar.
4. Incremental Price pressure on account of sugarcane FRP increase and
subsequent remunerative pricing of ethanol.
5. Alternative feedstock in the form of surplus grain (rice) is adequately available
 6. Benefits of setting of grain to Ethanol plants :
a. Control on Ethanol supply for non-sugar producing states and even
Sugarcane crop deficit years.
b. Ensuring minimum quantity sustainability of the EBP
c. In case of Grain to Ethanol, ZLD can be achieved with value added -
protein rich DDGS as a co-product.
d. Decentralized units will boost in achieving state blending targets and
reduce interstate transport. This will also reduce the carbon foot print due
to reduction in vehicle travelling.
7. Benefits of setting up higher capacity Grain to Ethanol plant :
a. Can achieve better Economy of Scale and reduce production costs
b. Provides cushioning against variation in Feedstock and by-product prices
Apart from above the potable alcohol market also has a huge potential with
average CAGR on 6 – 7% in India

4. Demand –Supply Gap

Ethanol demand scenario estimation for 2025

 The ethanol demand considering the preponement of EBP to year 2025 is of total
around ~1200 Cr lit per annum out of which around ~900 Cr lit is for fuel
ethanol and around ~ 300 Cr lit is from other sectors
 The above demand does not take into account additional requirement envisaged for
diesel blending and SAF (Sustainable aviation fuel)

Ethanol supply scenario

Backed by slew of measures by the Government and strong support by the

OMCs the ethanol blending targets are set to rise, but, still would fall short to
achieve 20 % blending
 Feedstock Wise Ethanol Demand - Supply Scenario Estimation For 2025
Ethanol supply trend and estimated quantity until 2022

Particulars 20% ethanol Other Uses ( Total (In

blending (Cr.lit.) Cr.lit) Cr.lit)
Total Requirement 900 300 1200

Estimated Ethanol Supply from Sugar Sector

 As derived from above maximum possible supply from Sugary feedstock is ~

600 Cr Ltrs post diverting 6 MMT surplus sugar
 This clearly denotes that blending targets cannot be achieved only by
diverting sugarcane/sugar to ethanol, so there is dire need for alternative
feedstock.
 Thus, the government is encouraging production of ethanol from other
feedstock like grains (Surplus rice/Maize/Damaged Food Grain (DFG)).

GRAIN FEEDSTOCK SCENARIO –

The Government has notified about surplus Grain availability of around 13.5
MMT which can be utilized to produce Ethanol.
Estimated Ethanol Supply from Grains

Existing and Required Capacities – India

Molasses Grain Based Total (

Particulars
Based (Cr.lit.) (Cr.lit) Cr.lit)
Supply requirement 660 540 1200
Installed Capacity required
825 675 1500
considering 80% Capacity
Utilization
Existing Ethanol / Alcohol 426 258 684
capacity
Capacity addition envisaged 93 - 93
by 2022
Capacities to be Added 306 417 723

Fuel Ethanol Blending Program

Existing and Required Capacities – M.P

Particulars Value

Yearly operational capacity by Year 2022 (In ~ 35.0

Cr Lit.)
Demand for E20 by Year 25 (in Cr.lit) ~43.0
Addn. Demand for potable alcohol by Year 25 ~ 11.0
(in Cr Lit)
Shortfall/Excess with 80% capacity (in Cr lit) ~19.0
 Opportunity to set up nearly 9 – 10 plants of 60 KLPD capacity

5. Imports Vs. Indigenous Production No import is proposed as demand in domestic

market is enough to consume the product.

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

7 Domestic/Export Markets
The Ethanol prices declared by Oil Companies are best in the world where Ethanol
is being produced. Government has announced different prices for the Ethanol
being produced from different sugary raw material that is sugar cane juice, syrup
and B-heavy and C molasses thus helping sugar factories to choose the raw
material. Also government is ensuring the payments against Ethanol supplied in
21 days thus helping sugar factories to improve their financial conditions better.

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

Proposed Employment : 50 Nos. (Permanent) and 90 nos ( Indirect)
Apart from that indirect employment generation is envisaged from the project.

9 Project Description

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

No interlinked and interdependent project with the proposed plant, however power
plant of 1.8 MW through co generation is proposed. CO2 will also generate as by
product from the fermentation process which is turn can be utilized after further
treatment at CO2 plant in industrial or food grade application. It is also proposed
Evaporation plant of effluent to provide better environment conservation and pollution
control arrangement in the unit as well as for the surrounding area.

ii. Location (map showing general location, specific location, and project boundary &
project site layout) with Coordinates:
The unit is spreaded over 1.22 hact of land in village Lawda Tehsil, Lalburra Dist. –
Balaghat of MP. The latitude and longitude of the site is as below
S. no. Latitude Longitude
1 22°56'36.23"N 78°20'56.74"E
2 22°56'36.15"N 78°20'59.44"E
3 22°56'34.26"N 78°21'2.43"E
4 22°56'33.52"N 78°21'4.38"E
5 22°56'32.74"N 78°21'5.57"E
6 22°56'30.86"N 78°21'7.87"E
7 22°56'27.80"N 78°21'4.76"E
8 22°56'29.69"N 78°21'2.30"E
 9. 22°56'29.60"N 78°21'1.60"E
10. 22°56'30.94"N 78°20'57.80"E
11. 22°56'33.82"N 78°20'55.88"E
Satellite Image of the Project area

Topographical base map

iii. Details of Alternate Site:
The green field unit of 60 kld is proposed at village aliganj with environmental
consideration and in line with guideline issued for setting up Industrial project . Hence
no alternate site is considered. Therefore proposed site suitable for the project
configuration.

iv. Size or magnitude of Operation:

It is proposed to produce 60 KLPD of fuel ethanol, 30 TPD of CO2 ( by product) from
grain based operation. 1.8 MW Co gen plant is also proposed be with the distillery
unit. The unit shall be adopted zero discharge technology for the effluent disposal. .

v. Project Description With Process Details:

The overall process is shown on the attached Block Flow Diagram, and Process Flow
Diagrams. The following describes the production of ENA and co-products from grain.

PROCESS DESCRIPTION
 Parameter Details
Grain type Convertible Starch Content
For Clean Grain containing minimum 58%
Broken Rice, Corn, Sorghum, Bajraetc.
w/w enzymatically convertible starch.
Plant Capacity 60 KLD Fuel Ethanol on Grain
Thin slop recycle to Liquefaction section 30%
Alcohol Concentration in Fermented Wash 13 % v/v Min
Product
Yield
Liter of alcohol (95 %v/v) per ton of clean Grain
flour containing 68% w/w (Min.) enzymatically 467 Lit/MT
convertible starch

 Plant will operate only one product at a time i.e Wash to A.A.
 Plant and products capacity, yield is subject to input quantity and specifications as
specified in respective section. Any variation in the same will affect plant overall
performance.

