Pre-Feasibility Report

for
Grain Based 200 KLD Fuel Ethanol Plant
& 4.80 Mw Co- Generation Power Plant
At
Umariya-Dungariya Industrial Area
Phase-II, Jabalpur (MP)

Proposed By
M/s Mahakaushal Distillery Pvt Limited
3,Todarmal Lane Bengali Market,
New Delhi 110001
1. Identification Of Project and Project Proponent
Mahakaushal Distillery Pvt. Ltd. is a company interested in venturing into
manufacturing of fuel ethanol and its by-products like CO2, DDGS and captive power
generation. The project will be based on MULTI FEED grains like broken rice, maize,
FCI Rice etc. for utilization of their starch to manufacture bio-ethanol and other
constituents like protein &fiber to produce value added cattle feed. The group wants to
generate this environment friendly fuel to promote the concept of sustainable
development as well as to promote Agro-based industries with assured returns for the
farmers. By setting up distillery and manufacturing fuel ethanol. This venture would
boost job opportunities and would also spur indigenous technological development.
According to the Govt. of India Ethanol Blending Programmed (EBP), India aims to
achieve 20% ethanol blending in petrol by [Link] ethanol from multi-feed Grains
for consumption, would be a great boost to the EBP plan execution.
The project would comprise of a Grain Based 200,000 LPD Distillery to produce
Fuel Ethanol (AA) along with 4.80 MW captive power plant and dry DDGS cattle
feed.
Brief Description of Nature of The Project
The present proposal is for setting up a grain based 200 KLD of fuel ethanol unit with
cogeneration of power (4.80 MW) at Umariya-Dungariya Industrial Area, PH-II,
Jabalpur in the State of Madhya Pradesh at an estimated cost Rs. 220 Crores.

The Products will have specified as 200 KLPD of fuel ethanol. The by product is
identified as CO2 which will generate at about 98 TPD (total generation). DDGS ( 102
TPD) shall also be recovered from the proposed unit
The Company proposes to set up an integrated pollution free (Zero discharge) Distillery
Complex in the State. The proposed Industrial Complex shall process waste and
coarse grains as its raw material to produce fuel ethanol, CO2 etc.:

Silent Feature of The Project

Liquefaction:
1. Maximum conversion of starch to sugar
2. Recycle of lees thus minimizing the fresh water requirement.

Fermentation:
1. High alcohol productivity with high efficiency of fermentation of up to 92%.
2. Higher alcohol content in the fermented mash, thus lower steam requirement.
3. High ease of operation
4. Design of equipment, piping and provision of cleaning in place ensures minimum
bacterial activity.
5. Mash coolers designed to reduce the possibilities of choking.
6. Water recycle and reuse system reducing fresh water requirement.
 Distillation:
1. Plant with maximum heat integration to produce alcohol with lowest energy
consumption.
2. Energy efficient integrated system Distillation efficiency up to 99.5% whilst
producing AA
3. Well-engineered plants with high efficiency trays to ensure elaborate separation
and removal of impurities ensuring superior quality of Spirit.
Proper care in design of calming zone on trays, large area of down-comers, gas-
liquid separators with tangential entry and vapor bottles ensures proper gas-liquid
disengagement and eliminates chances of liquid carryover
4. Mash column with hyper stat Rh Grid trays ensure high turbulence on tray, this
minimizes chances of scaling. Also, this special construction of trays and access to
each tray helps in easier cleaning of column internals.
5. Condensers are designed with multiple passes to ensure high velocity and to
minimize scaling inside tubes.
Water recycle and reuse system reducing fresh water requirement.

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

Dryer:
1. Multiple working references
2. Low Temperature drying – No product degradation
3. 100 % syrup can be consumed
4. Robust construction

Process Condensate Treatment Plant:

Designed to treat process condensate + Cooling Tower Blow down + Dryer vapor
condensate thus enhancing recycle and reducing fresh water requirement to up to
5.2 lit/lit for Distillery process
1. Technology available indigenously with successful plants running based on the
technology with focus on reducing water, energy and carbon footprint
2. Provided with most efficient Fed batch Fermentation technology
3. Distillation operating on Multi-Pressure Technology – an efficiently heat
integrated system, operating on fully automated PLC control system
4. Most efficient process technologies for liquefaction, fermentation, MPR
distillation , dehydration and evaporation to attain maximum and sustainable
plant outputs
5. Extensively process and heat integrated system to reduce energy consumption
6. Water management design based upon three principles of reduce, reuse and
recycle water to minimize fresh water requirement.
7. Zero effluent and liquid discharge norms applied while designing the plant.
8. Ethanol produced from the proposed 1G ethanol facility will be as per Indian
specifications (IS 15464:2004) of anhydrous ethanol for use of blending in
automobile fuel.
Salient Features of The proposed Project
Site Address Plot No.61, Umariya- Dungariya Industrial Area
Phase-II, Jabalapur -482003 (MP)
Production Capacity Grain base fuel ethanol unit of 200 KLPD along
with 4.80 MW Power Plant, 98 TPD CO2
generation and 102 TPD of DDGS
Cost of Project 220 Crore
Grain Requirement 481 TPD Rice @ 68 % starch and/or 550 TPD –
Corn @ 60 % starch.
Boiler capacity at MCR (100% Load) 42.00 TPH
Steam Requirement Process : 30 - 34 TPH @ 3.9 kg/lit of TS (Corn
as Base)
Fuel Rice husk ( 271 TPD) and/or Coal ( 217 TPD)
Total water Requirement 2862 KLD
Total Recycling of Water 2062 KLD
Net Fresh Water Requirement 803 KLD
Net Fresh Water Requirement including 1173 KLD
power plant and Domestic requirement
Spent Wash Generation 1300 KLD
DDGS Generation 102 TPD
Ash Generation from Boiler 66 TPD
Operating Power Requirement 3185 KWH (Process) / 4800 KW (Peak)
Capital Cost for Environmental measures 1842 Lacs
MEE, Dryer, BG for boiler ( proposed )
Recurring cost for environmental 81 Lacs
Management etc ( Proposed )
Total Acquired Land 8 Hact
Total Built Up area of Plant 2.70 ha
Proposed area for plantation 2.65 Hact
Alternative Source of Power Startup power DG set of 01 x 1500 KVA
Support power DG set of 01 x 250 KVA
Direct Employment Generation 100+92

3. Need for the project and its importance to the country and or region
 Reducing import dependency: The proposed 1G ethanol project will produce
around 200 KLD of Fuel Ethanol. This project is a step in utilizing renewable and
environment-friendly sources of energy like ethanol to supplement fossil fuels.
Cleaner Environment: As per the ministry of petroleum notification on new
biofuel policy, the proposed 1G ethanol project of DAPL will produce around ~1.92
– 1.98 Crore liters of Bio-Fuel Ethanol which has the potential to save around 45%
– 50% of CO2 emissions per year by replacing gasoline with bio-ethanol if biomass
is considered as possible fuel source
Employment Generation: The proposed 200 KLPD 1G ethanol project will create
around 100+ direct jobs in plant operations, and about further hundreds of
indirect jobs for personnel related to various supply chain & selling of by-product;
village level entrepreneurs and Grain and DDGS supply chain. DDGS as a protein
rich feed for animals will boost animal husbandry development in rural India. This
will provide boost to rural economy in India.
Income to Farmers: Farmers will get sustainable income source by growing
feedstock and there will be assured off take and utilization of grains for biofuel
production. This will help to increase farmer’s income.
Infrastructural Investment in Rural Areas: Proposed 1G ethanol plant will
require Capital Investment of ~ INR 18928 Lacs. Investment in proposed 1G
ethanol plant will spur infrastructural investment in rural areas.
Indian Outlook for Bioethanol

Progressive Vision and Strong Policy Support

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

Highlights Of National Biofuels Policy -

 Targets to achieve these key outcomes through the EBP Programme
 Ensuring energy security and self-reliance by enhancing biofuels production.
 Reducing import bill and conserving foreign exchange.
 Reduction in carbon emission
 Strengthening rural economy, Enhanced and sustainable income for farmers by
providing boost to agricultural sector
 Retain employment and additional employment generation in rural India.
 Targets 10% ethanol blending by 2022 and 20% blending by 2030
 Allowing additional feedstock for 1st Generation like sugarcane
juice/ syrup, surplus/damaged grains for production of ethanol
 Use of lingo cellulosic biomass such as agricultural crop residue, energy crops
,etc. for production of 2nd Generation Bioethanol

