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PRE-FEASIBILITY REPORT

FOR

100 KLPD Multifeed Distillery Plant Based on Molasses

and Grains i. e (Molasses based 60 KLPD and Grain

based 40 KLPD)

At

Village –Aurangabad, Taluka - Nawabganj, District- Barielly,

State –Uttar Pradesh

Submitted by

Oswal Overseas Limited.

Submitted to

Environment Appraisal Committee, New Delhi

Prepared by

Mantras Green Resources Ltd, Engineers & Environment Consultant

(QCI/NABET Certificate No. NABET/EIA/1619/RA0060)

Corporate Office: Plot No. A-9,Hall No.1, First Floor, NICE Sankul, Opp.-Nashik

Merchant Co-op Bank Ltd., ITI Signal, MIDC Satpur, Nashik-422007

Phone: +91-253-2355665, 2370086; Fax No.: +91-253-2316781

E-mail: [email protected] ,Website: www.mantrasresources.com,

Toll Free No.: 1800-233-5565

mailto:[email protected]


http://www.mantrasresources.com/


M/s Oswal Overseas Ltd, Bareilly, Uttar Pradesh Pre-feasibility Report

1.0 Introduction:

M/s Oswal Overseas Ltd. (hereafter being referred as OOL) has set up a business of manufacturing of sugar

and allied products at Aurangabad Village, Taluka Nawabganj, District Bareilly, State Uttar Pradesh. The

capacity of existing sugar mill is 3500 TCD sugar mill. The actual capital investment of the existing factory is

Rs.141.12 Crores. The number of working days of sugar mill is 330 days.

1.1 Project Background

Considering the availability of own molasses of about 36,000 MT after proposed sugar mill from 3500 TCD

and availability of grains in the command area of the company, the management of the company has taken

various steps for setting up of 100 KLPD Distillery Plant based on molasses and grains. The company has

already applied for IEM from the Ministry of Commerce & Industry, Govt. of India for setting up Distillery

and the IEM no. has been already issued by the Ministry of Commerce & Industry, Govt. of India. The

proposed distillery plant of 100 KLPD capacities will employ state-of-art-technology for production of ENA

/ ethanol i.e. milling and cooking, fermentation, multi pressure distillation system, integrated and standalone

evaporation section and slop fired incineration based Cogen power plant. Sugar factory will supply molasses,

while the incineration boiler and turbine will supply steam and power to the proposed ethanol plant. It will

employ high pressure incineration boiler of 22 TPH and 2.00 MW Back Pressure turbine for 60 KLPD

molasses based plant and high pressure boiler of 10 TPH boilers and 1 MW back pressure turbine. The total

requirement of molasses for the entire year operation (330 days a year) of the proposed 60 KLPD fuel

ethanol plant at 100% capacity utilization will be around 79200 MT. Considering the crushing of about 8

lakh MT, in-house molasses will be available around 36,000 MT and the balance 43200 MT of molasses will

be met out through procurement through nearby sugar factories or through use of own B-heavy molasses.

The total requirement of damaged grains for the entire year of operation (330 days a year) for the proposed

40 KLPD grain based distillery at 100% capacity utilization will be around 32195 MT. The company

proposes to procure the damaged grains from the district through traders / farmers.

Overall, the entire distillery plant of 100 KLPD is proposed to be set up based on the stand-alone commercial

viability of the captioned project, ensuring that the integration effort or synergy would enhance the overall

commercial viability of OOL.


1.2 Management of OOL

M/s Oswal Overseas Ltd has a team of dynamic and progressive members in the Management Board.

1. Mr. Paramjeet Singh, Managing Director

2. Mr. Harihar Nath Sharma, Independent Director

3. Mr. Anoop Kumar Srivastava, Director

4. Mr. Rajinder Pal Singh - Independent Director

5. Mrs. Ruchi Dawar - Woman Independent Director

1.3 Project Cost:

Total Project Cost : (Rs. in Lakh)

Land : 0.00

Site Development : 162.00

Civil works & Buildings : 1788.00

Indigenous Plant and Machinery : 10325.00

Miscellaneous Fixed Assets : 944.00

Prelim & Preoperative Expenses : 610.94

Contingencies : 138.24

Working Capital Margin : 143.82

Total : 14112.00


1.4 Current/Existing Project Activity

Products and by products allowed to be produced as per the latest Consent to Operate

Table 1: Products and Byproducts of Existing Plant of OOL

S. No Product/Byproduct Name Maximum quantity in

(MT/month)

1 Sugar 11025

2 Bagasse 31500

3 Press mud 4200

4 Molasses 5512.50

1.5 Proposed Project Activity

Molasses and Press mud which are the major byproducts from sugar mill are presently being sold to nearby distilleries

and to farmers. Hence the OOL sugar mill management has decided to set up a 60 KLPD capacity Molasses

based and 40 KLPD Grain based Distillery.

The proposed Distillery activity shall generate employment opportunity to the local people in nearby villages. Thus,

Management feel proud in obliging the sons of soil by providing the jobs to these people and fulfilling the social

commitments by extending the welfare amenities to their family.

After setting up of the proposed distillery, few ancillaries shall also come to support distillery operations and this shall

also increase employment and other business activities. In short, by putting up the proposed Distillery cum Ethanol

unit, there will be a further growth of sugar mill area in terms of Employment, Business, Education, Transportation,

Communication and of course Standard of living of families.

Sr. NO Name of the products Quantity

1 Sugar Mill 3500 TCD


1.6 Screening Category as per EIA notification 2006 & Subsequent Amendments

The Ministry of Environment and Forests (MoEF) Government of India has issued an EIA notification, S .O. 1533

dated 14 September 2006 notification. As per the EIA notification and its subsequent amendments, Distillery projects

are categorized under 5(g) of schedule of activities. As the proposed Distillery project is Molasses based, it comes

under category A under Schedule 5(g). Therefore, require prior Environmental clearance from the Expert appraisal

committee/authority (EAC), MoEF & CC, New Delhi.

