Proposed 150 KLPD Molasses/Grain based Distillery along with 7.0 MW Co-generation power plant & 10 KLPD Malt Spirit Plant
within existing non-operational Distillery Plant
At Village Satrod Khas, Tehsil & District Hisar, Haryana
Pre - Feasibility Report
Associated Distilleries (A Unit of Globus Spirits Limited) 1
PRE - FEASIBILITY REPORT
1.0 EXECUTIVE SUMMARY:
(I) Introduction
Associated Distilleries (A Unit of Globus Spirits Limited) installed 25 KLPD distillery and IMFL/CL
Bottling Plant at Village Satrod Khas, Tehsil & District Hisar, Haryana.
Presently, the distillery unit is non- operational and only IMFL/CL bottling is being carried out in
the plant. 25 KLPD distillery plant was commercially non- viable so the company suspended its
operation. But now because of the increasing demand of ethanol in Indian market, the company
intends to restart the plant operations and is thus proposing 150 KLPD grain/ molasses based
distillery along with 7 MW Co-generation power plant & 10 KLPD Malt Spirit Plant within existing
plant premises. The old redundant machinery will be replaced with the new one.
In view of above, the company is proposing 150 KLPD Molasses/Grain based Distillery along with
7.0 MW Co-generation power plant & 10 KLPD Malt Spirit Plant within existing non-operational
Distillery Plant at Village Satrod Khas, Tehsil & District Hisar, Haryana.
As per EIA Notification dated 14th
September, 2006 and subsequent amendments, the project falls
under Category “A”, Project or Activity 5(g).
TABLE – 1
Salient Features of the Project
S. NO. PARTICULARS DETAILS
A Nature & Size of the Project Proposed 150 KLPD Molasses/Grain based Distillery along with 7.0
MW Co-generation power plant & 10 KLPD Malt Spirit Plant within
existing non-operational Distillery Plant
B Category of the Project As per EIA Notification dated 14th
Sep., 2006 and subsequent
amendments; the project falls in Category ‘A’, Project or Activity - 5(g)
Distilleries.
C Location Details
Village Satrod Khas
Tehsil Hisar
District Hisar
State Haryana
Latitude 29008’08.79’’ N to 29
008’17.71’’ N
Longitude 75047’41.78’’ E to 75
048’00.27’’ E
Toposheet H43P16 and H43P12
D Area Details
Proposed 150 KLPD Molasses/Grain based Distillery along with 7.0 MW Co-generation power plant & 10 KLPD Malt Spirit Plant
within existing non-operational Distillery Plant
At Village Satrod Khas, Tehsil & District Hisar, Haryana
Pre - Feasibility Report
Associated Distilleries (A Unit of Globus Spirits Limited) 2
Total Plant Area o Existing plant area: 8.0 hectares (19.77 Acres)
o No additional land is required for the project, as the same will be
done within the existing non-operational Distillery Plant.
Greenbelt / Plantation Area 2.64 hectares i.e. 33% of the total plant area has already been
developed as greenbelt & plantation
E Environmental Setting Details (with approximate aerial distance & direction from plant site)
1. Nearest Village Satrod Khas (1 km in SW direction)
2. Nearest City Hisar (4.5 km in West direction)
3. Nearest National Highway /
State Highway
• NH 10 (Adjacent in SW direction)
• NH 65 (7.2 km in West direction)
4. Nearest Railway station Hisar (7 km in West direction)
5. Nearest Airport New Delhi (142 km in SE direction)
6. Reserved Forest (RF)/ Protected
Forest (PF)
Bir Hisar PF (5.0 km in NW direction)
7. National Parks, Reserved Forests
(RF)/ Protected Forests (PF),
Wildlife Sanctuaries, Biosphere
Reserves, Tiger/ Elephant
Reserves, Wildlife Corridors etc.
within 10 km radius
No National Parks, Wildlife Sanctuaries, Biosphere Reserves, Tiger/
Elephant Reserves, Wildlife Corridors etc. lies within 10 km radius of
the plant site.
8. Water Body (within 10 km
radius)
• Balsamand Sub Branch (Bhakra Canal) (Adjacent in East direction)
• Hisar Major Distributary (Western Yamuna Canal) (Adjacent in North direction)
• Dewa Distributary (~ 1.5 km in South direction)
• Petwar Distributary (~ 4.0 km in South direction)
Few minor agricultural canals are also present in 10 km radius area
F Cost Details
Total cost of the project Rs. 125 Crores
Cost for Environment
Management Plan
Capital Cost: Rs. 40 Crores
Recurring Cost: Rs. 4.0 Crores/annum
G Basic Requirements for the project 150 KLPD Distillery Plant
Water Requirement (KLD) 1450 KLPD (1350 KLPD Distillery + 80 KLPD Malt Spirit Plant + 15
KLPD Bottling Plant + Domestic 5 KLPD)
Source: Surface water (Canal water) /ground water
Proposed 150 KLPD Molasses/Grain based Distillery along with 7.0 MW Co-generation power plant & 10 KLPD Malt Spirit Plant
within existing non-operational Distillery Plant
At Village Satrod Khas, Tehsil & District Hisar, Haryana
Pre - Feasibility Report
Associated Distilleries (A Unit of Globus Spirits Limited) 3
Power Requirement (MW) 4.5 MW
Source: 7 MW Co-generation power plant
Man Power Requirement Regular Basis - 100 & Contract Basis - 200
Source: Unskilled/Semi-Skilled - local area; Skilled–Local & outside
areas
H Product Mix Ethanol / Extra Neutral Alcohol (ENA) / Rectified Spirit (RS) & Power
I By-products During Molasses based operation - CO2
During Grain based operation - DDGS and CO2
J Working Days 365 days/annum
1.1 ENVIRONMENT MANAGEMENT PLAN
Air Management:
� ESP/Bag Filter with stack of adequate height will be installed with the boiler to control the
particulate and gaseous emissions due to combustion of fuel.
� CO2 generated during the fermentation process will be collected by utilizing CO2 scrubbers
and sold to authorized vendors
� Roads within the plant will be concreted to control the fugitive emissions.
� Greenbelt around the periphery and within premises will be maintained.
� Online Stack Monitoring system will be installed.
� Ambient air quality will be regularly monitored to ensure that ambient air quality standards
and suggested limits are maintained.
Water Management:
� The distillery will be based on “Zero Effluent Discharge”.
� During Molasses Based Operation: The spent wash will be concentrated in MEE and the
concentrated spent wash will be mixed with auxiliary fuel and burnt in the incinerator boiler.
Process Condensate will be neutralized and treated in state of art Condensate Polishing
Unit (CPU) and recycled in Fermentation process and for Cooling Tower makeup.