Other Major Policy Measures To Support The EBP

 Interest subvention schemes introduced for sugar cane and molasses based
distilleries
 Remunerative ethanol pricing for various feed stocks independent of crude oil
pricing
 Assurance of OMCs to purchase ethanol for 10 years
 OMCs have modified there tender terms like
 Reduction in penalties from 5% to 1%
 Flexibility in supply

KEY DRIVERS

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

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

GOI is planning to reduce crude import up to 10% by 2022. EBP is one of the
key facilitator of reducing import bill by blending ethanol in gasoline thereby
reducing gasoline requirement and providing sustainable income to farmers.
The above table also depicts the ethanol available and shortfall in M.P and
potential demand going ahead
The following point’s highlight the advantages of establishing such plants in
order to bring sustainability to ethanol blending program –
1. In the current scenario Ethanol supply is dependent on Sugar sector.
2. Major Sugar Cane Crop Production is limited within Maharashtra, Uttar
Pradesh, Bihar and Karnataka. Due to this the major Alcohol Production is
also from these four states only, making imbalance for demand and supply
of other states.
3. Shortage in supply of fuel ethanol post diverting excess sugar.
4. Incremental Price pressure on account of sugarcane FRP increase and
subsequent remunerative pricing of ethanol.
5. Alternative feedstock in the form of surplus grain (rice) is adequately available
6. Benefits of setting of grain to Ethanol plants :
a. Control on Ethanol supply for non-sugar producing states and even
Sugarcane crop deficit years.
b. Ensuring minimum quantity sustainability of the EBP
c. In case of Grain to Ethanol, ZLD can be achieved with value added -
protein rich DDGS as a co-product.
d. Decentralized units will boost in achieving state blending targets and
reduce interstate transport. This will also reduce the carbon foot print due
 to reduction in vehicle travelling.
7. Benefits of setting up higher capacity Grain to Ethanol plant:
a. Can achieve better Economy of Scale and reduce production costs
b. Provides cushioning against variation in Feedstock and by-product prices
Apart from above the potable alcohol market also has a huge potential with
average CAGR on 6 – 7% in India
4. Demand –Supply Gap
Ethanol Demand Scenario Estimation for 2025

 The ethanol demand considering the preponement of EBP to year 2025 is of total
around ~1200 Cr lit per annum out of which around ~900 Cr lit is for fuel
ethanol and around ~ 300 Cr lit is from other sectors
 The above demand does not take into account additional requirement envisaged for
diesel blending and SAF (Sustainable aviation fuel)
Ethanol supply scenario
Backed by slew of measures by the Government and strong support by the
OMCs the ethanol blending targets are set to rise, but, still would fall short to
achieve 20 % blending
 Feedstock Wise Ethanol Demand - Supply Scenario Estimation For 2025
Ethanol supply trend and estimated quantity until 2022

Particulars 20% ethanol Other Uses ( Total (In

blending ([Link].) [Link]) [Link])
Total Requirement 900 300 1200

EstimatedEthanolSupplyfromSugarSector

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

600 Cr Ltrs post diverting 6 MMT surplus sugar
 This clearly denotes that blending targets cannot be achieved only by
diverting sugarcane/sugar to ethanol, so there is dire need for alternative
feedstock.
 Thus, the government is encouraging production of ethanol from other
feedstock like grains (Surplus rice/Maize/Damaged Food Grain (DFG)).
GRAIN FEED STOCK SCENARIO
The Government has notified about surplus Grain availability of around 13.5
MMT which can be utilized to produce Ethanol.
Estimated Ethanol Supply from Grains
 ExistingandRequiredCapacities–India
Particulars Molasses Grain Based Total (
Based ([Link].) ([Link]) [Link])
Supply requirement 660 540 1200
Installed Capacity required 825 675 1500
considering 80% Capacity
Utilization
Existing Ethanol / Alcohol 426 258 684
capacity
Capacity addition envisaged by 93 - 93
2022
Capacities to be Added 306 417 723

Fuel Ethanol Blending Program

Existing and Required Capacities –M.P
Particulars Value
Yearly operational capacity by Year 2022 (In Cr Lit.) ~ 35.0
Demand for E 20 by Year 25 (in [Link]) ~43.0
Addn. Demand for potable alcohol by Year 25 (in Cr Lit) ~ 11.0
Shortfall/Excess with 80% capacity (in Cr lit) ~19.0
Opportunity to set up nearly 9 – 10 plants of 60 KLPD capacities

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

market is enough to consume the product.