1.7 Estimated Project cost:

The estimated project cost of Distillery is Rs.141.12 Crores.

Name of the project proponent: Mr. B. N. Mishra (General Manager), OOL.

Project Location: Village - Aurangabad, Tal—Nawabganj, Dist-Bareilly, State Uttar Pradesh, India

1.8 Environment Settings of the Proposed Distillery Project

Table 5: Environment Settings

Particulars Details

Latitude & Longitude Latitude : 280 30’ 27.36” N Longitude : 790 36’ 43.64” E

Survey of India Toposheet no 53 P/10, 53 P/11 (1:50000 scale)

Nearest Highway SH-74- Satara- Pandharpur Road 5.9 km (North)

Nearest Village Mahmoodapur village.

Nearest Town Nawabganj City 5.5 km.

Nearest Railway station Nawabganj Railway Station, 5.6 km

Nearest Airport Pant-nagar Airport 62 km

Other Historical / Religious places

None

Defence installations No

Ecologically sensitive areas (National Parks / Wild life sanctuaries / bio-sphere reserves,

None


migratory routes within).

Reserved / Protected Forest Reserved Forest – 54.2km

Nearest Water Bodies Ramganga River- 32 km [SW]

1.9 Site Selection Criteria

Site selected for the proposed distillery has some advantageous features. These are:

The project is having its own sugar mill of capacity 3500 TCD.

Availability of surplus amount of Raw material (Molasses) from own mill and from nearby sugar

mills.

The cane potential and irrigation facilities in the command area are adequate and will ensure

sustained cane availability for the proposed project with the extensive experience of farmers in sugar

cane cultivation.

Required land is available at the project site and is owned by OOL.

Location in rural area ensures adequate availability of manpower at marginally lower Rates.

Accessibility to markets within and nearby states Connectivity of road/rail network.

Market demand for final Product

There is no National Park, Biosphere Reserves and Tiger Reserves within 10 km radius of study area.

Google Map is given as Figure –1 and Topographical map of Study area of the project site is presented

in

1.10 Project Location and Infrastructure

Company has already acquired land for their sugar mill & earmarked about 22 acres of land for its distillery project. Details of location & infrastructure advantages are as below:

Site location : Aurangabad Distance from nearest Tehsil : Nawabganj, 5 Km Distance from nearest Railway Station : Bijaria, 7 Km Distance from Nearest District : Bareilly, 27 Km


The proposed site is ideal for the proposed distillery project, due to following

reasons: Required land is available at the project site and is owned by OOL

The sugar mill is located in Bareilly District. There is wide scope of sugar cane cultivation. Along with Bareilly District neighboring districts producing rice and maize as grain source for distillery plant operation.

The Plant is well connected by road, railway and air port. Bijaria Railway station is 7 Km away from the site. The nearest town is Nawabganj which tehsil head quarter 5 Km away from the site.

SEB power and Communication facilities viz. Tele communication and postal services are easily available.

Required grains are available in the district.

Figure 1: Google imagery of the Project site location


Fig 3: 10KM Radius Topographical Map of the Study area (1:50,000 Scale


Fig 4: PLANT LAYOUT MAP

1.11 State wise Ethanol Manufacturing Installed Capacity

The state wise ethanol manufacturing Installed Capacity is given below:

Sr.

No.

State No. of Units Installed Capacity

KLPD KLPA

1 Bihar 5 275 74250

2 U.P. 33 2321 699900

3 Punjab 1 40 12000

4 Andhra Pradesh 16 555 166500

5 Tamil Nadu 8 320 96000

6 Maharashtra 63 2455 736500


7 Gujarat 10 340 101100

8 Karnataka 16 1000 300000

Total 152 7306 2186250

1.11 .1 Raw Material Availability

The unit is situated in the cane and food grains rich area in central Uttar Pradesh. The availability of sugar cane is sufficient for 3500 TCD sugar mill.

1.11.2 Plant and Machinery

The erected cost of plant and machinery for 100 KLPD Distillery plant including boilers and turbines is estimated at Rs. 10325.000 lakh based on the discussions with the machinery suppliers. The detail breaks up of cost of plant and machinery is given below:

#

Particulars

Amount, Rs. Lakh

1

Turnkey supply of 60 KLPD distillery based on molasses and 40 KLPD distillery based on Grain incl. and 60 KLPD ethanol plant, Plant electrical, auxiliary cooling tower, Air Compressor, etc.

3600.00

2 Alcohol/Ethanol / ENA Storage Tanks and Staging Structure for distillery plant 700.00

3 Condensate Polishing Unit (CPU) 200.00

4 Integrated and Standalone evaporation 950.00

5 Turnkey supply of Boiler & Turbine, auxiliaries and fuel & ash handling 3300.00

6 Sub-total 8750.00

7 Add : GST 1575.00

8 Total 10325.00

1.12 Geography


Aurangabad is a Village in Nawabganj Taluka in Barielly District of Uttar Pradesh State. Bareilly is

in northern India, at 28°10′N 78°23′E. On its east are Pilibhit and Shahjahanpur, Rampur on the

west, Udham Singh Nagar (Uttarakhand) to the north and Badaun to the south. The city is level and well-

watered, sloping towards the south. Its soil is fertile, with groves of trees. A rain forest in the north,

known as the tarai, contains tigers, bears, deer and wild pigs. The river Sarda (or Gogra) forms the

eastern boundary and is the principal waterway.[18] The Ramganga receives most of the drainage from

the Kumaon Mountains, and the Deoha also receives many small streams.

1.13 Climate & Rainfall:

Bareilly has a humid subtropical climate with hot summers and cool winters. The average temperature for

the year is 25°C. June, with an average temperature of 32.8°C is the warmest month, while the coolest

month of the year is January, with an average temperature of 15°C. Bareilly receives 1038.9 mm

precipitation for the year on average. The month with the most precipitation on average is July with

307.3 mm of precipitation, while November is the month with the least precipitation on average, with an

average of 5.1 mm. There is an average of 37.7 days of precipitation.