 Yield Chart
Combine Efficiency for A.A. Liquefaction, Fermentation and Distillation &Dehydration
–91.44% (Product Strength for A.A.- 99.8 % v/v)

PROCESS DESCRIPTION

1. GRAIN STORAGE SILOS, CLEANING, HANDLING AND MILLING SECTION:

Grain is received from various sources and is pre-cleaned off Stones, husk, straws
and iron metals etc. and then Stored in specially designed Storage Silos. Grains are
continuously lifted from the bottom of the Silos and screened followed by removal of
stones in De-stoner and iron metals 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 Batch Machine through a Screw Conveyor.

2. SLURRY PREPARATION / LIQUEFACTION

Slurry from pre-masher is taken to Initial liquefaction tank where liquefying enzyme is
added. The mixture of slurry and steam is then passed through the retention vessel
(cook tube) having sufficient capacity to provide the desired retention time at a given
flow rate. The cooked mash is discharged to a flash tank for liquefaction.
The gelatinized mash from the flash tank is further liquefied in a final liquefaction
tank where liquefying enzyme is added. Then the liquefied mash is passed through
plate heat exchanger and cooled slurry transferred to Fermentation section.
3. FERMENTATION SECTION
The purpose of fermentation is to convert the fermentable substrate into alcohol. 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 and Co 2 is
generated as by Product.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 fermenter into Beer Well.

4. DISTILLATION SECTION

Wash to ENA Multi-pressure:

Pre-heated fermented wash is fed into a series of Distillation Columns to increase the
alcohol concentration and remove various impurities including Fusel oil as by product
.The columns are termed as below:
a. Analyzer
b. Degasifier
c. Rectifier
d. Recovery
e. MSDH Section
RS will be taken out from Rectifier column having strength of 94.68% v/v .

5. EVAPORATION SECTION
The Spent Wash discharged from the Analyzer column bottom is taken to the Decanter
for separation of suspended solids then thin slop to evaporation section for
concentrating the slop up to 40%w/w solids.
Treatment scheme is a series of evaporation effects working on the principle of falling
film Evaporation & Forced circulation.

6. DRYER SECTION
The concentrated syrup is mixed with the wet cake from the decantation section .This
mixture is termed as DWGS which either sold as cattle feed or fed in Dryer to reduce
the moisture upto 10%.This by product is termed as DDGS which is in a powder form.

7. PROCESS CONDENSATE TREATMENT SECTION

The process condensate from the evaporation section is partially recycled in making
Grain Slurry and balance qty treated in this unit and this treated condensate is then
recycled back to process thus reducing the fresh water consumption.

PRODUCT SPECIFICATION
Absolute Alcohol (AA)

S.No Parameter Unit Value

1. Ethanol content at 15.6 deg C % v/v Min.99.8
 2. Miscibility with water Miscible

Typical DDGS Product Specification

Crude Protein, wt. percent, dry basis, min 30.0
Crude Fat, wt. percent, dry basis, min 6.0
Crude Fiber, wt. percent, dry basis, min 8.5
Ruminant TDN, wt. percent, dry basis, min 88.0
Note: This may vary depending on the quality of raw material.

PROCESS FLOW CHART FOR GRAIN BASED OPERATION

 Grain Receiving,Handling
To Various
&Storage
Units

Grain Cleaning
&Milling Power
Generation

Mashing &
Cooking
Steam
Generation

Liquefaction

Saccharification Cooling
& Fermentation Towers

Storage Distil+MSDH
Permeate

Decantation Evaporation

DDGS DDGSDryer

CPU

REJECT
Co-generation Power Plant [1.8 MW]
Proposed 1.8MW co-generation plant consists of high pressure AFBC water tube steam
boiler & back pressure 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 a bag house filter where the dust particles are
collected in filter bags & discharge from the bottom of the bag house filter. Dust will be
collected in the Ash Silo through pneumatic conveying system.

High pressure superheated steam from boiler is passed through a steam turbine and
low pressure goes to Low pressure header, which is used for distillery. 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.
 Process Flow Chart (CPP)

Steam 12 TPH @ 3.5 kg/cm2 Power 1.8 MW

To MEE Plant(integrated) -0.92 TPH

To Dryer -3.66 TPH
To Distillation - 5.40 TPH
To Hydro heater/Jet cooker - 1.25 TPH

Quantity of Raw Materials Requirement and storage facility

Item Type Capacity Requirement (TPD) Source
Grain / Flour / Others Grain Godown5000 MT 140-145 Rice mills
Rice Husk Husk Yard 2000 MT 100 Rice mills
Antifoam Agent HDPE Drum 50 kg/day Nagpur
NaOH (50% concentration) MS Tank 1000 Kg 20 kg/day Nagpur
Enzymes like 1500 Kg 150 kg/day Nagpur
Amyloglucosidase, AlphaCarboy
Amylase Viscozyme
Yeast Carton 500 Kg 45 kg/day Self gen./
Packing suppliers
H2SO4 (93%) Carboy As per
requirement
Spent wash - - 365
Alcohol Vessel 60 KL

vii. Resource optimization/ recycling and reuse

Advantages of Grain Plant over the Molasses Plant
• Water consumption is reduced by 30 to 40% % in the Grain based plant as compare to
Molasses based plant
• Effluent generation is also reduced by 30% in the Grain based plant as compare to
Molasses based plant
• Hydraulic Load is also reduced by 40-50% in the Grain based plant as compare to
Molasses based plant
• By adaptation of Grain based technology for production of RS/Ethanol , reduction in
pollution load is proven fact. Further the availability of raw material i.e. grain is in
abundance around the proposed site as compare to molasses which is not available
around the site hence selection has been made for grain base technology.
• Centrifuge Decanter is used for separation of suspended solid from the spent wash
coming out of the distillation plant.
• Wet cake has 30-35% w/w solids as removed from the bottom of the Decanter.
Thin slops coming out from decanter will be collected in a tank & transferred for the
partial recycling & remaining for Evaporation. The separated solid shall be converted
 as DWGS & DDGS which is protein reach cattle feed having good market value.

viii.: Availability of Water its source, energy / power requirement and source:
Water requirement:
Construction Phase – 10KLD
Operational Phase – Total water requirement will be 1200 KL per day
Source :Borewells/ River
ix. Power Requirement:
Construction Phase – 30 kw

Details of Power Requirement for Operating in Connected in

proposed project kwh kwh
Pre-cleaning, Storage Silo 35 35
Grain & Flour Handling
200 200
Hammer Mills (Buhler Make)
Liquefaction Section 50 100
Fermentation Section 175 200
Distillation Section 105 210
Decantation 50 35
 Dryer 100 100
Integrated Evaporation Section 150 300
Utilities: Cooling Towers, Instrument Air
225 450
Compressor and Yard piping
Alcohol Storage 25 20
Process Condensate Treatment Plant 75 75
WTP 40 40
Total Power requirement 1500 1765

During operation phase, the required power will be taken from 500 Kw cogeneration
power plant. One DG set of 500 KVA shall be kept as standby arrangement