� During Grain Based Operation: Grain Slops (Spent Wash) will be passed through centrifuge
decanters for separation of suspended solids separated as Wet Cake (also known as DWG –
Distillers Wet Grains). Thin Slops from the Decanter Centrifuge will be partly recycled back
to process (20% to 35%) and the balance will be fed to Thin Slop Evaporation Plant for
concentration of remaining solids to form Syrup (35% TS). DWGS Drier: The Wet Cake and
Syrup mixture (DWGS) will be dried in Steam Tube Bundle Dryer for producing DDGS with
8-10% moisture (max.). The DDGS will be utilized as Cattle, poultry and fish feed
ingredients. The process condensate will be treated in condensate treatment plant. The
Proposed 150 KLPD Molasses/Grain based Distillery along with 7.0 MW Co-generation power plant & 10 KLPD Malt Spirit Plant
within existing non-operational Distillery Plant
At Village Satrod Khas, Tehsil & District Hisar, Haryana
Pre - Feasibility Report
Associated Distilleries (A Unit of Globus Spirits Limited) 4
treated water will be recycled back in cooling tower makeup.
� Domestic waste water generated from the plant will be treated in STP.
� Rain Water harvesting will be done within the plant premises.
Noise Management:
� Personal Protective Equipment like earplugs and earmuffs will be provided to the workers
exposed to high noise level.
� D.G. sets will be provided with acoustic to control the noise level within the prescribed limit.
� Proper maintenance, oiling and greasing of machines at regular intervals will be done to
reduce generation of noise.
� Greenbelt of appropriate width inside the plant premises and at the plant boundary will be
developed.
� Regular monitoring of noise level will be carried out and corrective measures in concerned
machinery are also being done.
Solid Waste Management
� During Molasses based operation: The concentrated spent wash from molasses based
distillery will be burnt in incinerator boiler along with Biomass as fuel (15% coal will also be
used as auxiliary fuel).
� During Grain based operation: 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. Yeast sludge will be sent to the sludge drying beds or may be added to the wet cake.
� Ash from the boiler will be given to brick or cement manufacturing unit.
� ETP sludge will be dewatered using filter press and will be used as manure.
� Used oil & grease generated from plant machinery/gear boxes as hazardous waste will be
sold out to the CPCB authorized recyclers.
Odour Management
� Adequate greenbelt all around the periphery of the plant.
� Efficient CO2 scrubbing to avoid carryover of alcohol vapours & other fumes.
� DWGS dryer will be installed for complete drying of solids.
� Better housekeeping, hygienic conditions will be maintained inside as well as surrounding
areas of the plant.
� Regular use of disinfectants in the drains to avoid generation of putrefying micro-
organisms.
Greenbelt Development / Plantation:
� 2.64 hectares, i.e. ~33% of the plant area is already covered under greenbelt & plantation.
� Greenbelt development in and around the plant site helps to attenuate the pollution level.
� Greenbelt has been developed as per Central Pollution Control Board (CPCB) guidelines.
� Native species have been planted in consultation with the local DFO.
Proposed 150 KLPD Molasses/Grain based Distillery along with 7.0 MW Co-generation power plant & 10 KLPD Malt Spirit Plant
within existing non-operational Distillery Plant
At Village Satrod Khas, Tehsil & District Hisar, Haryana
Pre - Feasibility Report
Associated Distilleries (A Unit of Globus Spirits Limited) 5
2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION:
(i) Identification of Project and Project Proponent:
Globus Spirits Limited has enjoyed a good track record in the business of manufacture, marketing
and sale of Indian Made Foreign Liquor (IMFL), Industrial Alcohol comprising Rectified Spirit &
Extra –Neutral Alcohol and Country Liquor.
The company has 5 distillery industries which are situated in the states of Haryana, Rajasthan,
Bihar and West Bengal. Headquarter of the Globus Spirits Limited is situated in Delhi, the
company markets its own IMFL brands in North Indian states of Rajasthan, Haryana and Uttar
Pradesh and also in union territory of Chandigarh. Company also proposes to launch IMFL brands
in three more states in North India. In South India it is already selling in Kerala, Andhra Pradesh
and Karnataka. The company also has an extensive brand portfolio of its own brands in the
country liquor segment.
Given the new Bio-fuels policy of the government of India, there’s a huge surge in demand for
ETHANOL/ Alcohol in the country. The current capacity is not sufficient to meet this growing
demand in order to meet the ETHANOL targets for blending in petrol as per this policy. Hence we
decided to expand our capacity in order to meet this growing demand. This in turn will help
towards meeting the ETHANOL targets as set by the GOI & will also help provide in increased
employment & investment in the state of Haryana. Please provide us Company details
(ii) Brief description of Nature of the Project:
Associated Distilleries (A Unit of Globus Spirits Limited) has installed 25 KLPD distillery and
IMFL/CL Bottling Plant at Village Satrod Khas, Tehsil & District Hisar, Haryana.
Presently, the distillery unit is non- operational and only IMFL/CL bottling is being carried out in
the plant. 25 KLPD distillery plant was commercially non- viable so the company suspended its
operation. But now because of the increasing demand of Ethanol in Indian market, the company
intends to restart the plant operations and is thus proposing 150 KLPD grain/ molasses based
distillery along with 7 MW Co-generation power plant within existing plant premises. The old
redundant machinery will be replaced with the new one.
In view of above, the company is proposing 150 KLPD Molasses/Grain based Distillery along with
7.0 MW Co-generation power plant & 10 KLPD Malt Spirit Plant within existing non-operational
Distillery Plant at Village Satrod Khas, Tehsil & District Hisar, Haryana
As per EIA Notification dated 14th
September, 2006 and as amended from time to time, the
project falls under Category “A”, Project or Activity 5(g).
(ii) Need for the Project and its Importance to the Country and/ or Region:
Govt. of India has mandated 10% blending of Ethanol in Petrol by 2022 so as to reduce
dependence on imported Crude Oil and to provide a cleaner fuel. The project will help fulfilling
the demand for ETHANOL. In addition it will provide for employment & investment in the state of
UP.
Proposed 150 KLPD Molasses/Grain based Distillery along with 7.0 MW Co-generation power plant & 10 KLPD Malt Spirit Plant
within existing non-operational Distillery Plant
At Village Satrod Khas, Tehsil & District Hisar, Haryana
Pre - Feasibility Report
Associated Distilleries (A Unit of Globus Spirits Limited) 6
(iii) Demand- Supply Gap:
The total demand for alcohol in India is as follows
Current in bulk liters (BL) 2022 projected in bulk liters (BL)
Ethanol 330 cr 450 cr
Beverage alcohol 200 cr 250 cr
Industrial alcohol 70 cr 90 cr
TOTAL 600 cr 790 cr
The total demand for alcohol in India is expected to grow from 600 crore bulk liters currently to
790 crore bulk liters by 2022. The current installed capacity is 600 cr liter. Therefore capacity of
another 190 crore bulk liters is required to be set up in the next 3-4 years to meet the rapidly
increasing demand.
(iv) Import vs. Indigenous Production:
India is one of the largest importers of crude oil. The indigenous production of ethanol for
blending in petrol will substitute this imported crude oil.
(v) Export Possibility:
Currently India exports 7.5 Cr Bulk liters of ENA to various countries. As this project can also make
good export quality ENA the same can too be exported to countries in east and west Africa such
as Nigeria, Ghana, Angola, Camaroon, Congo, Kenya, Uganda, Zambia, Sierra Leone, Rwanda,
Tanzania, Togo and Liberia. Also export possibilities of ENA exist to Middle Eastern countries such
as Lebanon, Jordon and Turkey.