1.14 Soil

Bareilly is on the Ganges plain, with fertile alluvial soil

1.15 Rivers

Ramganga River is flowing at a distance of 32 km in south west direction from the project site. The city

is on the Ramganga, with seven other rivers passing through the district. The lower Himalayas are 40

kilometers (25 mi) north of the river.

1.16 IMPORTANCE TO THE COUNTRY AND REGION

India is predominately an agro based economy. Sugarcane plays a very vital role in the agro based

economy by providing sugar, the main sweetner used in India. With the growing demand for sugar, the

emphasis has been on increasing sugar production.

India is the second largest producer of sugar over the globe. With more than 45 millions of sugar cane

growers in the country, the bulk of the rural population in India depends on this industry. One of the

major agro-based industries in India, sugar industry is the second largest agricultural industry followed

after the textile industry.


There are few major reasons for the installation of ethanol plant. Since the absolute alcohol demand on

All India basis is going to increase in proportion to petrol consumption with 5% blend. The demand for

absolute alcohol outstrips the supply quite considerably. This proposed Distillery plant will help to cope

up some need of alcohol (ethanol) for the above said purpose.

1.17 JUSTIFICATION OF THE PROJECT

M/s Oswal Overseas Ltd is being managed in a very systematic and professional way. Hence, it has

registered a consistent profit since the establishment.

Further, during setting up of Sugar mill, The Management has purposefully acquired an extra Land for Expansion / Diversification in future. Accordingly, an adequate piece of Land is available in Sugar mill premises which can be used for setting up of the proposed 100 KLPD Distillery.

The Sugar mill management has thus decided to put up a 100 KLPD Capacity, Molasses based and Grain

based Distillery Plant. The Molasses requirement of the distillery could be met well by their own

molasses and by the molasses produced in the nearby sugar mills.

The proposed distillery shall generate employment opportunities to the needy people in nearby areas.

Thus, Management feel proud in obliging the sons of soil by providing the jobs to these people and

fulfilling the social commitments by extending the welfare amenities to their family.

After setting up of the Proposed Distillery, few ancillaries shall also come to support Distillery operations

and this shall also lead to generate some employment and other business activities.

In short, by putting up the proposed Distillery, there will be a further growth of Sugar mill area in terms

of Employment, Business, Education, transportation, communication and of course Standard of living of

families.

2.0 Manufacturing Process

2.1. Manufacturing Process of Sugar from Sugar cane:

The flow chart of sugar producing from sugar cane is as follows.


Fig 5: Sugar Manufacturing Process

Fig 6: Manufacturing Process of Molasses based Distillery plant


Fig 7: Manufacturing Process of Grain based Distillery plant


2.2 Source of water: The required water will be extracted as Ground water through Bore wells.

2.3 Manpower

The category wise details of personnel required for production, maintenance, administration and

marketing, including their salary levels and total manpower cost. These have been worked out on the

basis of discussions with the experts in the industry.

Company shall engage suitably qualified and experienced key technical staff by offering attractive

remuneration packages. The key staff shall be recruited at such a time that it will receive on the job

training on production, maintenance, quality control, etc. when the plant is being commissioned and trial

runs are being taken.

Company shall operate human resource development policy as ongoing basis, through formalised in-plant

training on key activities and also deputing its personnel to participate in seminars, training programmes,

etc. for keeping abreast with the latest developments in process, products, applications, etc.


2.4 Functional requirements are given in detail in the following table:

Sr.

No.

Category No. Minimum

Qualification

Function

A. DIRECT LABOUR AND SUPERVISORY STAFF

A.1 Skilled 32 ITI Trained Maintenance/ Plant

Operation

A.2 Semi-Skilled

18 Experience in

Operation of

distillery equipment/

machinery, boiler &

turbine

Assistance for

maintenance/

Operation

A.3 Unskilled 18 Experience in

Operation of

distillery equipment/

machinery

Assistance to operators/

technicians for repairs

material movement and

weighment, etc.

A.4 Lab / Shift Chemist 8 B.Sc. Supervision of

Production

A.5 General Manager 1 M.Tech. experience

in distillery

management

Management of

Production and

Administration

A.6 Distillery Incharge 2 B.Sc. Alco Tech.

experience in

distillery

management

Day to day management

and operation,

production, etc.

A.7 Maint. Manager 1 B.E. Mech. Maintenance of plant

A.6 Assistant Engineer 4 Diploma in Mech. Supervision of

preventive and break

down maintenance,

periodic plant

equipment

inspection and


Sr.

No.

Category No. Minimum

Qualification

Function

management of quality

control of input and

output material

A.7 Instrumentation and Electrical Engineer

4 Diploma / Degree in Instrumentation and Electrical

Regular electrical and instrumentation maintenance, turbine operation

B. ADMINISTRATIVE STAFF

B.1 Accountant 2 Graduate - B.Com/C.A with 5 years experience

Maintenance of account record assistance for finance management/ banking

B.2 Clerks 5 B.A/B.Com. Maintenance of record , assistance for stores/inventory management

B.3 Watchman 4 S.S.C Security of factory

B.4 Marketing and Procurement Staff

3 M.B.A. Procurement of Grains and marketing of DWGS & ENA

2.5 Broad Technical Specifications of Plant & Machinery for 60 KLPD Molasses based Distillery

Molasses Bulk Storage Section

# Equipment Technical Specification Qty. MOC

1 Molasses Storage Tank 10000 MT storage capacities.

1 No. Mild steel, painted

2 Raw molasses Transfer pumps.

Gear type positive displacement pumps

2+2 Nos. C.S.