X. Quantity of wastes to be generated (liquid and solid) and Scheme for their
management/ disposal
For Liquid Waste
During operation, Grain Slops will be taken through Centrifuge Decanters for
separation of suspended solids.
Spent wash (484 M3 per day) will pass through centrifuge decanter for separation of
solid. The part of thin slope (98 M3 per day) from centrifuge will be recycled to process.
• The remaining slop will be concentrated through multi effect evaporator.
• The concentrated syrup will be mixed uniformly in the ribbon mixer to form DWGS (
66 MT per day). Final product will be in the form of DDGS at 26-27 tons per day.
• DDGS powder will be sold as cattle feed.
Treatment Scheme
Decantation Section
• Centrifuge Decanter is used for separation of suspended solid from the spent wash
coming out of the distillation plant.
• Wet cake has 30-35% w/w solids as removed from the bottom of the Decanter.
• Thin slops coming out from decanter will be collected in a tank & transferred for the
partial recycling & remaining for Evaporation.

Evaporation section
The suggested treatment scheme is a Multi Effect Evaporator with thermal
recompression for Thin Slops Evaporation. The following points will elucidate the basic
working principal:
• Shell & Tube type Evaporators with highly efficient liquid distributor working on the
principal of Falling Film Evaporation.
• Analyzer vapors are fed to the 1 st effect evaporator shell side at the given pressure &
temperature as the heating medium.
• The Feed is fed from the top of the 1st effect evaporator which is Falling Film
 Evaporator-1
• Vapors generated in the 1st effect VLS (Vapour Liquid Separator) are used as heat
source in the 2nd effect. 3rd effect(finisher) is on steam. Vapours generated in the 2nd&
3rd effects VLS are condensed on shell side of Surface Condenser for Evaporator.
• The Total Solid will be obtained at the outlet of the 3rd effect evaporator. A shell &
tube type multi pass surface condenser is employed for condensing the shell side
vapors.
• The operation of the plant will be under vacuum. Vacuum will be created with the
help of a water ring vaccum pump. Cooling water from the cooling tower is used in
the surface condensers for condensing the vapors.
• Lees of 110 /day will be recycle back for Grain liquefaction section . 283 ( 168+ 74+ 42
) m3/day of Process condensate is fed to CPU unit.
• 795 m3/day treated water will return back to process for utilization in
liquefaction/fermentation/cooling tower etc. Balance Rejected 19m3 use in process for
Liquifaction section/fer.cleaning.
• Rainwater will be utilized to recharge the underground resource through scientifically
designed rainwater harvesting system.
• 4.5M3/day of boiler blow down will be sent for ash quenching.

Solid And Hazardous Waste Management

Type Of Waste Quantity Storage Utilization/ Disposal

DDGS – ( by product) 26 -27 Covered shed Sold as Cattle Feed, Poultry
TPD &Fisheries
Boiler ash 20 TPD Silo Brick making or land filling
Waste papers/Boxes 0.1 TPD Covered shed to recyclers
Used Oil <200Lt/Yr HDPE drums Given to re-cycler authorized by
in covered shed MPPCB/MoEF
Spent Resin from DM <50Kg/Yr HDPE drums Given to re-cycler authorized by
Plant in covered shed MPPCB/MoEF

Site Analysis:

• Connectivity
Location : Own land at Village Aliganj
Place : Tehsil-Bareli
District : Dist Raisen (MP)

S. No. Particulars Details

1 Project 60 KLD fuel ethanol unit with cogen plant of
1.8 MW and Co2 generation of 30 TPD
 2 Co-ordinate
S. no. Latitude Longitude
1 22°56'36.23"N 78°20'56.74"E
2 22°56'36.15"N 78°20'59.44"E
3 22°56'34.26"N 78°21'2.43"E
4 22°56'33.52"N 78°21'4.38"E
5 22°56'32.74"N 78°21'5.57"E
6 22°56'30.86"N 78°21'7.87"E
7 22°56'27.80"N 78°21'4.76"E
8 22°56'29.69"N 78°21'2.30"E
9. 22°56'29.60"N 78°21'1.60"E
10. 22°56'30.94"N 78°20'57.80"E
11. 22°56'33.82"N 78°20'55.88"E

3 Height above mean sea level 320m and Lowest elevation- 318m
4 Nearest Town Bareli – 13 km-WNW
5 Nearest Railway Station/Town Piparia Railway station – 21.00 km –S
6 Nearest Airport Raja Bhoj Airport Bhopal – 110.00 km – WNW
7 Nearest Highway/Road SH-19 – 0.50 KM – E
8 Hills/Valley None
9 Ecological Sensitive Zone None in 10 km radius
10 Reserve& protected Forest None in 10 km raidus
11 Nearest Village Deori - 0.10 km –W
12 Nearest River/ Nalla  Narmada River -2.0km-S
 Anjan River- 2.75km- SSE
 Tandoni Nadi -4.50 km- NW
 Machhawai Nala- 4.00km- WSW
 Cannel – 7.50 km- 7.50km -W
 Dudhi River – 10.0 km- ENE
 Khand Nadi – 8.75 km-ENE
 Ikyawan Nadi- 7.00km- N
 Canal -8.25km- NNW
 10. Local Nala- 7.25 km- NNW
14 Surrounding Features N- Road surrounded by Agricultural land
E- Agricultural land followed by Nalla
S- Agricultural land followed by forest
W- Waste land

• Land Form, Land use and Land Ownership

Project Proponent is having 4.359 ha of land which is possession and diverted for
industrial purposes.

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

• Existing Land use pattern

 The land use of the project area is pertaining to industrial activity only. Out of project
area is predominantly being used or agricultural purposes.

Land use Break-Up for proposed unit

Particular In sqmtrs
Built up area for plant, building and 16500
machinery
Area under road 2000
Area for Raw Material Storage 3500
Area for Fuel Storage 2500
Area for Green Belt 14500
Total 39000
Open land 4590
Total Area 43590

• Existing Infrastructure
The required infrastructure will be in place as proposed site is barren land. State
Highway is passing at 3 km from the industry.