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

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

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

Proposed Employment :100 Nos. (Permanent) and 92 nos (Indirect) Apart from that
indirect employment generation is envisaged from the project.

9 Project Description

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

 No interlinked and interdependent project with the proposed plant, however power
plant of 4.8 MW through co-generation is proposed. CO2 will also generate as by
product from the fermentation process which is turn can be utilized after further
treatment at CO2 plant in industrial or food grade application. It is also proposed
Evaporation plant of effluent to provide better environment conservation and pollution
control arrangement in the unit as well as for the surrounding area.

ii. Location (map showing general location, specific location, and project boundary &
project site layout) with Coordinates:
The unit is spreaded over 8 Ha of land in Umariya- Dungriya Industrial Area Jabalpur
(MP).

Google Image of the Project area

 Topographical Base Map
iii. Details of Alternate Site:
The green field unit of 200 klpd is proposed at industrial area with environmental
consideration and in line with guideline issued for setting up Industrial project. Hence
no alternate site is considered. There for proposed site suitable for the project
configuration.

iv. Size or magnitude of Operation:

It is proposed to produce 200 KLPD of fuel ethanol, 98 TPD of CO 2 (by product) from
grain based operation. 4.8 MW Co gen plant is also proposed be with the distillery
unit. The unit shall be adopted zero discharge technology for the effluent disposal. .

v. Project Description with Process Details:

The overall process is shown on the attached Block Flow Diagram, and Process Flow
Diagrams. The following describes the production of ENA and co-products from grain.
 PROCESS DESCRIPTION
Parameter Details
Grain type Convertible Starch Content
For Clean Grain containing minimum
Broken Rice, Corn, Sorghum, Bajra etc. 58% w/w enzymatically convertible
starch.
Plant Capacity 200 KLD Fuel Ethanol on Grain
Thin slop recycle to Liquefaction section 30%
Alcohol Concentration in Fermented Wash 13 % v/v Min
Product
Yield
Liter of alcohol (95 %v/v) per ton of clean Grain
flour containing 68% w/w (Min.) enzymatically 467 Lit/MT
convertible starch

 Plant will operate only one product at a time i.e. Wash to A.A.
 Plant and products capacity, yield is subject to input quantity and specifications as
specified in respective section. Any variation in the same will affect plant overall
performance.
 Yield Chart
Combine Efficiency for A.A. Liquefaction, Fermentation and Distillation &Dehydration
–91.44% (Product Strength for A.A.- 99.8 % v/v)
PROCESS DESCRIPTION
FuelEthanolSpecifications
Property Limit
Ethanol,vol.% 92.1
Water,vol. % 1.0max
Methanol,mg/L 0.5max
Acetic Acid, wt% 0.007
Chlorine,mg/L 40max
Copper,mg/l 0.1max
Denaturants, vol.% 1.96–4.76

Characteristics of Absolute Alcohol

Sr. Description Unit Characteristics of
No. Absolute Alcohol
1. Specific gravity at 15.6 / 15.6 C
0 0 0.7961
Max.
2. Molecular Weight 46
3. Oxygen Content % 34.70
4. Latent Vaporization heat KJ/Kg. 925
5. Low Calorific value KJ/Kg. 27723
Kcal/Kg. 6642
 6. Boiling Point 0C 78.30
7. Energy per unit and volume KJ/Kg. 22012
8. Viscosity at 200 C Centipoises 1.192
9. Vapor Pressure at 200 C Atm 0.058
10. Vapor Pressure at 400 C Atm 0.177
11. Vapor Pressure at 600 C Atm 0.463
12. Octane number (research) RON - 106
13. Octane number (motor) MON - 87
14. Stoichiometric mixture Air : Fuel 8.95 : 1