(vi) Employment Generation (Direct and Indirect) due to the project:
Direct and indirect employment will be generated due to the project. The total manpower
requirement for the project will be 100 persons on regular basis and 200 persons on contract
basis. Unskilled / semi-skilled manpower will be sourced from the local area and skilled
manpower will be sourced from outside / local.
3.0 PROJECT DESCRIPTION:
(i) Type of Project including interlinked and independent projects, if any.
There are no interlinked projects related to this proposed project.
(ii) Location (map showing general location, specific location, and plant boundary &
plant site layout) with coordinates
Proposed 150 KLPD Molasses/Grain based Distillery along with 7.0 MW Co-generation power plant & 10 KLPD Malt Spirit Plant
within existing non-operational Distillery Plant
At Village Satrod Khas, Tehsil & District Hisar, Haryana
Pre - Feasibility Report
Associated Distilleries (A Unit of Globus Spirits Limited) 7
Figure - 1: Location Map
Proposed 150 KLPD Molasses/Grain based Distillery along with 7.0 MW Co-generation power plant & 10 KLPD Malt Spirit Plant within existing non-operational Distillery Plant
At Village Satrod Khas, Tehsil & District Hisar, Haryana
Pre - Feasibility Report
Associated Distilleries (A Unit of Globus Spirits Limited) 8
(iii) Key Plan
Figure - 2: Key Plan
Proposed 150 KLPD Molasses/Grain based Distillery along with 7.0 MW Co-generation power plant & 10 KLPD Malt Spirit Plant
within existing non-operational Distillery Plant
At Village Satrod Khas, Tehsil & District Hisar, Haryana
Pre - feasibility Report
Associated Distilleries (A Unit of Globus Spirits Limited) 9
(iv) Details of alternative sites consideration and basis of selecting the proposed
site, particularly the environmental considerations gone into should be
highlighted.
The company is proposing 150 KLPD Molasses/Grain based Distillery along with 7.0 MW
Co-generation power plant within existing non-operational Distillery Plant; therefore, no
alternative site has been considered.
(v) Size or magnitude of operation
Proposed 150 KLPD Molasses/Grain based Distillery along with 7.0 MW Co-generation
power plant within existing non-operational Distillery Plant at Village Satrod Khas, Tehsil
& District Hisar, Haryana
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.
Units Plant
Capacity
Product By product
Molasses/Grain
based Distillery
Plant
150 KLPD Ethanol / Extra
Neutral Alcohol (ENA)
/ Rectified Spirit (RS)
During Molasses based operation - CO2
During Grain based operation - DDGS
and CO2
Co-Generation
Power Plant
7.0 MW Power
Malt Spirit Plant 10 KLPD Malt Spirits DDGS
(vi) Project Description with Process Details
A) Proposed 150 KLPD Molasses Based Distillery
� Molasses Unloading and Storage
Molasses from tankers/pipe line will be unloaded at unloading point and transferred in to
molasses storage tank.
� Yeast propagation and fermentation:
Yeast activation:
Yeast seed material will be prepared in water-cooled Yeast Activation vessel by
inoculating sterilized mash with active dry yeast. Optimum temperature will be
maintained by cooling water. The contents of the yeast activation vessel will be then
transferred to fermenter.
Fermentation:
The Molasses from storage tank to be pumped to dilutor installed in fermentation section
and diluted with water. The diluted molasses called Wort will be fed into culture vessels
Proposed 150 KLPD Molasses/Grain based Distillery along with 7.0 MW Co-generation power plant & 10 KLPD Malt Spirit Plant
within existing non-operational Distillery Plant
At Village Satrod Khas, Tehsil & District Hisar, Haryana
Pre - feasibility Report
Associated Distilleries (A Unit of Globus Spirits Limited) 10
and Pre-fermenter for activation of yeast. The activated yeast from the yeast activation
vessel transferred into pre fermenter.
Once the yeast activated in pre-fermenters, it will be transferred in to fermenters and
diluted molasses to be added. The process of fermentation is to convert the fermentable
substrate into alcohol. The pH of the wort is adjusted by the addition of acid. Yeast will be
available in sufficient quantity to initiate fermentation rapidly and complete it within the
cycle time.
At the start of the cycle, the fermenter will be charged with wort 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 will be emptied, they will be cleaned with water and caustic solutions
and sterilized for the next batch. The carbon dioxide evolved during the process will be
vented to atmosphere (to be processed and stored for industrial use) after recovery of
alcohol in a scrubber.
� Distillation: (Multi Pressure Distillation with Integrated Evaporation)
Fermented wash from wash holding tank will be pumped by wash feed pump to the top
of degassing column after preheating the same in beer heater and spent wash heat
exchanger. The vapours along with non-condensable gases from the top of degassing
column will be rectified in Heads column, to expel the high volatiles, technically known as
heads. Bottom liquid from the degasser flows into analyzer column where alcohol is
stripped from the liquid. The liquid from bottom of analyzer column will be completely
stripped of alcohol and will be pumped out by thick slop discharge pump through heat
exchanger where it preheats the fermented wash before it enters degassing column. The
slop from the analyzer column will be fed in to decanter. The dilute alcohol vapors from
near the top of analyzer column will be condensed first in beer heater while exchanging
heat with wash feed and then in analyzer condenser. Degasser and analyzer operate
under vacuum. The condensate will be collected in rectifier feed tank. The vapors for
stripping alcohol will be generated from analyzer column bottom liquid in the analyzer
column re-boiler by using the rectified column top vapors, as discussed subsequently.
Vapors from the top of heads column are condensed in heads column condenser and
then in head column vent condenser. Part of the condensate is returned to column as
reflux while a small portion is taken out as an impure spirit cut. Liquid from bottom is also
taken into rectified feed tank.
Dilute alcohol water mixture from rectifier feed tank will be pumped by rectifier feed
pump through rectifier feed pre-heater in to rectifying column. Rectifier and its associated
equipment work under pressure so that these vapors can supply the necessary heat for
generating the vapors.
Proposed 150 KLPD Molasses/Grain based Distillery along with 7.0 MW Co-generation power plant & 10 KLPD Malt Spirit Plant
within existing non-operational Distillery Plant
At Village Satrod Khas, Tehsil & District Hisar, Haryana
Pre - feasibility Report
Associated Distilleries (A Unit of Globus Spirits Limited) 11
The condensate is then pumped as reflux to rectifying column. Rich alcohol vapors at a
concentration of 95.5% v/v from top of rectifying column are condensed first in analyzer
and then in reflux vent condenser. The liquid form will be collected in rectifier reflux tank.
Part of the liquid 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
RS/ ENA. From rectifier column the draw will be taken to produce RS and for ENA draw
will be sent to ED column, rectifier column and finally to polishing column to maintain
quality of ENA and final draw from polishing column will be sent to receivers.
Liquid from the reflux tank is pumped by product pump partly as product and partly as
reflux to the top of the rectifying column. The necessary rectifying vapors are generated
by boiling the bottom liquid in Rectifier Column Re-boiler 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 and are mixed with water and
allowed to separate out in fusel oil separator. All vents will be connected to Vent Gas
Absorber where the vent gases are scrubbed with water to recover entrained alcohol. The
scrubber water is used for washing the fusel oils in fusel oil separator to recover alcohol
from the fusel oil fractions. The absorber vent is connected to vacuum pump 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.