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

• Climate data from Secondary Source:

• Meteorological data of month of 1st March, 2019 to 31st May, 2019
Relative Humidity Morning Evening
Temperature OC Cloudiness %
% 8.00 18.00
Date Wind Wind
Wind Wind
Max Avg Min Max Avg Min Spee Spee Mor Eve.
Dirt Dirt
d d
1 33 27 19 100 68 36 NNE 2 WSW 5 0 2
2 34 28 21 94 57 28 E 2 ENE 1 0 0
3 36 28 21 80 49 28 SE 2 SW 0 0 0
4 36 28 21 89 52 28 WSW 1 SSW 4 0 0
5 36 27 17 91 53 25 WSW 1 SW 3 0 2
6 36 28 20 89 54 27 SE 3 SW 3 1 4
7 36 28 21 80 48 20 S 2 SSW 4 1 4
8 36 28 20 82 42 20 SE 3 WSW 2 1 3
9 35 28 21 75 42 26 S 6 WSW 4 1 1
10 39 29 19 74 35 16 SSE 4 W 2 0 0
11 39 30 21 72 36 17 SE 2 NNW 4 0 0
12 39 31 22 92 39 16 SE 5 SSW 5 0 0
 13 33 27 21 87 57 36 NNE 2 WNW 6 1 4
14 35 28 20 85 47 20 ESE 4 SSW 1 1 2
15 33 27 21 87 58 32 ESE 3 N 3 0 2
16 35 27 19 92 48 28 NE 5 NW 3 0 2
17 37 28 20 77 45 32 SE 2 W 4 0 4
18 39 31 22 88 43 17 SSW 2 S 6 1 1
19 39 30 21 70 31 13 WNW 1 W 5 1 0
20 39 31 22 56 26 11 N 5 NNW 6 0 0
21 39 29 20 60 20 8 N 3 WNW 4 0 0
22 39 30 21 61 31 10 NNE 9 N 5 0 0
23 39 29 18 60 22 7 N 6 N 4 0 0
24 39 28 16 58 22 4 NNE 3 NNW 2 0 0
25 40 29 19 33 20 6 SSE 3 WSW 2 0 0
26 39 29 18 49 27 9 S 5 WSW 3 0 0
27 39 31 23 64 41 13 SSE 4 NNW 11 0 0
28 37 28 19 83 49 22 SSE 5 NW 2 0 0
29 41 31 22 78 42 7 S 4 WNW 2 0 0
30 41 31 22 57 37 10 S 6 SW 1 0 0
31 40 31 22 53 30 12 SSE 6 NW 2 0 0
•
• Meteorological data of 1st April, 2019 to 30th April, 2019
Relative Humidity Morning Evening
Temperature OC Cloudiness %
% 8.00 18.00
Date Wind Wind
Wind Wind
Max Avg Min Max Avg Min Spee Spee Mor Eve.
Dirt Dirt
d d
1 42 31 19 33 17 7 SSW 3 ENE 1 0 0
2 42 33 23 34 19 9 SSE 3 NNW 2 0 0
3 43 33 23 44 23 11 S 6 SSW 2 0 0
4 42 33 24 52 28 14 SSW 3 NW 8 0 0
5 41 32 24 48 30 14 S 3 SW 3 0 1
6 38 32 25 53 37 21 WNW 7 N 3 4 3
7 39 31 23 65 38 18 SW 4 SSW 4 2 4
8 41 32 23 64 30 14 ESE 2 SW 5 0 0
9 41 32 23 51 28 14 S 6 WNW 4 0 0
10 42 33 25 48 27 17 SW 5 SSW 6 0 0
11 42 33 24 47 22 14 WSW 7 NNW 2 0 0
12 42 32 23 49 23 14 N 5 W 6 0 0
13 42 32 23 43 19 11 N 11 WNW 5 0 0
14 43 33 23 46 17 7 NNE 1 WSW 3 0 0
15 44 33 22 43 18 9 NNW 1 SSW 3 0 0
16 44 34 25 35 18 9 SSW 3 SSW 4 0 0
17 44 35 26 57 21 11 SSW 6 SW 5 0 0
18 43 33 23 58 23 12 NW 6 WSW 6 2 0
19 43 35 27 49 28 10 SW 8 WSW 6 0 0
20 43 36 28 52 27 15 W 6 SW 9 0 0
21 45 36 27 44 21 12 N 5 WNW 5 0 0
22 44 36 26 38 18 11 WNW 7 W 11 0 0
23 42 34 27 46 22 14 NW 11 W 8 0 0
24 43 34 26 42 20 11 NNW 5 WSW 10 0 0
25 44 34 24 28 18 6 N 4 WSW 8 0 0
26 44 35 26 31 18 9 ENE 2 WSW 5 0 0
27 44 34 24 39 23 11 NW 3 WNW 2 0 3
28 43 34 27 49 27 13 WSW 3 W 4 3 3
29 44 36 28 42 25 12 SSW 6 WNW 3 0 2
30 45 37 28 42 22 11 S 9 SSW 5 0 3
•
• Meteorological data of 1st May, 2019 to 31st May, 2019
Relative Humidity Morning Evening Cloudiness
Temperature OC
% 8.00am 17.00pm %
Wind
Date Wind Wind Wind
Max Avg Min Max Avg Min Spee Mor Eve.
Dirt Speed Dirt
d
1 45 36 26 55 21 9 SW 5 SW 2 0 4
2 44 36 27 46 24 13 NW 6 WSW 5 0 0
3 42 33 24 55 30 13 WSW 5 WSW 6 9 0
4 42 33 24 79 42 20 SS 8 S 10 0 0
5 40 31 22 97 51 22 SSW 6 SW 6 1 0
6 37 29 21 94 51 21 SSW 6 SW 9 0 0
7 39 31 23 64 37 21 SW 5 WNW 7 0 1
8 41 32 24 68 41 20 SSW 7 SW 4 0 0
9 42 32 23 70 38 18 SSW 9 NW 12 0 1
10 40 32 24 60 34 19 S 5 W 6 1 0
11 42 34 26 45 31 16 WNW 2 WSW 5 0 0
12 44 34 26 52 31 14 WSW 8 W 4 0 0
13 45 36 27 49 26 12 SSW 7 NW 5 0 0
 14 46 36 26 44 21 12 SW 9 SSW 5 0 0
15 46 37 29 60 30 13 SW 8 SSW 6 0 0
16 45 37 28 57 27 12 SSW 9 NW 6 0 0
17 46 37 28 48 28 13 SW 10 SW 3 0 1
18 44 38 32 59 35 18 S 7 ESE 7 0 0
19 42 36 29 63 38 23 S 6 ESE 7 0 0
20 46 37 28 66 32 14 SSW 6 WSW 6 0 0
21 46 38 29 57 29 10 SSW 7 W 5 0 8
22 45 38 31 57 25 12 WNW 9 NW 5 0 4
23 45 38 32 41 26 10 WNW 9 WNW 8 0 0
24 44 38 31 46 27 7 NNW 9 WSW 5 0 0
25 44 37 31 71 29 8 NW 11 NW 9 0 0
26 43 34 25 52 31 15 NW 8 WNW 6 0 0
27 45 38 32 44 29 16 N 3 W 6 1 2
28 44 37 30 44 27 14 NW 10 W 9 0 0
29 43 36 28 50 32 17 NNW 6 SSW 5 0 0
30 43 36 28 59 34 18 W 8 WSW 9 2 3
31 43 35 27 57 34 20 NNE 4 WNW 6 1 0

• Social Infrastructure available

Social infrastructure like community center, hospital and electricity is available in
Bareli as well as in Raisen

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

iii Land use planning

As above

Amenities / facilities
• First aid facility will be provided at site.
• The area shall not being used at all by general public.
• A rest shelter will be there for workers.
• Guards during day & night shall be deputed at site to prevent unauthorized entry.
• In case of natural hazards such as earthquake we will take assistance from the local
competent authority of Govt.