3 Interconnecting piping. Carbon steel pipes. LOT MS


Molasses Storage & Handling:


1 Raw Molasses transfer pump Type- Screw/Gear type Capacity- 30 MT/hr

1+1 CI

2 Day Molasses Tank Capacity- 400 MT 1 MS

3 Molasses Transfer Pump Type- Screw/Gear type Capacity- 30MT/hr

1+1 CI

4 Molasses Filter Type- Basket Strainer 1+1 MS

5 Molasses Receiving Tank Type- Cyl/Vert. Shell with Open Top & Conical Bottom, Capacity- 5MT

1 MS

6 Molasses Weighing System Type- Load Cell Capacity4 MT Per Trip

1 MS

7 Weighed Molasses Tank Type- Cyl/Vert. Shell with Conical Top & Sloping Bottom, Capacity- 40 MT

1 MS

8 Weighed Molasses Transfer Pump with Motor

Type- Screw/Gear type Capacity- 25 MT/hr

1+1 CI

9 Molasses Diluter For Yeast Vessel

Type- Static Mixer 1 AISI304

Fermentation Section:


1 CO2 Scrubber Type: Sieve Trays Dia: 800 mm

1 AISI 304

2 Culture Vessel-I with Air Sparger

Type - Cyl/Vert Shell, Jacketed with Dished Ends.

1 AISI 304

3 Culture Vessel-II with Air Sparger


1 AISI 304

4 Culture Vessel-III with Air Sparger

Type - Cyl/Vert Shell, Jacketed with Dished Ends. Capacity- 16 m3

1 AISI 304


5 Cell Mass Transfer Pump with Motor

Type- Centrifugal with Trolley Capacity- 14 m3

1

6 fermenter /Yeast Activation Vessel with SG,LG

Type- Cyl/Vert. Shell with Conical Top & Sloping Bottom, Capacity- 400m3

4 AISI 304

7 Molasses Broth Mixer for Fermenter

Type- Static Mixer 4 SS 304

8 Fermenter Recirculation Pump with Motor

Type- Centrifugal Capacity- 300m3/hr

4+1 CF8

9 Fermenter Wash Cer Type- PHE 4 Plates AISI 316

10 Pre fermenter /Yeast Activation Vessel with SG,LG

Type- Cyl/Vert. Shell with Conical Top & Sloping Bottom, Capacity- 75m3

2 AISI 304

11 Molasses Broth Mixer for Yeast Activation Vessel

Type- Static Mixer 2 AISI 304

12 Yeast Activation Vessel Transfer Pump with Motor

Type- Centrifugal Capacity- 60 m3/hr

1+1 CF8

13 Yeast Activation Vessel Cer Type- PHE,Frame MS 1 Plates AISI 316

14 Wash Holding Tank Type – Cyl/Vert. Shell with Conical Top & Sloping Bottom, Capacity – 400 m3

1 MS Epoxy

15 Wash Transfer Pump Type- Centrifugal Capacity- 40 m3/hr 1+1 CF8

16 Air Filter Type- HEPA 1+1 MS Frame

17 Air Blower with Motor Type- Watering Capacity- 240 Am3/hr

1+1 CI

18 Nutrient Dosing Tank with Agitator

Capacity- 2 m3 1 AISI 304



19 Nutrient Dosing Pump Type- Centrifugal Capacity- 1 m3/hr 1+1 CI

20 Acid Dosing Tank Type- Cylindrical, Vertical Capacity- 2m3

1 MS

21 Acid Dosing Pump Type- Centrifugal Capacity- 1 m3/hr 1+1 Wetted Parts Alloy 20

22 Antifoam Dosing Tank Type- Cylindrical, Vertical Capacity- 3 m3

1 MS

23 Antifoam Dosing Pump Type: Gear Capacity- 1 m3/hr 1+1 CI

24 CIP tank Type- Cylindrical, Vertical Capacity- 50 m3

1 AISI304

25 CIP Pump Type- Centrifugal Capacity- 25 m3/hr 1+1 Wetted Parts Alloy 20

26 Piping, Valves Instrumentation As Per Standards Lot

Distillation Section:

# Description MOC Tech. Specs. Qty.

1 Analyser Column (Rh Grid Trays) AISI 304 Dia: 1800 mm No. of Trays : 19 1

2 Degasifying Column

(Seive Trays) AISI 304 Dia: 1000mm

No. of Trays : 5 1

3 Pre-Rectifier Column

(Bubble Cap Trays) AISI 304 Dia: 1300 mm

No. of Trays : 56 1

4 Extractive Column

(Bubble Cap Trays) AISI 304 Dia: 1000 mm

No. of Trays : 45 1

5 Rectifier Cum Exhaust Column (Bubble Cap Trays)

Shell : AISI 304 Trays AISI 304

Dia: 1400 mm No. of Trays : 72 1


6 Simmering Column (Bubble Cap) (Bottom Segment in SS 304)

Shell : Dow Cu Trays: Dow Cu

Dia: 1000 mm No. of Trays : 50

1

7 Recovery Column

(Bubble Cap) AISI 304 Dia: 700 mm

No. of Trays : 50 1

8 Alcohol Scrubber AISI 304

1

Reboilers

1 Analyzer Column Reboiler Shell & Tube Type

AISI 304 1

2 ED Column Reboiler Shell & Tube Type

AISI 304 1

3 Rectifier Cum Exhaust Column Reboiler Shell & Tube Type

AISI 304 1

4 Simmering Column Reboiler Shell & Tube Type

AISI 304 1

5 Pre Rectifier Column Reboiler Shell & Tube Type

AISI 304 1

Condensers & Coolers

6 DG Condenser I&II Shell & Tube Type

AISI 304 2

7 Analyser Condenser I& II Shell & Tube Type

AISI 304 3

8 ED Condenser I& II Shell & Tube Type

AISI 304 2

9 Recovery Condenser Shell & Tube Type

AISI 304 1

10 Simmering Condenser Shell & Tube Type

AISI 304 1

11 Vent Condenser for Reboiler Shell & Tube Type

AISI 304 2


12 PCV Condenser Shell & Tube Type

AISI 304 2

13 Product Alcohol Cooler Shell & Tube Type

DOW Cu 1

14 Product (RS) Cooler Shell & Tube Type

AISI 304 1

15 TA Cooler Shell & Tube Type

AISI 304 1

16 FO Cooler Shell & Tube Type

AISI 304 4

17 R/E Alcohol Cooler Shell & Tube Type

AISI 304 1

18 ED Feed Cooler Shell & Tube Type

AISI 304 1

PHE's, Pumps

19 DM Water Preheater PHE SS 316 Plates /MS Frame 1

20 Rectifier Feed Preheater PHE SS 316 Plates /MS Frame 1

21 PR Feed Preheater PHE SS 316 Plates /MS Frame 1

22 Analyser Bottom Transfer Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

23 Rectifier Lees Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

24 PR Lees Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

25 Pre Rectifier Feed Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

26 PR Reflux Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

27 Rectifier Reflux Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

28 FO Washing Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

29 ED Bottom Transfer Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

30 Alcohol Transfer Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1


31 Recovery Feed Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

32 Steam Condensate Pump Centrifugal Type CI 1+1

33 Vacuum Pump Water Ring Type CI 1+1

34 Emergency Water Supply Set Standard 1

Others

# Description Tech. Specs. Qty.

1 FO Decanters As Per Standard 2

2 Mixing Bottle As Per Standard 1

3 Vapour Bottles As Per Standard Lot

4 Manometer Bottles As Per Standard 2

5 Seal Pot As Per Standard 1

6 Siphon For Recovery Column As Per Standard 1

7 TA Mixing Bottle As Per Standard 1

8 Pipes, Valves and Instrument As Per Standard Lot

Storage Section for RS, Ethanol Section

# Equipment Technical Specification

MOC Qty.

1 RS Receivers Capacity: 70 m3 MS 3

2 IS Receivers Capacity: 10 m3 MS 1

3 Ethanol Receiver Capacity :70m3 MS 3

4 RS Bulk Storage Tank * Capacity: 700 m3 MS 3

5 Ethanol Bulk Storage Tank * Capacity: 700 m3 MS 3

6 IS Bulk Storage Tank * Capacity: 400m3 MS 1

7 FO Storage Capacity: 10 m3 MS 1


8 Alcohol Pumps with Flameproof Motor Centrifugal CF 8 Suitable

9 Issue Measures PD Flow meters Standard 4 3

10 Piping & Fittings Standard Std 1 Lot

*Bulk storage tank with vent condenser, flame arrester.

Integrated Evaporator:

# Description Qty. Technical data M.O.C.

1 Multiple effect evaporator

Suitable Shell & Tube type, Falling Film

SS304

2 Vapor Separator Suitable Cylindrical SS304

3 Surface condenser 1 Sheet & Tube type SS304

4 Circulation pump Suitable Double Mech Shaft Contact Part SS 304

5 Process Condensate pump

1+1 Contact Part SS 304

6 Concentrated Spent wash transfer pump

1+1 Contact Part SS 304

7 Condensate Pump 1+1 Contact Part SS 304

8 Vacuum pump 1+1 Contact Part SS 304

9 Piping & Valves Lot Suitable

10 Electrical & Instrumentation

Lot Std. Specification


Independent Evaporator:

# Description Qty. Technical data M.O.C.

1 Feed and Product Tank 2 Type:- Rectangular SS304

2 Feed Pump& Spent wash pump 1+ 1 each Type - Centrifugal type

Suitable

SS 316

3 Evaporators Suitable Type : Forced circulation SS304

4 Vapor Liquid Separators Suitable Type : Gas liquid separator type SS304

5 Evaporation Pump Suitable Recirculation pump SS 316

6 Surface Condenser 1 Type : shell & tube; SS 304

9 Vacuum Pump 1+ 1 Type - Water ring type SS 316

10 Condensate Tank 1 Capacity – Suitable SS 304

11 Condensate Pump 1+ 1 Type - Centrifugal type SS 316

12 Piping and Valve, Electrical and Instruments

Utilities: Cooling Tower:

# Equipment Description Specifications Qty. (Nos.)

1 Cooling tower for Fermentation plant 1800 M Kcal/hr 1

2 Cooling tower for Distillation 4000M Kcal/hr 1

3 Cooling tower for Ethanol 900M Kcal/hr 1

4 Cooling tower for evaporation 3000M Kcal/hr 1

5 CW Recirculation pump for Fermentation Suitable. Centrifugal, 1+1

6 CW Recirculation pump for Distillation Suitable. Centrifugal, 1+1

7 CW Recirculation pump for evaporation Suitable. Centrifugal, 1+1

8 CW Recirculation pump for Ethanol Suitable. Centrifugal, 1+1

9 PRDS Suitable. 2


10 Instrument Air compressor & dryer Suitable capacity 1+1

11 Piping, Valves standard Lot

12 Instrumentation standard Lot

Slop Fired Incinerator Boiler & Turbine

# Particulars Specification

1 Slop fired incinerator boiler with bagasse as supporting fuel

22 TPH, 45 Kg/Cm2 (g) Pressure

2 Turbine Suitable capacity of 2.00 MW Back Pressure of 4.5 Kg/Cm2(g)

Water Treatment Area Filtration Plant Common for Molasses and Grain based Distillery Plant

1. Multi grade Sand Filter 1 No.

Pressure vessel internally painted with black bituminous and externally with red oxide primer :MOC

1 No.MS with epoxy coating

Piping works with valves 1 No.

Graded filtering sand specifically selected and graded 1 No.

2. Activated Carbon Filter 1 No.

Pressure vessel internally painted with black bituminous and externally with red oxide

1 No. MS with epoxy coating

Piping works with valves 1 No.

3. Softener 1 No.

Pressure with rubber lining from inside and externally with red oxide primer

1 No.

Piping works with valves 1 set

Cation Exchange resign 1 set


Hardness test kit 1 set

Brine saturated tank of MS construction 1 No.

Brine distribution system 1 Lot

4. D.M. PLANT ( 1 No.)

1 Strong acid cation 1 No.

2 Degasser tower & pump 1 No.

3 Strong acid anion 1 No.

4 Mixed bed exchanger 1No

Broad Technical Specifications of Plant & Machinery for 40 KLPD Grain based Distillery

Grain Handling and Milling

Sr. No.