Rectified spirit, after preheating by waste hot streams, is vaporized and superheated by
using medium pressure steam at 6 Kg/cm2g pressure. Hot vapors at 6 kg/cm² g pressure
and 130° C temperature pass through PSA column, where the water vapors are retained
while water free alcohol is released as vapors. The vapors are condensed 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 and the vent vapors are recovered through scrubber. Vacuum can
be created. Product will be cooled and transferred to absolute alcohol receiving tank and
then on to storage tank.
� Alcohol bulk storage:
Alcohol will be first taken to daily receiver storage tanks, which will be based on the State
Excise laws, storage for three days considering the weekly holidays of two days.
Thereafter, the alcohol will be transferred to bulk storage tanks after taking the daily
receiver Dip. This is transferred using flameproof pumps. Final dispatch of alcohol will be
metered and again will be carried out using special flameproof pumps. The Bulk spirit
storage is proposed to be set up for 30 days.
Proposed 150 KLPD Molasses/Grain based Distillery along with 7.0 MW Co-generation power plant & 10 KLPD Malt Spirit Plant
within existing non-operational Distillery Plant
At Village Satrod Khas, Tehsil & District Hisar, Haryana
Pre - feasibility Report
Associated Distilleries (A Unit of Globus Spirits Limited) 12
� Effluent handling section in the process
a) Evaporation section:
• The spent wash coming from distillation section will be fed in to first calendria of
the evaporator section. There will be five calendria installed as per design to
concentrate the dissolved solids. Suggested treatment scheme is a four FF +
finisher evaporation plant for spent wash evaporation. The following points will
elucidate the basic working principle:
• After Integrated evaporator spent wash will be fed to stand alone evaporators
four effects ( 3+1) Forced circulation to concentrate it up to 60 brix to burn in
incineration boiler
• Shell & tube type evaporators with highly efficient liquid distributor working on
the principle of falling film evaporation will be used, with Plate type Preheaters
for preheating of FEED stream which serves the purpose of energy conservation.
• Analyzer vapor will be fed to the first effect evaporator shell side at the given
pressure and temperature as the heating medium.
• The feed from the feed balance tank will be taken to make the best heat recovery.
• The feed after getting heated to the predetermined temperature in pre-heater
will be fed from the first effect evaporator which is falling film evaporator -1
• Vapors generated in 1steffect VLS (Vapor Liquid Separator) will be used as heat
source in the 2nd
effect and from 2nd
to third and so on.
• The product at the desired concentration of TS will be obtained at the outlet from
the final effect.
• A Shell & tube type multi-pass surface condenser will be employed for
condensing the shell side vapors.
• 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 will operate under vacuum. Water-ring vacuum pumps will be used to
maintain a desired vacuum.
• Cooling water from cooling tower is used in the surface condensers for
condensing the vapors.
b) Incineration boiler along with the turbine generator:
The concentrated effluent will be mixed with bagasse/biomass/coal and fired into
specially designed incineration boiler to generate steam and power.
Proposed 150 KLPD Molasses/Grain based Distillery along with 7.0 MW Co-generation power plant & 10 KLPD Malt Spirit Plant
within existing non-operational Distillery Plant
At Village Satrod Khas, Tehsil & District Hisar, Haryana
Pre - feasibility Report
Associated Distilleries (A Unit of Globus Spirits Limited) 13
Figure 3:- Process flow diagram of 150 KLPD Molasses based Distillery
Proposed 150 KLPD Molasses/Grain based Distillery along with 7.0 MW Co-generation power plant & 10 KLPD Malt Spirit Plant
within existing non-operational Distillery Plant
At Village Satrod Khas, Tehsil & District Hisar, Haryana
Pre - feasibility Report
Associated Distilleries (A Unit of Globus Spirits Limited) 14
Distillery Effluent Treatment Scheme - RO based Process condensate Treatment
Plant
The process condensate treatment plant will be based on the process of Reverse Osmosis
technology. The system will comprise of following unit process & equipment.
• Equalization tank
• Neutralization tank
• Filtration section
• Pressure sand filter
• Dual media filter
• Feed RO system
• Permeate RO system
• Reject RO system
• RO CIP system
Neutralization process: The stored process condensate will be transferred to the
downstream neutralization tank. Process condensate will be neutralized in this tank with
dosing of alkali solution. The neutralization process will be automated &will be controlled
through the controller. Neutralized condensate will be then collected in filter feed tank
for further processing through the filtration system.
Filtration Process: Neutralized condensate from the filter feed tank will be passed
through two stage media filters. First condensate will be filtered by pressure sand filter in
order to remove suspended matters & turbidity present in it. The primary sand filter
outlet will be filtered in Dual media filter to remove the fine suspended solids.
Feed RO system: The neutralized & filtered water will be treated through Feed RO
system. The feed water will be dosed with anti-scalant& SMBS solutions to condition the
feed water prior to passing it through Feed RO system. The feed RO skid will be two stage
systems comprising of two pressure vessels containing six elements each configured in
series. As the feed water flows through the first pressure membrane from feed to reject
end, the pure water permeates through membrane and will be collected in the permeate
header. The concentrated water will be collected in Reject header& then passed through
the second pressure vessel. The permeate generated from the Feed RO system will be
collected in the permeate RO feed tank & Reject generated will be collected in the Reject
RO feed tank.
Permeate RO system: The permeate generated from the feed RO skid will be passed
through the permeate RO system for further removal of dissolve solid. The system
comprises of two pressure vessels containing four elements each configured in series. As
the feed water flows through the first membrane from feed to reject end the pure water
permeates through the membranes &will be collected in the permeate header. The
concentrated water will be collected in Reject header & then passes through the second
Proposed 150 KLPD Molasses/Grain based Distillery along with 7.0 MW Co-generation power plant & 10 KLPD Malt Spirit Plant
within existing non-operational Distillery Plant
At Village Satrod Khas, Tehsil & District Hisar, Haryana
Pre - feasibility Report
Associated Distilleries (A Unit of Globus Spirits Limited) 15
pressure vessel. The permeate generated from the system will be collected on the
permeate RO product tank & Reject generated will be collected in reject RO feed tank.
Reject RO system: The reject generated from the feed RO skid & permeate skid will be
passed through the Reject RO system for further recovery of low TDS water. The system
will comprise of two pressure vessels containing four elements each configured in series.
As the feed water flows through the first membranes from feed to reject end the pure
water permeates through the membranes & will be collected in the permeate header. The
concentrated water will be collected in Reject header & then passed through the second
pressure vessel. The permeate generated from the Reject RO system will be collected in
the reject RO product tank & reject generated will be collected in the final reject
collection tank. The permeate from Permeate RO system & permeate from Reject RO
system will be used in cooling towers & fermentation for makeup water & molasses
dilution. The final reject will be fed to evaporation again.
Table - 2
Characteristics of Untreated and treated effluent
S.
No.