• Proposed Infrastructure
The major plant & machinery required for the proposed project is as given under.
PLANTCAPACITY

Products : FuelEthanol
RatedPlantCapacity : 63,000LPDTS@94.68%v/v
60,000LPDNetEthanol@99.80%v/v
RawMaterial : BrokenRice

RAWMATERIAL

RawMaterial : BrokenRice
Starch 68%w/w
EstimatedAlcoholYiel : 460liters@95%v/vethanolcontent
d(perMTofRice)
RequirementofGrainFl : 137MT/day,approx.
our@Rice

LIQUEFACTION

LiquefiedSlurry : ~19.00m3/hr.with30%solids
Enzymeconversioneffici : 98%(Expected;DependingupontheEnz
ency ymeManufacturer)

FERMENTATION

AlcoholConcentratio : 12.5%v/v,minimum
ninFermentedWash
QuantityofFerment : 491m3/day
edWashProduced

MODEWASHTOAADISTILLATION
 PLANTCAPACITY
: 63,000LPD
 TotalSpirit
: 60,000LPD
 Ethanol
ProcessDistillation : 98.5%
&MSDHEfficiency
STEAMCONSUMPTION : 5.40TPHat3.5kg/cm2(g),(2.05Kg/lit)

EVAPORATOR (Integrated with Distillation +Steam)

Type : CombinationofFallingFilm&For
cedcirculation
ThinStillageFlow : 12.50m3/hr
WaterEvaporation : 10.83TPH
ConcentrateFlow : 1.67TPH
InitialSolidConcentration : 4.00%w/w,approx.
FinalSolidConcentration : 30.00%w/w,approx.
SteamConsumption@0.35K : 0.92TPH
g/litoftotalspirit

DDGSDRYER

 Feed : DWGS(mixtureofwetcake&syrup)

 FeedRate : 4.30TPH.
- 2.63TPHwetcake@30%w/wSolids
- 1.67TPHSyrup@30%w/wsolids
 FeedMoistureContent : 70%w/w,maximum

 ProductRate : 1.43TPH.

 ProductMoisture : 10%w/w,maximum

 Waterevaporationrate : 2.87TPH

 SteamConsumption : 3.66TPHat3.5kg/cm2(g)(1.40Kg/Lit)

CONDENSATEPOLISHINGUNIT:
 Feed&Rate : 10 m3/hr ( Boiler Blow Downs + CTBlow
Down + DM water Back wash
+Fermenterwashings+DesignMargin)

 Recovery : 80%

 Reject : 20%

 Permeatei,eProduct : 8.0m3/hr

MILLINGSECTION-18hrs

S.No. Equipment Specifications M.O.C. Qty.

1. BucketElevator#1 8.0TPH,Belt&Buckettypewit MS 1
hstandardaccessories
2. GrainCleaner 8.0TPHforremovalofimpuritie MS 1
sanddustfromgrain
3. MagneticSeparator 8.0TPHforremovalofferrousp MS 1
articlesfromgrain
4. De-stoner Vibratory;forremovalofstones MS 1
fromgrain
5. BucketElevator#2 8.0TPHBelt&Buckettypewith MS 1
standardaccessories
6. SurgeBin ConicalBottomandwithrotary MS 1
airlockvalve
7. WeighFeeder Batchweighsystemwithloadc MS 1
ells&dischargegate
8. HammerMill 8.0TPHwithaccessories MS 1+1

9. BucketElevator#3 8.0TPH,Belt&Buckettypewit MS 1
hstandardaccessories
10. BufferFlourHopper Withbinactivatorandrotaryai MS 1
rlockvalvewithVFD.Capacity:
20MT
11. Aspirationsystem Airblower,baghousewithpuls STD 1
ejetcleaner,airlockvalve,sucti
onhoods;forcontrolofdustinM
illingSection
12. Ducting Interconnecting ducting/chutes with required
slidegates/dampers/air lock valves in mild steel, as
perprocessrequirement.
13. Electrical MCCwithswitchgearandcablingforallelectricaldriveswithi
nthebatterylimits.
14. Instrumentation Instrumentsforlocaldisplayandelectronicfieldinstrument
s

LIQUEFACTION

SN Equipment Specifications M.O.C. Qty.

1. Pre-masher Ribbonmixerwithpaddles SS304 1

2. MashTank 20.0m3;ConicalBottom SS304 1

3. MashTankAgitator TopenteringHighShearMixer SS304 1

4. CookerFeedPump 25m3/hr;Centrifugal SS304 1+1

5. JetCooker 25m3/hr;withactuatorforsteamflo SS316 1

wregulation

6. RetentionVessel HighPressureVesselforprovidingreq SS304 1

uiredresidencetimeforheatedgrain
mash

7. FlashVessel 4.0 m3; Dish top & Bottom SS304 1

forflashingtheheatedgrainmash

8. VentCondenser Shell&TubeHeatExchanger SS304 1

9. HotWaterTank 20m3 MS 1

10. HotWaterPump 20m3/hr;Centrifugal CI 1+1

11. LiquefactionTank 35.0m3;ConicalBottom SS304 1

12. LiquefactionTankAgi TopenteringDoublepaddlehighshea SS304 1

tator rmixer

13. MashCoolerPump 25m3/hr;Centrifugal SS304 1+1

14. MashCoolers FreeFlowWideGapPlateHeatExcha SS316 2+2
ngers

15. Enzyme Tank Dosing Tank HDPE 1

16. Enzyme Pumps Dosing Pump PP 2+1

17. Lime/Caustic Tank with agitator SS 304 1

18. Piping,Fittings&Valv Interconnectingpipingwithvalves/fittingsinMS/SS-

es 304,asperprocessrequirement.

19. Insulation Insulationonhotsurfaceswithmineralwoolandcladwithalu

minumsheet,asrequired.

20. Electrical MCCwithswitchgearandcablingforallelectricaldriveswithin

thebatterylimits.

21. Instrumentation Instrumentsforlocaldisplayandelectronicfieldinstruments

linkedtothePLCSystem

PREFERMENTATION

Sr. Equipment Specifications M.O.C. Qty.

No.
1. Pre-fermenters 70m3;conicalbottomwith MS+ 2
light/sightglass,manhole,CIPnozzle,airspa Epoxy
rger,etc.
2. Pre- 50m3/hr;Centrifugalwithopenimpeller SS304 2
fermenterCircul
ationPump
3. Pre- WideGapFreeFlowTypePlateHeatExchange SS316 2
fermenterCooler rs Plates
4. Pre- Pressure Jet Type Rotating SS304 2
fermenterCleane TankCleaningNozzleconnectedtoCIP
r
5. AirBlower WithHEPAfiltersforsuctionandotheraccess CI 1+1
ories
6. Piping,Fittings& Interconnectingpipingwithvalves/fittingsinMS/SS-
Valves 304,asperprocessrequirement.
7. Electrical MCCwithswitchgearandcablingforallelectricaldriveswithinth
ebatterylimits.
8. Instrumentation InstrumentsforLocalDisplayandElectronicFieldInstrumentsl
inkedtothePLCSystem.