Item Technical Specification

QTY MOC

1 Grain loading elevator Bucket 1

Suitable

2 Grain Storage Silo

Cyl and vertical with conical top 5000 MT

2 Suitable

3 Grain Feeding elevator Bucket 1

Suitable

4 Milling with required auxiliaries Suitable Hammer mill 1+1

Suitable and lot

Liquefaction

Sr. No.

Item Technical Specification QTY MOC

1 Liquefaction Tank with sparger and Agitator

Type-Cylindrical/ vertical 1 SS 304

2 Caustic Dosing tank

Type :Cylindrical/ vertical 1 Mild Steel

3 Recycle Stream collection tank

Type : Cylindrical

1 SS 304

4 Enzyme Dosing Tank Type :Vertical 1 SS 304


5 Premasher

Mixer 1 AISI 304

6 Caustic dosing pump

Type :Centrifugal 1+1 CI

7 Liquefaction tank pump

Type :Centrifugal 1+1 Wetted Parts CF8

8 Recycle stream collection tank transfer pump

Type :Centrifugal 1+1 Wetted Parts CF8

9 Slurry cooler Type : PHE 1+1 Plate - AISI 316

10 Liquefying Enzyme dosing pump

Type :metering Standard

Fermentation Section:

Sr. No.

Equipment Technical Specification Qty MOC

1 CO2 Scrubber Type: Sieve Trays Dia: 600 mm 1 AISI 304

2 Culture Vessel-I with Air Sparger

Type - Cyl/Vert Shell, Jacketed with Dished Ends. 1 AISI 304

3 Culture Vessel-II with Air Sparger


1 AISI 304

4 Culture Vessel-III with Air Sparger

Type - Cyl/Vert Shell, Jacketed with Dished Ends. Capacity- 10 m3

1 AISI 304

5 Cell Mass Transfer Pump with Motor

Type- Centrifugal with Trolley Capacity- 10 m3 1

6 Fermenter with Agitator, SG, LG

Type- Cyl/Vert. Shell with Conical Top & Sloping Bottom, Capacity- 200 m3

4 AISI 304


7 Fermenter Recirculation Pump with Motor

Type- Centrifugal Capacity- 150m3/hr 4+1

CF8 (Wetted Parts Only)

8 Fermenter Wash Cooler Type- PHE 4 Plates AISI 316 Frame MS

9 Pre fermenter /Yeast Activation Vessel with SG,LG

Type- Cyl/Vert. Shell with Conical Top & Sloping Bottom, Capacity- -50m3

2 AISI 304

10 Yeast Activation Vessel Transfer Pump with Motor

Type- Centrifugal Capacity- 40 m3/hr

1+1 CF8 (Wetted Parts Only)

11 Yeast Activation Vessel Cooler Type- PHE 1 Plates AISI 316 Frame MS

Sr. No. Equipment Technical Specification Qty MOC

12 Beer well Type- Cyl/Vert. Shell with Conical Top & Sloping Bottom, Capacity- 200 m3

1 MS Epoxy

13 Wash Transfer Pump Type- Centrifugal Capacity- 20 m3/hr 1+1 CF8 (Wetted Parts

Only)