Parameters Untreated Effluent Treated effluent Evaporation process
condensate Cooling tower
blow down
1. TDS 200 mg/l 2000 mg/l <10 mg/l
2. pH 3.5 7.2 6.5-7.5
3. BOD 2500 mg/l 60 mg/l <10 mg/l
4. COD 3500 mg/l 200 mg/l <100 mg/l
B) Process Description of 150 KLPD Grain based operation
Distillery Unit - Production from Grain:
• Grain storage
• Grain cleaning, milling and flour handling
• Slurry preparation & liquefaction
• Multi pressure distillation
• Alcohol (ENA & IA) daily receivers & bulk storage
• MEE & Dryer
1) Grain Storage Silos, Cleaning, Handling and Milling Section:
Grain is received from various sources and is pre-cleaned off stones, husk, etc. and then
stored in specially designed storage silos. Grains are continuously lifted from the bottom
of the silos and screened followed by removal of stones in de-stoner and iron matters in
magnetic separators. Cleaned Grains are then milled using dry milling process in Hammer
Mills. The flour is fed through the bucket elevator and conveyed to the Batch Tipping
Machine through a Screw Conveyor.
Proposed 150 KLPD Molasses/Grain based Distillery along with 7.0 MW Co-generation power plant & 10 KLPD Malt Spirit Plant
within existing non-operational Distillery Plant
At Village Satrod Khas, Tehsil & District Hisar, Haryana
Pre - feasibility Report
Associated Distilleries (A Unit of Globus Spirits Limited) 16
2) Liquefaction Section
Grain flour mixed with recycle streams and water in Pre-masher and slurry has been fed to
Liquefaction tank. Required temperature has been maintained by applying steam through
steam sparger in liquefaction tank. The cooking process, accomplished in the above
manner, converts the slurry into a hydrated, sterilized suspension (as starch molecule is
solubilized) and is therefore susceptible to enzyme attack for liquefaction. The liquefied
mash is cooled in slurry cooler and transferred to Fermentation section.
3) Fermentation Section
The purpose of fermentation is to convert the fermentable substrate into alcohol. To
prepare the mash for fermentation, it is diluted with water. Yeast is added in sufficient
quantity to complete fermentation to produce alcohol.
At the start of the cycle, the Fermenter is charged with mash and contents of the Yeast
Activation Vessel (Pre-fermenter). Significant heat release takes place during
fermentation. This is removed by passing the mash through heat exchangers to maintain
an optimum temperature. The recirculation pumps also serve to empty the Fermenters
into Beer Well. CO2 evolved during fermentation carries along with it some entrained
alcohol. This CO2 is taken to a CO2 scrubber where it is washed with water to remove the
entrained alcohol. The scrubbed CO2 can then be taken to CO2 plant or vented out. After
emptying of Fermenter, it is cleaned with CIP using cleaning nozzles. After CIP Fermenter
is ready for next batch to be filled.
4) MPR Distillation Wash to ENA:
Multi-Pressure Distillation system has eight Distillation columns operating at various
pressure conditions. Heat energy from columns operating under high pressure is utilized
for columns operating under low pressure to optimize the operation for energy
consumption. Following Columns will be under operation
• Analyser Column
• Degasifying Column
• Pre-Rectifier Column cum
• Exhaust Column
• Extractive Distillation Column
• Rectifier cum Exhaust Column
• Recovery Column
• Simmering Column
Pre-heated fermented wash is fed at the top of the Degasifying column. Analyser Column
is provided with Re boiler. Top vapors of Analyser column containing all the alcohol in the
wash are sent to Pre-Rectifier column. Rest of the fermented wash flows down the
Analyser column and is taken out as thick slops from Analyser column bottom. Low
Proposed 150 KLPD Molasses/Grain based Distillery along with 7.0 MW Co-generation power plant & 10 KLPD Malt Spirit Plant
within existing non-operational Distillery Plant
At Village Satrod Khas, Tehsil & District Hisar, Haryana
Pre - feasibility Report
Associated Distilleries (A Unit of Globus Spirits Limited) 17
boiling impurities are concentrated in the Pre-Rectifier column. A draw of impure alcohol
is taken out from the top of the Pre-Rectifier column. RS draw is taken from the top of Pre
rectifier column, which further is sent to Extractive Distillation column. Dilution water is
fed to this column. The Extractive Column operates on the principle of inversion of
relative volatility. Low boiling impurities are separated in the Extractive Distillation
Column & bottom is sent to Rectifier cum Exhaust column. The Rectifier/Exhaust column
concentrates the alcohol to 96% v/v. The spirit is drawn from the upper trays of the
Rectification Column. Fusel oil build up is avoided in the Rectifier cum exhaust column by
withdrawing side streams (fusel oils). ED condensates, fusel oil draw from R/E column are
sent to Recovery column where these fusel oils are concentrated and then sent to
decanter where these streams are diluted with water and fusel oil rich layer is separated.
Washings are sent back to the column to recover alcohol. The spirit Draw from the
Rectifier column is sent to the Simmering column where methanol is separated in the
form of a cut from the top and ENA is taken out from the bottom. ENA drawn from the
Simmering Column is taken to the receiver after cooling in ENA cooler.
5) Decantation Section Excluding Decanter Centrifuges
Decantation section comprises of a Centrifuge Decanters (Client scope) for separation of
suspended solids from Thick slop coming out of Grain Distillation Plant. Wet cake is
removed from bottom of Decanter. Thin slops coming out of Decanter are collected in a
tank and partly recycled into the process & Evaporation for further concentration. The
concentrated thin slops called as Syrup is mixed with Wet cake and sold in wet form as
cattle feed (DWGS) or the entire mixture can be dried in a DWGS Dryer and then sold in
dry form as Cattle feed (DDGS).
6) Integrated Evaporation
The suggested treatment scheme is a Multi Effect Evaporation Plant for Thin Slop
Evaporation. Shell & Tube type Evaporators with highly efficient liquid distributor working
on the principle of Falling Film and Forced circulation Evaporation has been used.
The product at the desired concentration of 40%w/w Total Solid is obtained at the outlet
of the final effect. Each effect is provided with recirculation cum transfer pumps. The
condensate from surface condensers is collected in a common condensate pot. The
condensate is transferred for further treatment / drain by using centrifugal pump. The
system operates under vacuum. Water-ring vacuum pumps are used to maintain a desired
vacuum. Cooling water from cooling tower is used in the surface condensers for
condensing the vapours.
7) DWGS Dryer Section
Wet distiller’s grains shall be fed into the dryer housing at controlled rate through a
suitable feeding system. The Rotary Bundle is enclosed in an insulated dryer housing and
on its outer flights are fixed. Dry, saturated steam is to be supplied to the bundle through
Proposed 150 KLPD Molasses/Grain based Distillery along with 7.0 MW Co-generation power plant & 10 KLPD Malt Spirit Plant
within existing non-operational Distillery Plant
At Village Satrod Khas, Tehsil & District Hisar, Haryana
Pre - feasibility Report
Associated Distilleries (A Unit of Globus Spirits Limited) 18
rotary joint at one end & the condensate is discharged through rotary joint mounted of
another 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
vapors 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 Local Indication cum Control panel.
8) Process Condensate Treatment Section
The process condensate from the evaporation section is treated in this unit and this
treated condensate is then recycled back to process thus reducing the fresh water
consumption.