FERMENTATION

Sr. Equipment Specifications M.O.C. Qty.

No.

1. Fermenters 500m3;withlight/sightglass,man MS+ 3

holes, CIP nozzle, safetysystem Epoxy
2. FermenterCoolers FreeFlowWideGapPlateHeatExcha Plates:SS 3
nger 316

3. Fermenter Re- 350m3/hr;Centrifugal SS304 3

CirculationPumps

4. FermenterCleaners PressureJetTypeRotatingTankCle SS304 3

aning Nozzle connected
toCIPSystem

5. CO2Scrubber VentGasScrubbingColumnwithSi SS304 1

eveTrays

6. AntifoamTank 3.0m3;Tank MS 1

7. AntifoamPump 3.0m3/hr;Centrifugal CI 1+1

8. Beerwell 500m3;ConicalBottom MS 1

9. BeerFeedPump 40m3/hr;Centrifugal SS304 1+1

10. Piping,Fittings&Va Interconnectingpipingwithvalves/fittingsinMS/SS-

lves 304,asperprocessrequirement.

11. Electrical MCCwithcablingandswitchgearforalldriveswithinbat

tery limits.

12. Instrumentation Instrumentsforlocaldisplayandelectronicfieldinstru

mentslinkedtothePLCSystem

DISTILLATION

Sr. Equipment Specifications M.O.C. Qty. Remarks

No.
1. DegassingColumn(u TrayType:SieveNo.ofTra SS304 1
ndervacuum) ys:7
2. Beer TrayType:SieveNo.ofTra SS304 1
StripperColumn ys:21
(undervacuum)
3. Pre- TrayType:Sievetrays SS-304 1
RectificationColumn No.ofTrays:72
(underPressure)
4. VentScrubber TrayType:SieveTrays SS304 1
No.ofTrays:10

5. Beer ThermosiphonShell&Tu SS304 1+1

StripperColumnReb beExchanger
oiler
6. RectificationColum Thermosyphon SS304 1
nReboiler Shell&TubeExchanger
7. DegassingMainCon Shell&TubeHeatExcha SS304 1
denser nger

8. Degassing Shell&TubeHeatExcha SS304 1

VentCondenser nger
9. Analyser Shell&TubeHeatExcha SS304 1
VentCondenser nger
10 RectificationVentCo Shell&TubeHeatExcha SS304 1
ndenser nger

11. RS Cooler Shell & Tube Heat SS 304 1

Exchanger
12. Impure Spirit Shell and Tube Heat SS 304 1
Cooler Exchanger
13. Fuel Oil Cooler Shell and Tube Heat SS 304 1
Exchanger
14. Rectifier Feed Plate Heat Exchanger SS 316 + 1
Preheater IS2062
15. Fermented wash Plate Heat Exchanger SS 316 1+1
preheater + IS2062
16. Fuel Oil Decanter With light and sight SS 304 1
glasses
17. Rectifier Feed Tank Cylindrical with Dished SS 304 1
ends
18. Rectification Cylindrical with dished SS 304 1
Column Reflux ends
Tank
19. Steam Condensate Cylindrical with dished MS 1
Tank ends
20. CIP Tank 20 m3, vertical type SS 304 1
21. CIP Pumps 20 m3/hr, Centrifugal SS 304 1+1
22. Spent Wash Centrifugal pump with SS 304 1+1
Circulation Pump flameproof electric
motor
23. Spent Wash Centrifugal pump with SS 304 1+1
transfer Pump flameproof electric
motor
24. Rectification Centrifugal pump with SS 304 1+1
Column Feed Pump flameproof electric
motor
25. Rectification Centrifugal pump with SS 304 1+1
Column Lees Pump flameproof electric
motor
26. Gas Liquid Cylindrical SS 304 1
Separator

27. Rectification Centrifugal pump with SS 304 1+1

Column Reflux flameproof electric
Pump motor
28. Steam Condensate Centrifugal pump with CI 1+1
Pump flameproof electric
motor
29. Vacuum Pump Water ring vacuum CI/SS 1+1
Pump 304
30. Piping,Fittings&Val Interconnecting piping withvalves/fittingsinMS/SS-
ves 304,asperprocessrequirement.

31. Insulation Insulationonhotsurfaceswithmineralwoolandcladwithal

uminumsheet,asrequired.
32. Electrical MCC with switchgear and cabling for
allelectricaldriveswithinthebatterylimits.
33. Instrumentation Instruments for local display
andelectronicfieldinstrumentslinkedtothePLC

MSDHPLANT:VAPOURBASEDSYSTEM
Sr. Equipment Specifications M.O.C. Qty. Remarks
No.

1. Superheater Shell&TubeHeatExchanger SS-304 1

2. MolecularSieveV Pressure vessel SS-304 2

essels withbedofmolecularsievebea
ds and ceramicsupportballs
3. ProductCondens Shell&TubeHeatExchanger SS-304 1
er
4. ProductCooler Shell&TubeHeatExchanger SS-304 1

5. ProductTank Dishedtop&bottom SS-304 1

6. ProductPump CentrifugalPumpwithflamep SS304 1+1

roof electricmotor
7. RegenerationCo Shell&TubeHeatExchanger SS-304 1
ndenser

8. SealCooler PHE SS316 1

Remarks
Sr. Equipment Specifications M.O.C. Qty.
No.
9. Regeneration Dished top & bottom SS-304 1
Tank
10. Vacuum Pump Liquid Ring vacuum pump SS- 1+1
304/CI
11. Separator Tank Knockout Drum for vacuum MS 1
pump
12. Regeneration Centrifugal Pump with SS 304 1+1
Pump flameproof electric motor
13. Vacuum seal Centrifugal pump SS 304 1+1
pump
Inter connecting piping with valves/fittings in carbon
14. Piping,Fittings&
steel/SS-304
Valves
Insulation on hot surfaces with mineral woodland clad with
15. Insulation
aluminum sheet

Instruments for local display and electronic field

16. Instrumentation
instruments linked to PLC Panel.
 MCC, cabling and switch gear for all drives
17. Electrical

INTEGRATEDEVAPORATOR(HeatedbyAlcoholVapors&Steam)