Specifications of Rectified Spirit & ENA

Parameters Rectified Spirit ENA
Clear Colorless Clear Colorless
Appearance Liquid Liquid
Ethanol content %v/v at 15.6 deg C 94.68 96.00
Specific gravity at 15.6 deg C 0.81 0.81
Alkalinity Nil Nil
Miscibility with water Miscible Miscible
Ethyl acetate (G C Analysis) 200 ppm < 5 ppm
Acetaldehyde 60 ppm < 1 ppm
2-Butanol To satisfy test < 1 ppm
n- Propanol To satisfy test < 1 ppm
Iso-Butanol To satisfy test < 5 ppm
n-Butanol To satisfy test < 1 ppm
Iso-Pentanol To satisfy test < 1 ppm
n-Amyl Alcohol To satisfy test < 1 ppm
Methanol To satisfy test < 5 ppm
Diacetal To satisfy test < 5 ppm
Potassium Permanganate time 50 min 50 min
Furfural To satisfy test To satisfy test
Residue on Evaporation 50 ppm 10 ppm max.
Acidity Expressed as Acetic Acid 20 ppm max. 10 ppm max.

Fuel Ethanol Specifications: IS 15464:2004

Absolute (Anhydrous) Alcohol Special Grade Test
Method
Relative Density @ 15.6/15.6 oC, Max. 0.7961 A
 Ethanol content @ 15.6 oC, vol %, v/v Min. (excluding 99.6 – 99.85 B
denaturant)
Miscibility with water Miscible C
Alkalinity Nil D
Acidity (CH3COOH), mg/l, Max. 30 D
Residue on evaporation, wt%, Max. 0.005 E
Aldehydes, as (CH3CHO), mg/l, Max. 60 F
Copper, mg/kg, Max 0.1 G
Conductivity, micro S/m, Max. 300 H
Methyl alcohol, mg/l, Max. 300 J

Appearance Clear & Bright Visual

INDUSTRIAL ALCOHOL SPECIFICATIONS

Sr. No Component Unit IA Grade Limit
1 Ethanol @ 15 deg C % v/v 95 to 96 Minimum
2 Aldehydes as Acetaldehyde PPM 50 Maximum
3 Methanol PPM 50 Maximum
4 N-Propanol & Iso -Propanol PPM 40 Maximum
5 Butanol PPM 25 Maximum
6 Acids as Acetic acid PPM 35 Maximum
7 Esters as Ethyl Acetate PPM 25 Maximum
8 Furfural PPM Nil
9 Lead PPM Nil
10 Copper PPM Nil
11 Dry extract PPM Negligible
12 Permanganate Test Time Minutes 7 to 10 Minimum