14 Air Filter Type- HEPA 1+1 MS Frame

15 Air Blower with Motor

Type- Watering Capacity- 100 Am3/hr 1+1 CI

16 Nutrient Dosing Tank with Agitator

Capacity- 1 m3 1 AISI 304

17 Nutrient Dosing Pump Type- Centrifugal Capacity- 1 m3/hr

1+1 CI


18 Acid Dosing Tank Type- Cylindrical, Vertical Capacity- 1 m3 1 MS

19 Acid Dosing Pump Type- Centrifugal Capacity- 1 m3/hr

1+1 Wetted Parts Alloy 20

20 Antifoam Dosing Tank

Type- Cylindrical, Vertical Capacity- 1 m3 1 MS

21 Antifoam Dosing Pump Type: Gear Capacity- 1 m3/hr 1+1 CI

22 CIP tank Type- Cylindrical, Vertical Capacity- 30 m3 1 AISI304

23 CIP Pump Type- Centrifugal Capacity- 10 m3/hr 1+1 Wetted Parts Alloy

20

24 Piping, Valves Instrumentation As Per Standards Lot

Distillation Section

Sr. No. Description MOC Tech. Specs. Qty

1 Analyser Column (Rh Grid Trays AISI 304 Dia: 1100 mm

No. of Trays : 19 1

2 Degasifying Column (Sieve Trays)

AISI 304 Dia: 800mm No. of Trays : 5

1

3 Pre-Rectifier Column (Bubble Cap Trays) AISI 304 Dia: 900 mm

No. of Trays : 56 1

4 Extractive Column (Bubble Cap Trays) AISI 304 Dia: 800 mm

No. of Trays : 45 1


5 Rectifier Cum Exhaust Column (Bubble Cap Trays)

Shell : AISI 304 Trays AISI 304

Dia: 1100 mm No. of Trays : 72 1

6 Simmering Column (Bubble Cap)

Shell : Dow Cu Trays: Dow Cu

Dia: 900 mm No. of Trays : 50

1

7 Recovery Column (Bubble Cap) AISI 304 Dia: 400 mm

No. of Trays : 50 1

8 Alcohol Scrubber AISI 304

1

Reboilers

1 Analyzer Column Reboiler Shell & Tube Type AISI 304 1

2 ED Column Reboiler Shell & Tube Type AISI 304 1

3 Rectifier Cum Exhaust Column Reboiler Shell & Tube Type

AISI 304 1

4 Simmering Column Reboiler Shell & Tube Type AISI 304 1

5 Pre Rectifier Column Reboiler Shell & Tube Type AISI 304 1

Condensers & Coolers

6 DG Condenser Shell & Tube Type AISI 304 2

7 Analyser Condenser Shell & Tube Type AISI 304 2

8 ED Condenser Shell & Tube Type AISI 304 2

9 Recovery Condenser Shell & Tube Type AISI 304 2

10 Simmering Condenser I Shell & Tube Type AISI 304 1

11 Vent Condenser for Analyzer Shell & Tube Type AISI 304 1


Column Reboiler

12 Vent Condenser for Simmering Column Reboiler Shell & Tube Type AISI 304 1

13 Rectifier PCV Condenser Shell & Tube Type AISI 304 1

14 PR PCV Condenser Shell & Tube Type AISI 304 1

15 Product Alcohol Cooler Shell & Tube Type DOW Cu 1

16 TA Cooler Shell & Tube Type AISI 304 1

17 FO Cooler Shell & Tube Type AISI 304 2

18 Pre Rectifier FO Cooler Shell & Tube Type AISI 304 1

19 R/E Alcohol Cooler Shell & Tube Type AISI 304 1

20 ED Feed Cooler Shell & Tube Type AISI 304 1

PHE's, Pumps

1 DM Water Preheater PHE SS 316 Plates /MS Frame 1

2 Rectifier Feed Preheater PHE SS 316 Plates /MS Frame 1

3 PR Feed Preheater PHE SS 316 Plates /MS Frame

1

4 Analyser Bottom Transfer Pump Centrifugal Type CF8 (Wetted Parts Only)

1+1

5 Rectifier Lees Pump Centrifugal Type CF8 (Wetted Parts Only)

1+1

6 PR Lees Pump Centrifugal Type CF8 (Wetted Parts Only)

1+1

7 Pre Rectifier Feed Pump Centrifugal Type CF8 (Wetted Parts Only)

1+1


8 PR Refux Pump Centrifugal Type CF8 (Wetted Parts Only)

1+1

9 Rectifier Reflux Pump Centrifugal Type CF8 (Wetted Parts Only)

1+1

10 FO Washing Pump Centrifugal Type CF8 (Wetted Parts Only)

1+1

11 ED Bottom Transfer Pump Centrifugal Type CF8 (Wetted Parts Only)

1+1

12 Alcohol Transfer Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

13 Recovery Feed Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1

14 Steam Condensate Pump Centrifugal Type CI 1+1

15 Vacuum Pump Water Ring Type CI 1+1

16 Emergency Water Supply Set Standard 1

Others

Sr. No. Description Tech. Specs. Qty

1 FO Decanters As Per Standard 2

2 Mixing Bottle (For ED/Purifier Column) As Per Standard 1

3 Vapour Bottles As Per Standard Lot

4 Manometer Bottles As Per Standard 2

5 Seal Pot As Per Standard 1

6 Siphon For Recovery Column As Per Standard 1

7 TA Mixing Bottle As Per Standard 1

8 Pipes & Fittings, Valves and Instrument As Per Standard Lot


Storage

Sr. No. Equipment Technical Specification MOC Qty

1 TA Receivers Capacity: 5 m3 MS 1

2 ENA Receivers Capacity: 40 m3 MS 3

3 ENA Storage Tank with Vent Condenser & Flame Arrestors Capacity: 1200 m3 MS Suitable

4 TA Bulk Storage Tank with Vent Condenser & Flame Arrestors

Capacity: 200m3 MS Suitable

5 FO Storage Capacity: 30 m3 MS 1

6 Alcohol Pumps with Flameproof Motor

Centrifugal Wetted Parts CF 8

Suitable

7 Flow meters Standard 2

8 Piping & Fittings Standard Standard 1 Lot


Decantation Section

Sr. No.

Item Technical Specification

QTY MOC

1 Decanter Centrifuge Centrifuge 1+1

. AISI 304 Internals

2 Thin Slop Holding Tank After Decanter

Vertical Type 1 AISI 304 1

3 Thin Slops Transfer Pump

Centrifugal Type 1+1

Wetted parts CF8

4 Ribbon Mixer Ribbon type 1 AISI 304

Independent Evaporator

Sr. No. Description Qty Technical data M.O.C.

1 Feed Tank 1 Type:- Rectangular Capacity :- Suitable

SS304

2 Feed Pump 1 + 1 Type - Centrifugal type Cap Suitable

SS 316

3 Evaporators Suitable Forced circulation type SS304

4 Vapor Liquid Separators

Suitable. Type : Gas liquid separator type SS304

5 Evaporation Pump Suitable Recirculation pump

SS 316

6 Surface Condenser 1 nos. Type : shell & tube;

SS 304

7 Product Tank 1 no. Capacity Suitable Type : vertical / cylindrical

SS 304

8 Spent Wash Pump 1 + 1. Type - Centrifugal type Material – Casing and impeller

SS 316

9 Vacuum Pump 1 + 1 Type - Water ring type

SS 316

10 Condensate Tank 1 Capacity – Suitable Type : vertical/ cylindrical

SS 304

11 Condensate Pump 1 + 1 nos. Type - Centrifugal type

SS 316

12 Piping and Valve, Electrical and Instruments


Utilities: Cooling Tower

Sr. No. Equipment Description Specifications Qty. (Nos)

1 Cooling tower for Liquefaction plant Suitable 1

2 Cooling tower for Fermentation plant 900 M cal/hr 1

3 Cooling tower for Distillation 2500 M cal/hr 1

4 Cooling tower for evaporation 2000 Mcal/hr 1

5 CW Recirculation pump for liquidation

Suitable. Centrifugal, 1+1

6 CW Recirculation pump for Fermentation


7 CW Recirculation pump for Distillation


8 CW Recirculation pump for evaporation


9 PRDS Suitable. 2

10 Instrument Air compressor with Air dryer Suitable capacity 1+1

11 Piping, Valves standard Lot

12 Instrumentation standard Lot

Bagasse Fired Boiler & Turbine Sr. No

Particulars Specification

1 Bagasse fired incinerator boiler

10 TPH, 45 Kg/Cm2 (g) Pressure

2 Turbine Suitable capacity of 1 MW Back pressure with exhaust pressure of 4.5 Kg/Cm2(g)


3.0 Energy and Water Conservation

The consumption of energy is a vital factor in any industry. Energy saving may be achieved in the

following manner:

• The process involves multi pressure system which is heat saving & efficient system

• Insulation of all columns, pipelines, vessels are essential.