Proposed 150 KLPD Molasses/Grain based Distillery along with 7.0 MW Co-generation power plant & 10 KLPD Malt Spirit Plant within existing non-operational Distillery Plant
At Village Satrod Khas, Tehsil & District Hisar, Haryana
Pre - feasibility Report
Associated Distilleries (A Unit of Globus Spirits Limited) 19
Figure - 4: Process flow chart For Grain Based Distillery
Proposed 150 KLPD Molasses/Grain based Distillery along with 7.0 MW Co-generation power plant & 10 KLPD Malt Spirit Plant within
existing non-operational Distillery Plant
At Village Satrod Khas, Tehsil & District Hisar, Haryana
Pre - feasibility Report
Associated Distilleries (A Unit of Globus Spirits Limited) 20
C) Manufacturing process of Malt Spirit Plant (10 KLPD)
Malt Spirit Production process is given below:
� Malt handling- Malt is usually stored in silos before being milled and mashed. It has a low
moisture content of between 3 and 5%. The main processes in malt handling are Intake,
storage, conveying, removing unwanted materials & stones, weighing.
� Milling - The objective of milling is to reduce the malt to particles sizes, which will yield the
most economic extract (wort) and will operate satisfactorily under brewhouse conditions
and throughout the brewing process. The more extensive the malt is milled, the greater the
extract production.
� Mashing- Mashing is the process of combining a mix of milled grain (typically malted barley
with supplementary grains such as corn, sorghum, rye or wheat), known as the "grain bill",
and water, known as "liquor", and heating this mixture. Mashing allows the enzymes in the
malt to break down the starch in the grain into sugars, typically maltose to create malty
liquid called wort.
� Fermentation- Fermentation is an essential stage in the brewing process. It involves adding
yeasts to the cooled malt. These yeasts are fed by the amino acids in the brew and produce
alcohol from the sugar that is present. These natural reactions also produce carbon dioxide.
� Pot Distillation- Malt Whisky is distilled twice - although a few distilleries may undertake a
third distillation - in Pot Stills which resemble huge copper kettles. The spirit is driven off
from the fermented liquid as a vapour and is then condensed back to a liquid. In the first
distillation the fermented liquid, or wash, is put into the Wash Still which is heated either
directly by fire or by steam-heated coils. At this stage the wash contains yeast, crude
alcohol, some un-fermentable matter and the by-products of fermentation. During the
process of boiling the wash, changes take place in its constituents which are vital to the
flavour and character of the whisky. As the wash boils, vapours pass up the neck of the still
and then pass through a water-cooled condenser or a worm, a coiled copper pipe of
decreasing diameter enclosed in a water jacket through which cold water circulates. This
condenses the vapours and the resulting distillate, known as low wines, is collected for re-
distilling. The liquor remaining in the Wash Still is known as pot ale or burnt ale and is
usually treated and converted into distillers' solubles for animal feed.
� Decantation- The decantation section comprises of a Centrifuge Decanter for separation of
suspended solids from Spent Wash coming out of distillation Plant.
Wet cake/DWGS- Spent grains also known as DWGS, has a commercial value and can be sold as
by-products for livestock feed or Wet cake / DWGS will be passed through steam tube bundle
drier for drying into cake with 10 - 12% moisture (max.) to give higher shelf life.
Proposed 150 KLPD Molasses/Grain based Distillery along with 7.0 MW Co-generation power plant & 10 KLPD Malt Spirit Plant within
existing non-operational Distillery Plant
At Village Satrod Khas, Tehsil & District Hisar, Haryana
Pre - feasibility Report
Associated Distilleries (A Unit of Globus Spirits Limited) 21
Figure 5: Process flow diagram of Malt Spirit production
D) Power Co-Generation (7.0 MW)
The unit proposes to set-up boiler (56 TPH) and power turbine (7 MW). Boiler will operate mainly
to feed steam to distillery and 7.0 MW power generations from Turbine. During Molasses based
operation boiler fuel will used concentrated Spent Wash and Coal or Biomass and during Grain
based operation boiler fuel will used biomass/Rice Husk/ Bagasse/ Paddy & Wheat Straw or Coal.
Proposed 7 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
Proposed 150 KLPD Molasses/Grain based Distillery along with 7.0 MW Co-generation power plant & 10 KLPD Malt Spirit Plant within
existing non-operational Distillery Plant
At Village Satrod Khas, Tehsil & District Hisar, Haryana
Pre - feasibility Report
Associated Distilleries (A Unit of Globus Spirits Limited) 22
house i.e. for running the distillery and utilities like boiler auxiliaries etc. Surplus power can be
exported to Grid.
Figure 6: Process flow chart for Proposed Co-generation Power Plant
(vii) Raw material required along with estimated quantity, likely source, marketing area of
final products, mode of transport of raw material and finished product.
(a) Raw Material Requirement:
The basic raw material for the manufacturing of Ethanol & ENA/RS will be Molasses and Grain.
Molasses will also be used as a raw material in molasses based operation which is available from
nearby sugar mills. Grains such as damaged grain feed stock, broken rice, maize, bajra & sorghum
will be used as raw material which is easily available from the local market.
The raw material for the boiler fuel will be various biomasses such as Rice Husk/ paddy straw/ cow
dung/ poultry waste etc. and concentrated spent wash for incineration when the distillery is
operated on molasses.
TABLE - 3 Raw Material Requirement
S.
No.
Particular Total
Requirement
Source & Mode of
Transportation
1 Molasses 660 to 700 TPD From nearby sugar mill & suppliers by
tankers (road)
Or
Grain - Broken Rice, Sorghum, Baira,
Maize etc.
335 to 360 TPD Through Grain suppliers By road
2. Barley Malt & adj Flour for Malt Plant 22 TPD Through suppliers By road
3. Process Chemicals Near-by Markets by road
Sodium Hydroxide (Caustic) 1200 Kg/day
Enzyme 9 Kg/day
Proposed 150 KLPD Molasses/Grain based Distillery along with 7.0 MW Co-generation power plant & 10 KLPD Malt Spirit Plant within
existing non-operational Distillery Plant
At Village Satrod Khas, Tehsil & District Hisar, Haryana
Pre - feasibility Report
Associated Distilleries (A Unit of Globus Spirits Limited) 23
Antifoam Agent 225 Kg/day
Others Chemicals 300 Kg/day
Yeast (Active Dry Yeast/Distiller’s
Yeast)
Own Propagation
(B) Fuel Requirement for Boilers:
During Molasses based operation - Concentrated Spent Wash and Coal or Bagasse / Rice husk /
Indian coal will be used for the proposed boiler of 56 TPH.
During Grain based operation Coal or Biomass will be used for the proposed boiler of 56 TPH.
Details regarding fuel requirements are given below.
TABLE – 3
Fuel Requirement
Operation Mode
Name of Raw Material
Total Requirement Source & Mode of Transportation
Molasses based operation
Concentrated Spent Wash and Coal or Biomass
Concentrated Spent Wash - 560 TPD and
Biomass 190TPD / Coal 140 TPD
Spent wash - Own plant through pipelines
Coal / biomass - From authorized dealers by road
or
Grain based operation
Coal or Biomass Coal 240 TPD or Biomass 375 TPD
(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.