Sr. Equipment Specifications M.O.C. Qty. Remarks

No.
1. FeedBufferTank Conical SS-304 1

2. FeedPump Centrifugal SS-304 1+1

3. Evaporators Falling SS-304 5

FilmEvaporators
4. Evaporator ForcedCirculationE SS-304 1
vaporator
5. VaporSeparator Withsight/lightglas SS-304 6
sassembly
6. CirculationPump CentrifugalPumpwit SS-304 6
s hFPmotor
7. ProcessCondensa SS-304 1
teVessel
8. ProcessCondensa Centrifugalpumpwit SS-304 1+1
tePump hFPmotor
9. SurfaceCondens Shell&TubeType SS-304 1
er
10. Syruptank Cylindrical SS-304 1
11. Syruppump Centrifugalpumpwit SS-304 1+1
hFPmotor
12. Sealwatertank 1.0m3 SS-304 1

13. Sealwaterpump Centrifugal SS304 1

14. SealwaterPHE PHE SS316 1

Sr No Equipment Specifications M.O.C. Qty. Remarks

15. Vacuum pump PHE SS 316 1

Seal Cooler
16. Vacuum Pump Water ring vacuum CI/SS 1+1
Pump with FP 304
motor
17. Ducts, Interconnecting vapor ducts, piping
Piping,Fittings& withvalves/fittingsinMS/SS-
Valves 304,asperprocessrequirement.
18. Insulation Insulationonhotsurfaceswithmineralw
oolandcladwithaluminumsheet,asreq
uired.
19. Electrical MCC with switchgear and cabling for
allelectricaldriveswithinthebatterylimi
ts.
20. Instrumentation Instrumentsforlocaldisplayandelectro
nicfieldinstrumentslinkedtothePLC

DECANTATION

Sr.No. Equipment Specifications M.O.C. Qty.

1. SpentWashTank ConicalBottom@1hou SS304 1

rRetention
2. SpentWashTankAgita TopenteringDoublepa SS304 1
tor ddle
3. DecanterFeedPump Centrifugal SS304 1+1
4. Decanter Standard SS-304 1+1
5. ThinStillageTank ConicalBottom@1hou SS304 1
rRetention
6. ThinStillageTransferP Centrifugal SS304 1+1
ump
7. Piping,Fittings&Valve Interconnectingpipingwithvalves/fittingsi
s nMS/SS-304,asperprocessrequirement.
8. Electrical MCCwithswitchgearandcablingforallelect
ricaldriveswithinthebatterylimits.
9. Instrumentation Instrumentsforlocaldisplayandelectronicf
ieldinstrumentslinkedtothePLCSystem

DDGSDRYER

Sr.No Equipment Specifications M.O.C. Qty

.
1. PaddleMixer Formixingwetcake,thickslop SS304 1
sandrecycledDDGS
2. ScrewFeeder TwinscrewfeederwithVFDfor SS304 1
feedingDWGStodryer
3. Dryershell(fixed) “U”Typefixedshellwithvapou Dish End:MS 1
rhood for collecting
Shell: SS304
andexhaustingwatervapours

4. SteamTubeBundl Tubes(ERW)withbafflesandS Tubes:SS30 1

e(Rotating) S304 lined tube 4
withRotaryJoint sheets,Trunions,lifters,etc.
HTA:750.0m2
5. ProductChute With rotary valve for SS304 1
thedischargeofdriedproduct
6. Back mixing Suitableconveyingsystemas MS 1
withsieving&crus perlayout for recycling of
hersystem driedproducttopaddlemixer
7. DriveMechanism Electricmotor,gearboxandsp STD 1
urgear/pinionforrotatingthe
dryerwithsphericalrollerbear
ings.
8. Induceddraftfan VbeltdrivenCentrifugalFanw SS304 1
ithelectricmotor
9. ProductCooler PneumaticType SS304 1
10. Interconnectingdu Interconnectingductingwithre MS/SS-304 Lot
cting gulators/dampers
11. Cycloneseparator Forseparationoffineparticles SS304 As
&rotaryvalve ofDDGS & continuous perrequireme
discharge ofthefines. nt @twosets

12. PLC PLCbasedwith

basedInstrumenta
a. VFD–Steamtubebundle&IDFan
tion b. Steamcontrolloopforsteamflow
c. FlowTransmitterforSyrup
d. PG&TGasperrequirement
e. Temperatureindicator/controllersetc.withproperinterlock
sandsafetyofdryersystem.

DDGSSTORAGE&BAGGING:

Sr.No Equipment Specifications M.O.C. Qty.

.
1. DiversionChuteforsilo Asperprocessrequirem SS304 1
ent
 2. Silo 6MT MS 1

3. RotaryValve Standard SS304 1

4. Semi- Suitable SS304/MS 1No

AutomaticBaggingsyst
em
5. MCCPanel&Cablingto Standardwithswitchge Panel:CRCA Lot
motors arforallelectricaldrives.
Cables:
Asperrequiremen
t
6. Instrumentation

Onoffvalveforsilo 1Nos

Levelswitchforsilos 1Nos

Baggingsystem As
perstandard
s

CONDENSATEPOLISHINGUNIT:

a. PreTreatment:ChemicalandFlocculationChamber
b. RO:Twostage
c. Filtration:ACF&MGF
d. Piping&valves
e. Electrical
f. Instrumentation

COOLINGWATER&ALLIEDSYSTEM:

S. Equipment Specifications M.O.C. Qty.

No.

1. Cooling Tower 500m3/hr. Wood 1

forLiquefaction,Distillation
DeltaT=8deg.C
&Integrated
Evaporationsection
 2. CoolingTowerpumpsforliqu 500m3/hr. C.I 1+1
efaction,Distillation&Integr
ated Evaporationsection

3. Cooling Tower 600m3/hr. Wood 1

forFermentationsection
DeltaT=2deg.C

4. CoolingTowerpumpsforfer 600m3/hr. C.I 1+1

mentationsection

5. Piping&Valves Standard C.I Lot

6. Electricals Standard As
&Instrumentation perrequiremen Lot
t
7. Instrument AirCompressor 75Nm3/hr Standard 1+1

PRODUCTSTORAGESECTION:

S.No. Equipment Specification M.O.C. Qt

s y
1. AAReceiver 66.0m3 MS 3
2. AABulkStoragetank 1000.0m3 MS 2
3. Issuetank 15.0m3 MS 1
4. Denaturanttank 10.0m3 MS 1
5. Vent Condensers for STHE SS304 4
allReceiver&Bulkstorageta
nks
6. FlameArrestorforallstor Standard 4
agetanks
7. PDflowmeters Standard 2
8. Transferpumps 20m3/hr SS304 4
9. Piping,Fittings&Valves Interconnectingvaporducts,pipingwithv
alves/fittings in MS/ SS-304, as per
processrequirement.
10 Electrical CablingfromMCCtomotors.
.
11 Instrumentation Instrumentsforlocaldisplayandelectron
. icfieldinstrumentslinkedtotheJBSyste
m
 BOILER&ACCESSORIES:

o Fuel:RiceHusk
o Capacity:15TPH
o Pressure:45.0Kg/Cm2(g)
o Items:
 Mainboiler
 FuelHandling&conveying/feeding
 AshHandlingSystem
 ElectricalControlpanelforBoilersection

TURBINE&ACCESSORIES:

o Capacity:1.25MWhr
o Backpressure:4.0Kg/cm2(g)
o Items:
o Mainturbine
o Alternatoralongwithitsaccessories
o Oilcleaningandcoolingsystem
o Coolingtower&Coolingwaterpiping
o RelatedutilitiesforTurbinehouse

WATERTREATMENTPLANT:
WaterTreatmentPlantIncludesfollowingsections:
1. SofteningplantforCoolingtowermakeupforvarioussectionsasperrequire
ment
2. DMwaterplantforsteamgenerationforvarioussectionsn
3. Processwaterforthefermentationsection
4. Pump & respective MS piping for process ,soft &DM water as per
requirement.