DETAILMANUFACTURINGPROCESS
Alcohol From Dry Milling
The production of ethanol or ethyl alcohol from starch or sugar-based feedstocks is
among man's earliest ventures into value-added processing. While the basic steps
remain the same, the process has been considerably refined in recent years, leading to
a very efficient process. There are two production processes: wet milling and dry
milling. The main difference between the two is in the initial treatment of the grain.
Dry Milling - Process
In dry milling, the entire grain kernel or other starchy grain is first ground into flour,
which is referred to in the industry as "meal" and processed without separating out
the various component parts of the grain. The meal is slurried with water to form a
"mash." Enzymes are added to the mash to convert the starch to dextrose, a simple
sugar. Ammonia is added for pH control and as a nutrient to the yeast.
The mash is processed in a high-temperature cooker to reduce bacteria levels ahead of
fermentation. The mash is cooled and transferred to fermenters where yeast is added
and the conversion of sugar to ethanol and carbon dioxide (CO2) begins.
The fermentation process generally takes about 40 to 50 hours. During this part of the
process, the mash is agitated and kept cool to facilitate the activity of the yeast. After
fermentation, the resulting "beer" is transferred to distillation columns where the
ethanol is separated from the remaining "stillage." The ethanol is concentrated to 190
proof using conventional distillation and then is dehydrated to approximately 200
proof in a molecular sieve system.
The anhydrous ethanol is then blended with about 5% denaturant (such as natural
gasoline) to render it undrinkable and thus not subject to beverage alcohol tax. It is
then ready for shipment to gasoline terminals or retailers.
The stillage is sent through a centrifuge that separates the coarse grain from the
solubles. The solubles are then concentrated to about 30% solids by evaporation,
resulting in Condensed Distillers Solubles (CDS) or "syrup." The coarse grain and the
syrup are then dried together to produce dried distillers grains with solubles (DDGS), a
high quality, nutritious livestock feed. The CO2 released during fermentation is
captured and sold for use in carbonating soft drinks and beverages and the
manufacture of dry ice.
Rice/ Grain Storage Handling And Milling
The objective of milling is to convert Rice/ Grain into flour with particle size in the
range of 0.3 to 0.8 mm. The pre-cleaned grain, stored in bulk silos, is transferred to
Day Silo by grain transfer conveyor. The Day Silo is equipped with Automatic Flow
Balancing device for metering and free discharge of grain.
Rice/ Grain is transferred to grain Cleaning system Consisting of mainly Destoner and
Magnetic Separator. Destoner operation is based on vacuum principle and separation
is based on density difference. Destoner is provided with air regulating valve and
vacuum indicator.
Cleaned Rice/ grain is transferred to a flow meter using bucket elevator. This is
electronically monitored (Load Cell Type) device based on differential weight feeding. It is
provided with inlet gate and outlet gate for refilling and continuous discharge of grain.
Rice/ Grain is fed to Hammer Mill /roller mill through intermediate Hopper Bin.
Hammer mill is provided with removable doors and pneumatically operated safety
system to lock the doors while mill is in operation. A pneumatically operated flap valve
directs the products to appropriate side of the machine. Hammer Mill is also provided
with Air jet Filter assembly to minimize dusting and milling losses.
The flour is then fed to sieving machine, comprises Screens of required sizes. The
coarser material is recycled back, where as the flour is transferred to flour Bins. Flour
Bins are provided with Vibro-Discharger. Vibro- Discharger has flexible connecting
sleeves. The metered quantity of flour is then transferred to Pre-masher in
Liquefaction Section.
 Slurry Preparation and Liquefaction
Starch Slurry (35 DS) is taken to slurry preparation tank. The slurry is then
transferred to initial liquefaction Tank, where the portion of liquefying enzymes is
added to initiate the liquefaction of the starch. The slurry is then cooked in the jet
cooker. The slurry is continuously pumped to a steam jet cooker where high-pressure
steam rapidly raises the slurry temperature.
The mixture of slurry and steam is then passed through the holding coil which has
several ‘U’ bends in series and of sufficient capacity to provide the desired retention
time at the given flow rate.
The cooked mash is discharged to a flash tank. The flash steam is condensed in a vent
condenser and used in the process for slurry Preparation. The cooking process,
accomplished in the above manner, converts the slurry into a hydrated, sterilized
suspension (as starch molecule gets Solubilised) and is therefore susceptible to enzyme
attack for liquefaction.
The mash from the flash tank is transferred to final liquefaction tank, where
remaining part of liquefying enzyme is added to complete the liquefaction process. The
mash is then cooled and transferred to fermentation Section.
Saccharification And Fermentation
The liquefied slurry is taken to Pre-fermenters, where Saccharifying enzyme is added to