• Preheating of wash

• The wash feed temperature to analyzer column can be raised to 80-850C by efficient use of

beer heater and heat exchangers; besides the heating of boiler feed water with excess spent

wash can also be raised to 80-850C. Substantial reduction in steam consumption may be

achieved with maintaining a proper reflux ratio.

• Condensers.

• High alcohol % in wash can result in substantial reduction in steam consumption.

• Reducing the quantity of spent wash generation through multistage evaporation by using

steam as heating media. Therefore, less steam is required for integrated evaporation.

• It is possible to recycle of low strength waste generated i.e. process condensate, spent lees

and other streams in distillery after treating through condensate polishing unit. It will help to

reduce the consumption of fresh water for process and non-process applications.

• During spent wash treatment the concentrated spent wash is burnt with support fuel bagasse

or coal. Due to concentrated spent wash, fresh fuel (bagasse) requirement is reduced.

3.1 Fire Fighting and Safety:

In view of the inflammable nature of the end product the plant incorporates suitable firefighting

equipment and flameproof lighting and power control arrangements. Non inflammable and

flameproof motors are used wherever absolutely necessary. Water hydrants will be provided at all

strategic points. A suitable Fire ring system as per the guidelines of TAC will be incorporated.

Non-flameproof and flameproof area will be separated by minimum distance of 15 meters.


4.0 Socio-Economic and Environmental Benefits

The proposed project will be a landmark achievement in Bareilly District of UP State. It will

truly become a role model of zero pollution industry by utilizing the waste effluent which will be

burnt with support fuel bagasse in the most efficient manner for eco-friendly products like fuel

ethanol and ENA. The sound techno-economic and commercial viability of this project, coupled

with highest efficiency in all aspects of product manufacture, will pave the way for integration of

sugar and alcohol industry in the State of Uttar Pradesh. Establishment of the latest and most

efficient technologies adopted for fuel ethanol / ENA manufacture, will also help the Indian

sugar industry and equipment manufacturers to grow leaps and bounds, at the national and the

international levels.

The socio-economic benefits arising out of this project for the local populace will include

creation of direct and indirect jobs and consequent rise in the income levels, associated

commercial and social infrastructure development in the mo fussil areas, better environment and

higher returns for the cane crop due to higher yield and cane price. At the national and the State

levels, the benefits include reduced emissions, increased tax revenues and reduction in the

transportation costs.

At the project and promoter levels, the captioned project offers excellent opportunities for

manufacture of fuel ethanol and improved returns from trade of emission reductions from the

upcoming international emissions trade market, under the Kyoto Protocol.

5.0 Hazardous waste and its disposal

Spent Oil from the gear boxes, DG set is being reused for chains, bullock carts, and conveyor belts and if

in excess is disposed to the authorized vendors as per the Hazardous Wastes (Management and Handling)

Amendment Rules, 2016


6.0 Rehabilitation and Resettlement:

Rehabilitation or resettlement will not be required in case of proposed project as the site is a barren land

with no human settlement.

7.0 Environment Management Cell

OOL will set up a dedicated Environmental cell to monitor and analyze the air quality, water and

wastewater quality and noise levels under the supervision of Environmental engineer either in-house

or through third party laboratories.

8.0 Corporate Social Responsibilities (CSR) Budget

Oswal Overseas Ltd (OOL) has allocated a budget of Rs.352.8 Lakhs i. e >2.5% of the total project cost

(Rs.141.12 Crores) of the distillery plant.

Table20: CSR Budget Plan


S. No.

Activities Social Benefits Expenses

(Rs. Lacs)

1 Education Development

Providing scholarships and prize amounts for merit students

Providing reimbursement of cost of uniform, notebooks for factory employee children’s.

Providing skill development trainings

Conducting Art of Living classes to the employees and villagers so as to create value in the lives of people.

5.292

2 Rural Road Development

Provide Road infrastructure facilities from the factory connecting to nearby villages.

Providing repairs for the damaged roads due to the vehicular movement.

5.292

2. Drip Irrigation To save water, increase crop production

Minimize use of water

3.528

3. Rain water Harvesting

Water collection from factory terrace

Rain water for reuse, landscape irrigation

Greenbelt development

7.056

4. Greenbelt Greenery for ecological balance

Enrich local biodiversity

Control Air & Noise pollution,

3.528


windbreak

Helpful to control soil erosion

Plan for plantations

5. Health Programme

Conducting frequent health Checkups for all the workers regularly.

Providing Personnel Protective Equipment (PPE) for all the workers

Providing safety training programs for all workers

Providing safe drinking water with RO Treatment facility.

Providing hygienic toilets to the workers and cane truck drivers.

5.292

6. Organic Farming : Supply of Bio-Fertilizer. Bio-compost distribution at subsidized rates to the farmers and cane growers

5.292

TOTAL FUND FOR CSR ACTIVITY 35.28 Lakhs

9.0 The salient features of Demographic Structure are as follows:

According to the 2011 census Bareilly district has a population of 4,465,344

The district has a population density of 1,084 inhabitants per square kilometre (2,810/sq mi)

Bareilly has a sex ratio of 883 females for every 1000 males.

Bareilly has a literacy rate of 60.52%

The area under the city region is 123.46 km². The density of the population is among the highest in the country, almost 5000 per km2.

The predominant languages are Hindi and Urdu. Other lesser spoken languages are Punjabi and Kumaoni


10.Conclusions & Recommendations

The captioned project is technically feasible and commercially viable. The project is recommended to financial institutions / banks for financing term and working capital loans.

pre-feasibility report forenvironmentclearance.nic.in/writereaddata/online/tor/08_jan_2019... ·...

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