(viii) Availability of water it’s source, energy /power requirement and source should be
given.
(a) Water Requirement and Source
Total fresh water requirement for the project will be 1450 KLPD (1350 KLPD Distillery + 80 KLPD
Malt Spirit Plant + 15 KLPD Bottling Plant + Domestic 5 KLPD) which will be sourced from
Surface water (Canal) or Ground Water
Water Requirement for Proposed 150 KLPD Molasses based Distillery based on Incarnation
Boiler
The water requirement for the first run for project would be 2789 KLPD, which will be further
reduced through recycling to 1439 KLPD. Hence, fresh water requirement is 1350 KLD. Details
given below:
Proposed 150 KLPD Molasses/Grain based Distillery along with 7.0 MW Co-generation power plant & 10 KLPD Malt Spirit Plant within
existing non-operational Distillery Plant
At Village Satrod Khas, Tehsil & District Hisar, Haryana
Pre - feasibility Report
Associated Distilleries (A Unit of Globus Spirits Limited) 24
Figure 7: Mass & water balance of proposed 150 KLPD Molasses based Distillery based on Incarnation Boiler
Proposed 150 KLPD Molasses/Grain based Distillery along with 7.0 MW Co-generation power plant & 10 KLPD Malt Spirit Plant within
existing non-operational Distillery Plant
At Village Satrod Khas, Tehsil & District Hisar, Haryana
Pre - feasibility Report
Associated Distilleries (A Unit of Globus Spirits Limited) 25
(b) Power Requirement and Source
The total power requirement will be 4.5 MW, which will be sourced from 7.0 MW Co-Generation
Power Plant. Surplus power can be exported to Grid.
(c) Steam Requirement
Total Steam requirement will be met by 56 TPH boiler. The steam requirement for different
purposes is given below:
TABLE – 4
Steam Requirement
S.
No.
Purpose Total Steam Requirement for 150 KLPD Molasses based
distillery (Incineration Route)
1. Multi-pressure Distillation 10.5
2. Multi Effect Evaporator 14.25
3. Boiler De - Aeration 3.75
Total 28.5
Source Proposed 56 TPH Incinerator Boiler
Steam for Malt Spirit 4 TPH
Boiler Details:
Details regarding boilers are mentioned in the table given below:
TABLE – 5
Boiler Details
S. No. Item Boiler details
1. Boiler Capacity 56 TPH
2 Type of Fuel During Molasses based operation - Concentrated Spent Wash and Coal or Biomass
During Grain based operation - Coal or Biomass
3. Stack Height 82 Metres
4. Pollution Control Equipment Measures
Electrostatic Precipitator (ESP)
Details regarding the D.G. Sets
2 nos. of D. G. Sets of capacity 1500 KVA each will be installed with the plant for emergency back-
up. Details regarding the D.G. Sets are mentioned in the table given below:
TABLE – 6
Details Regarding the D.G. Sets
S. No. Details
1. Type of Fuel HSD
2. Capacity 2 x 1500 KVA
3. Stack Height (above roof level) As per CPCB/SPCB norms
4. Pollution Control Equipment Measures Adequate stack height/ Acoustic Enclosure
Proposed 150 KLPD Molasses/Grain based Distillery along with 7.0 MW Co-generation power plant & 10 KLPD Malt Spirit Plant within
existing non-operational Distillery Plant
At Village Satrod Khas, Tehsil & District Hisar, Haryana
Pre - feasibility Report
Associated Distilleries (A Unit of Globus Spirits Limited) 26
(x) Quantity of Waste to be generated (liquid and solid) and Scheme for their
Management/Disposal:
Waste Water Generation and management:
� The project will be based on “ZERO EFFLUENT DISCHARGE”.
� Fresh water requirement of the project will be met by ground water. Efforts will be made to
conserve as much water as possible by recycling and reusing waste water.
� Molasses slops (spent wash) shall be concentrated in evaporators and incinerated in boiler.
� Grain Slops (Spent Wash) will be taken through Decanters Centrifuge for separation of
Suspended Solids separated as Wet Cake. Thin Slops from the Decanter Centrifuge will be
partly (20%) recycled back to Liquefaction Process), partly (20%) used in Analyser Column
Reboiler for flash steam generation under vacuum and the balance (60%) taken to Multi
Effect Evaporation Plant for concentration of thin slop to form a Syrup. This Syrup as
Condensed Distillery Solubles (CDS) is mixed with the Wet Cake coming out of Decanter
Centrifuge and the mixture is known as Distillers Wet Grain with Solubles (DWGS). DWGS
will be fed to Dryers operating on steam and is dried to make it DDGS – Distillers Dried
Grain with Solubles.
� Process condensate is cooled and collected into an equalization tank with sufficient
residence time. After equalization, this process condensate will be fed for Ecophotox and
after treatment it will be used for greenbelt development within the complex.
� 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 given to brick manufacturing unit.
� 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.
4.0 SITE ANALYSIS:
(i) Connectivity
The plant site is well connected to Highway NH 10 (Adjacent in SW direction) and NH 65 (~ 7.2
km in West direction). The nearest railway station is Hisar (~ 7 km in West direction) and nearest
airport is New Delhi (~ 142 km in SE 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
The existing plant area is 8.0 hectares (19.77 Acres). No additional land is required for the
proposed project as the same will be done within the existing old non - operational 25 KLPD
Distillery plant premises. The project is being proposed in existing old non- operational distillery
plant premises and land has already been converted for industrial use.
Proposed 150 KLPD Molasses/Grain based Distillery along with 7.0 MW Co-generation power plant & 10 KLPD Malt Spirit Plant within
existing non-operational Distillery Plant
At Village Satrod Khas, Tehsil & District Hisar, Haryana
Pre - feasibility Report
Associated Distilleries (A Unit of Globus Spirits Limited) 27
(iii) Topography
Topography of the core zone of the project is 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
Environmental Settings of the Area
S.
NO.
PARTICULARS DETAILS
1. Nearest Village Satrod Khas (1 km in SW direction)
2. Nearest City Hisar (4.5 km in West direction)
3. Nearest National Highway / State
Highway
• NH 10 (Adjacent in SW direction)
• NH 65 (7.2 km in West direction)
4. Nearest Railway station Hisar (7 km in West direction)
5. Nearest Airport New Delhi (142 km in SE direction)
6. Reserved Forest(RF)/Protected Forest (PF) Bir Hisar PF (5.0 km in NW direction)
7. National Parks, Reserved Forests (RF)/
Protected Forests (PF), Wildlife
Sanctuaries, Biosphere Reserves, Tiger/
Elephant Reserves, Wildlife Corridors etc.
within 10 km radius
No National Parks, Wildlife Sanctuaries, Biosphere
Reserves, Tiger/ Elephant Reserves, Wildlife Corridors etc.
lies within 10 km radius of the plant site.