convert the liquefied starch to sugars. The required quantity of active dry yeast is
added to prepare cell mass. The propagated cell mass is then transferred to fermenter.
The liquefied slurry is taken to fermenter. The cell mass from Pre- fermenter is added.
Significant heat release takes place during fermentation. The heat due to exothermic
reaction of ethanol formation is removed by forced circulation cooling in external heat
exchangers (wide gap PHE). The fermented mash is taken to beer well. CO2 Produced
during the process is vented to atmosphere through scrubber. CIP system is provided
for cleaning of Fermenter after every batch.
Distillation And Decantation Section
Following are the columns, which are under operation
1. Analyzer Column (Operating pressure: Partial Vacuum)
2. Pre-rectifier Column (Operating pressure: Partial Vacuum)
3. Purifier Column (Operating Pressure: Atmospheric)
4. Recovery Column (Operating Pressure: Atmospheric)
5. Rectifier Cum Exhaust Column (Operating pressure: Pressure)
6. Heads Concentration Column (Operating Pressure: Vacuum)
7. Simmering Column (Operating pressure: Atmospheric)
Fermented Mash from beer well is pumped to Analyzer column through mash
Preheater. The mash is heated in mash Preheater by thick slops to saturation
temperature before feeding to Analyzer column. Ascending vapors in the Analyzer
Column strips ethanol present in fermented mash. Rectifier cum Exhaust Column
vapors provides heat to Analyzer Column. Rectifier Vapors are condensed in Analyzer
column reboiler. Thick Slops from bottom of Analyzer Column are diverted to decanter
after recovering the heat, where centrifugal action separates thin slops and wet cake.
Part of the thin slops is recycled back to the process and the remaining is sent to the
Effluent Treatment
Fusel oils streams drawn from Rectifier cum Exhaust column and Pre-rectifier Column
are cooled in a Fusel Oil Coolers before feeding to Fusel Oil Decanter. The fusel oil
stream is diluted with water for separation of fusel oils. The aqueous layer is then
pumped back to columns and fusel oils sent to storage.
Analyzer vapors are fed to Pre-rectifier and Stripper Column for rectification of alcohol
and concentration of impurities. Technical Alcohol (Low boiling impurities) is drawn
from top trays of Pre-rectifier column and fed to Heads concentration Column. The
partially concentrated ethanol from pre-rectifier column is then fed to Purification
Column, where ethanol is further diluted for stripping of low and high boiling
impurities. The energy to the Purifier column is supplied through a reboiler where
steam is used as heat source. The vapors from top of column are fed to Recovery
Column for further concentration.
Technical Alcohol from Pre-rectifier Column, Rectifier Column and Recovery Column is
collected in technical alcohol Tank. The TA is then transferred to Heads Concentration
Column for further recovery of ethanol and concentration of impurities. Recovery
Column vapors are condensed in Heads Concentration Column Reboiler to provide the
required heat.. The ethanol water mixture from bottom of Purifier Column is fed to
Rectifier column for further concentration.
Ethanol draw is taken from the Rectifier cum Exhaust Column and fed to Simmering
Column mainly for separation of methanol and furfural. Technical alcohol is drawn as
heads and Product Extra Neutral Alcohol (96% v/v) is withdrawn from the bottom. The
top vapors from the Purifier Column before being sent to the Recovery Column
provides required heat for Simmering Column.
Dehydration with Molecular Sieve Process
The rectified spirit from the rectifier is superheated with steam in feed super-heater.
Super-heated rectified spirit from feed super-heater is passed to one of the pair of
molecular sieve beds for several minutes. On a timed basis, the flow of superheated
rectified spirit vapor is switched to the alternate bed of the pair. A portion of the
anhydrous ethanol vapor leaving the fresh adsorption bed is used to regenerate the
loaded bed. A moderate vacuum is applied by vacuum pump operating after
condensation of the regenerated ethanol water mixture. This condensate is transferred
from recycle drum to the Rectified Column in the hydrous distillation plant Via Recycle
pump. The net make of anhydrous Absolute alcohol draw is condensed in product
condenser and passed to product storage.
Liquefaction :
In liquefaction process, starch is hydrolyzed to dextrin. The Liquefaction is carried out
in Single Liquefaction Tank. Feedstock Flour is transferred to Pre‐masher and mixed
with Recycle Streams, thin stillage and liquefying enzyme. Slurry from Pre‐masher is
taken to Liquefaction tank where temperature is maintained by means of steam.
Necessary retention time is maintained in the Liquefaction Tank. Slurry pH is
maintained by supplying dilute caustic solution. Contents in Slurry Tank are kept in
suspension by Agitation. The Liquefied Slurry is then cooled in Slurry Cooler (wide
Gap PHE) and transferred to Pre-fermentation and Fermentation section.
Fermentation :
Yeast Activation:
Yeast seed material is prepared in Yeast Activation Vessel (Pre‐fermenter) by
inoculating sterilized mash with yeast. Optimum temperature is maintained by
circulating cooling water. The contents of the Yeast Activation Vessel are then
transferred to Fermenter.