ELECTRICALSYSTEM:
 PowercontrolCentre(PCC)
 PCCtoMCCcabling
  Synchronizationpanel
 DGSet500KVA-1No

FIREFIGHTINGSYSTEM
FiresafetysystemforthedistilleryplantwhichwillincludesectionslikeFermentat
ion, Distillation, alcohol Receiving Storage Section & othersections
wherever it is necessary. Fire safety systems will have
FireFightingSystemandFireAlarmSystem.

 FireFightingSystemshallcompriseofthefollowing:
 SingleHydrant
 Hosewithbranchpipeandhosebox
 Firepumpset withelectricalandstand
byDieselEnginedrivenpumpalongwithJockeypumpandcontrolpanelet
c.
 Pipingaccessories,fittings,valves–MSpiping
 PortablefireextinguishersDCP/ABC/CO2
 Watercumfoammonitor

INTERCONNECTIONSSYSTEM:

 FordistributionofPowerfromPCCtovariousMCC’s
 ForwaterfromWTPplanttovarioussections
 Forsteamcondensatefromoutletofthepumpsatrespectivesectionstotheboiler

ii Residential area (Non Processing area)

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

iii Greenbelt
Approx 1.45 ha area shall be covered with the good green belt in next 02 years of
time.

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

v Connectivity
 Site is well connected with by State Highway, which is 0.5 km away from proposed
site

vi Drinking water management

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

vii Sewerage System

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

viii Industrial waste management

As described earlier.

ix Solid waste management

As described earlier.

x Power Requirement and supply / source

As described earlier.

7.0 Rehabilitation & Resettlement Plan

No R & R plan is required.

• Project Schedule and Cost estimate

• Likely date of start of construction and likely date of completion
After obtaining environmental clearance and water / air consent the company shall
start the project. Proposed date shall be December 2021 (subject to clearances).

• Estimated project cost along with analysis in terms of economic viability of the
project

Estimated Investment:

Estimated Investmentfor Design, Engineering, Manufacture, Supply,Erection and

Supervision of commissioning For 60 KLPD of total spirit (Grain Based ) Plant as per
the sections mentioned below are as follows:
S. N Particulars Value in INR
Lakhs
PART A – MAIN DISTILLERY PROCESS BLOCK
Liquefaction Section :
Consisting of SS 304 Liquefaction tanks, Jet cooker along with Site
1. fabricated, Shop Fabricated, Bought outs, Piping & Valves,
Electrical & Instrumentation
Fermentation Section
Consisting of MS Epoxy Fermenters – 3 No’s, MS Epoxy Pre-
2. fermenters, MS Epoxy Beer Well – 1 No, Site fabricated, Shop
Fabricated, Bought outs, Piping & Valves, Electrical &
 Instrumentation.

Multi Pressure Distillation (Wash to RS) & MSDH Section

Consist of shop fabricated Distillation Columns along with Re-
3. boilers, Heat Exchangers, Coolers, Condensers, Site fabricated,
shop fabricated, Bought outs, piping & valves, Electricals &
instrumentation
2880.00
Integrated Evaporation Section
Consist of FF evaporator Calendria, FC Forced Circulation
4. Evaporators, along with VLS, Surface Condenser, Site fabricated,
shop fabricated, Bought outs, piping & valves, Electricals &
instrumentation etc.
Dryer Section + Decantation excluding Decanters
5. Drier along with Site fabricated, shop fabricated, Bought outs,
piping & valves, Electricals & instrumentation etc.
Process Condensate Treatment Section – To treat Process
condensate + C/T blow down
6. Consist of RO system along with pumps, tanks, piping and valves,
electrical & Instrumentation etc.
Alcohol Storage Auxiliaries:
7. Necessary condensers Bought out Items, Instrumentation, and
MCC onwards Electricals, Piping and valves etc.
Utility Section
8. Cooling Towers, Air compressor along with pumps, Piping, valves,
electrical & Instrumentation etc.
Installation of the above sections shall be carried out by M/s Praj
9. Engineering & Infra Ltd. Pune, a wholly owned subsidiary
company of PRAJ.
10. Civil Design & Engineering of for Praj’s scope of section only.
11. Pre Order services for part B

TOTAL FOR PART (A) 2880.00

PART B Value in INR
Lakhs
Alcohol Storage Section (Only Tank Farms):30 Days
Inclusive of MS Daily Receivers – 70 m3 x 3 no’s, MS Bulk Storage
1 for AA 900 m3 x 2 no’s, RS feed tank – 70 m3 x 1 No, RS storage –
700 m3 x 1 No
Structural Works:
2 Design, Engineering, Supply & Erection of structural work for
Praj’s scope of sections as specified in process block above.
 Grain storage, handling, cleaning and milling and Flour storage
:
3 Consisting of Grain storage silos (15 days) – 2500 MT x 1 nos., pre
cleaners, Local Hammer Mills 10 TPH - 2 nos., Flour storage silo,
dust extraction systems, elevators, conveyors, Piping & Valves,
Electrical & Instrumentation
4 Decantation –
Consist of Decanters – SS 304 Internals - 3 nos.(2W+1S)
Boiler with Accessories including structure – Uttam / 3150.00
5 Equivalent make Turbine with Accessories – Triveni
/Equivalent make
18 TPH with Ash handling, Fuel handling & pollution control
accessories & 1.8 MW Back Pressure Turbine with all auxiliaries,
HP/LP piping, PRDS
Plant Electrical Up to MCC inlet
Bus Duct Alternator to Breaker Panel , PCC, PCC to MCC cabling -
6 Max dist. 100 Mt
DG set for emergency Power
Plant Lighting
WTP Section:
7 Inclusive of site Fabricated, shop Fabricated, Bought out Items,
Instrumentation and MCC onwards Electricals, Piping and valves
as per specifications.
8 Fire Fighting – As per TEC/IS guidelines
9 Lab Equipment
10 Weigh Bridge
11 Packing & Forwarding, Loading & Unloading etc.
TOTAL FOR PART (B) 3150.00
GRAND TOTAL FOR (A + B) – Rupees Sixty Crore and Thirty 6030.00
lacs only/-

9.0 Analysis of Proposal (Final Recommendation)

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