8. Water Body (within 10 km radius) • Balsamand Sub Branch (Bhakra Canal) (Adjacent in East direction)
• Hisar Major Distributary (Western Yamuna Canal) (Adjacent in North direction)
• Dewa Distributary (~ 1.5 km in South direction)
• Petwar Distributary (~ 4.0 km in South direction)
Few minor agricultural canals are also present in 10 km
radius area
9. Seismic Zone Zone II: Low Damage Risk Zone (MSK VI or less)
(v) Existing Infrastructure
The existing plant area is 8.0 hectares (19.77 Acres). No additional land is required for the
proposed project as the same will be done within the existing old non-operational distillery plant
premises. Existing infrastructure includes 25 KLPD distillery & CL/IMFL Bottling Plant and utilities
Proposed 150 KLPD Molasses/Grain based Distillery along with 7.0 MW Co-generation power plant & 10 KLPD Malt Spirit Plant within
existing non-operational Distillery Plant
At Village Satrod Khas, Tehsil & District Hisar, Haryana
Pre - feasibility Report
Associated Distilleries (A Unit of Globus Spirits Limited) 28
like boilers, water treatment plant, steam, power, ETP, storage facilities etc.
(vi) Soil classification
The soils of the district are of three types i.e. Arid brown solonized (in north eastern parts
covering north eastern part of Narnaund and Uklana Mandi blocks.), Sierozem (in major parts
covering Barwala, Hansi-I, Bass (Hansi-II), Hisar-I & Agroha blocks and parts of Uklana, Narnaund,
Adampur & Hisar-II blocks) and desert soils (in southern western parts covering part of Adampur
and Hisar-II blocks).
(vii) Climatic data from secondary sources
The climate of Hisar owes to its continental location on the outer margins of the south-west (SW)
monsoon region. It has tropical monsoonal climate and is characterized as arid type of climate.
The district has characteristically four seasons during the year viz., summer (March to May), SW
Monsoon (June to September), Post-Monsoon (October to November) and winter (December to
February) season. SW monsoon also known as summer monsoon brings rain during last week of
June to mid-September. The period from October onward until next June remains almost dry
except, few light showers received due to westerly depressions/western disturbances (WDs). The
summers are generally quite hot and winters are fairly cool. The main characteristics of climate of
in the district are its dryness, extremes of temperature and scanty rainfall.
Rainfall: The normal annual rainfall of the district is 330 mm which is unevenly distributed over
the area 22 days .Around 75 to 80 per cent of the annual rainfall is received during South West
Monsoon season (June to September) with 50 per cent coefficient of variation (CV). The average
annual rainfall is around 450 mm, of which the average monthly rainfall received during July and
August months is 133.4 and 116.2 mm, respectively. The average monthly rainfall during
September is 54.5 mm and June 49.8 mm. The average rainfall received during normal monsoon
season is 283 mm. Generally rainfall in the district increases from southwest to northeast.
(viii) Social Infrastructure available
There are primary schools, dispensaries, small hospital, places of worship in nearby area of the
plant site.
5.0 PLANNING BRIEF
(i) Planning Concept (type of industries, facilities, transportation etc.) Town and country
Planning/ Development authority classification.
Proposed industry is a Molasses / grain based distillery. Facilities required for the 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 plant premises.
(ii) Population Projection
Temporary influx of people will be there as the managerial and supervisory staff will generally be
outsiders. A projection may be made by a governmental organization, or by those unaffiliated
with a government.
(iii) Assessment of infrastructure demand (Physical & Social)
Proposed 150 KLPD Molasses/Grain based Distillery along with 7.0 MW Co-generation power plant & 10 KLPD Malt Spirit Plant within
existing non-operational Distillery Plant
At Village Satrod Khas, Tehsil & District Hisar, Haryana
Pre - feasibility Report
Associated Distilleries (A Unit of Globus Spirits Limited) 29
The company already have infrastructure (Physical & Social) in nearby area of the plant site under
corporate social responsibilities programs.
(iv) Amenities/Facilities
The company has already developed the amenities/facilities in nearby areas of the existing
plant/project site as per requirement of local people under Corporate Social Responsibilities
Programs.
6.0 EXISTING INFRASTRUCTURE:
(i) Industrial Area (Processing Area)
The existing plant area is 8.0 hectares (19.77 Acres). No additional land is required for the
proposed project as the same will be done within the existing old 25 KLPD Distillery plant
premises. The project is being proposed in existing old non - operational distillery plant premises
and land has already been converted for industrial use.
(ii) Residential area (Non Processing area)
Residential colony is not existing and also not proposed for the plant. The local labour was/ will
be preferred to provide employment opportunities. All operation managers and operation staff
are stayed nearby towns.
(iii) Greenbelt
2.64 hectares, i.e. ~33% of the plant area has already been covered under greenbelt & plantation.
(iv) Social Infrastructure
Project results in growth of the surrounding areas by increased direct and indirect employment
opportunities in the region including ancillary development and supporting infrastructure.
(v) Connectivity
The site is well connected with communication facilities like telephone, fax, and wireless as such
no constraints are envisaged in this aspect.
(vi) Drinking Water
5 m3/ day water will be required for drinking purpose after installation which will be sourced from
Ground Water.
(vii) Sewage Treatment System
Domestic waste water generated from the plant will be treated in STP.
(viii) Industrial Waste management
The distillery will be based on “ZERO EFFLUENT DISCHARGE”. Waste water generated from
plant premises will be treated in ETP.
(ix) Solid Waste Management
• Molasses slops (spent wash) shall be concentrated in evaporators and incinerated in boiler.
• Solid waste from the grain based operations generally comprises of fibres and proteins in
the form of DDGS, which will be ideally used as cattle/poultry/fish feed.
• Ash from the boiler will be given to brick manufacturers.
Proposed 150 KLPD Molasses/Grain based Distillery along with 7.0 MW Co-generation power plant & 10 KLPD Malt Spirit Plant within
existing non-operational Distillery Plant
At Village Satrod Khas, Tehsil & District Hisar, Haryana
Pre - feasibility Report
Associated Distilleries (A Unit of Globus Spirits Limited) 30
• ETP sludge will be dewatered in filter press and used as manure.
(x) Power Requirement and Source
The total power requirement for the project will be 4.5 MW which will be sourced from the 7 MW
Cogeneration Plant.
7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN
(i) Policy to be adopted (Central/State) in respect of the project affected persons
including home oustees, land oustees and landless labourers (a brief outline to be
given).
Rehabilitation & Resettlement is not applicable because the proposed project will be done within
the existing old 25 KLPD non - operational Distillery plant premises. The complete land is already
under the company’s possession.
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 the molasses part within 3 to 4 years.
(ii) Estimated project cost along with analysis in term of economic viability of the
project.
� Total cost of the Project: Rs. 125 Crores
� Cost for Environment Protection Measures:
� Capital Cost: Rs. 40 Crores
� Recurring Cost/annum: Rs. 4.0 Crores
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 will result in growth of the surrounding areas by increasing ancillary development and
supporting infrastructure. Special emphasis on financial and social benefits will be given to the
local people including tribal population, if any, in the area. Development of social amenities will
be in the form of medical facilities, education to underprivileged and creation of self-help groups.
Haryana state will get revenues in terms of taxes. Business opportunities for local community will
be available like transport of raw material/product to market, fly ash transport to brick
manufactures, maintenance & house-keeping contract work etc.