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 recirculating pumps also serve to empty the Fermenters
into Beer Well. CO2 can then be taken to CO2 vent line where it is 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.
MPR Distillation - Wash To ENA : (In Case Only Of ENA)
It offers various Multi-Pressure (MPR) Distillation schemes under the above systems &
applies various heat integration methods, for the optimal economic operation of the
plant, keeping in mind the requirements of our Clients.
Multi-Pressure Distillation system has six to 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.
Wash to ENA Mode:
Following Columns will be under operation
Analyzer 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 Analyzer column. Analyzer Column
is provided with re-boiler. Top vapors of Analyzer column containing all the alcohol in
the wash are sent to Pre rectifier column. Rest of the fermented wash flows down the
Analyzer column and is taken out as thick slops from Analyzer column bottom. Low
boiling impurities are concentrated in the Pre Rectifier column. A draw of impure
alcohol is taken out from the top of the Pre Rectifier column. RS draw is taken from
 the top of Pre rectifier column, which further is sent to Extractive Distillation column.
Dilution water in the ratio of 1:9 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 high grade 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 High 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.
Decantation :
Decantation section comprises of a Centrifuge Decanter for separation of suspended
solids from Spent Wash coming out of Grain Distillation Plant. Wet cake is removed
from bottom of Decanter which can be sold directly in wet form as cattle feed (DWGS).
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 as an
option, the entire mixture can be dried in a DWGS Dryer and then sold in dry form as
Cattle feed (DDGS).
Integrated Evaporation Section:
The suggested treatment scheme is a Five EFFECT working on the principle of falling
film Evaporation for Thin Slop Evaporation Plant.
The following points will elucidate the basic working principle:
1. Shell & Tube type Evaporators working on the principle of Falling film Evaporation has
been used.
2. Steam of medium pressure is fed to the first effect.
3. The Feed is at predetermined temperature is fed from the top of First effect evaporator.
4. Vapors generated in 1st effect VLS (Vapor Liquid Separator) are used as heat source in
the 2nd effect and so on to sixth effect. Live steam provided to finisher.
5. Vapors from sixth Effect are condensed in Surface Condenser. A Shell & tube type
Multi‐pass Surface condenser is employed for condensing the shell side vapors.
6. The product at the desired concentration is obtained at the outlet of the finisher.
7. Each effect is provided with recirculation Cum transfer pumps.
8. The condensate from surface condensers is collected in a common condensate pot.
The condensate is transferred for further treatment / drain by using centrifugal pump.
9. The Pure steam condensate are collected in receiving vessels and can be pumped to
desired battery limit
10. Highly efficient operating pumps have been provided for pumping the required fluid.
11. The plant is having high level of automation to get consistent output at required
concentration.
12. The system operates under vacuum. Water‐ring vacuum pumps are used to
maintain a desired vacuum.
13. Cooling water from cooling tower is used in the surface condensers for condensing the
vapors.
DDGS DRYER :
 Wet distiller’s grains shall be fed into the dryer housing at controlled rate through a
suitable feeding system. The Rotary Tube Bundle is enclosed in an insulated dryer
housing and on its outer flights are fixed. Dry, saturated steam is to be supplied to the
tube bundle through 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 rs are
exhausted through an Exhaust Blower & passed through a cyclone separator for
separating fines.
 Dry product partially recycled back to Feed conditioner for feed conditioning through
Product Screw & Recycle Conveyor.
 Entire operation of the Dryer is controlled through Control panel.
PROCESS CONDENSATE TREATMENT SECTION
The process condensate from the evaporation section is partially recycled in making
Grain Slurry and balance qty treated in this unit and this treated condensate is then
recycled back to process thus reducing the fresh water consumption.
Typical DDGS Product Specification
Crude Protein, wt. percent, dry basis, min 30.0
Crude Fat, wt. percent, dry basis, min 6.0
Crude Fiber, wt. percent, dry basis, min 8.5
Ruminant TDN, wt. percent, dry basis, min 88.0
Note: This may vary depending on the quality of raw material.

Co-generation Power Plant [4.8 MW]

Proposed 4.80 MW co-generation plant consists of high pressuretraveling gratewater
tube steam boiler & back pressure steam turbine. Fuel in the steam boiler will be
burnt with the help of air in the boiler furnace. Water will be circulated in the boiler
drum and tubes thus getting heated by the flame burning in the boiler furnace. Water
comes out of the boiler drum located at the top of the boiler as steam. Flue gases rise
in the boiler furnace and come in contact with the steam coming out of boiler drum.
Steam after coming in contact with flue gases gets heated up further thus getting
superheated. Super heated steam leaves the boiler in a pipe. Flue gases after super
heating the steam pass through economizer where they pre-heat the boiler feed water
before it enters the boiler drum. After economizer, flue gases pass through air pre-
heaters where they heat the air which is fed to the boiler furnace for burning the fuel.
 After air pre heaters flue gases pass through a bag house filter where the dust
particles are collected in filter bags & discharge from the bottom of the bag house
filter. Dust will be collected in the Ash Silo through pneumatic conveying system.
High pressure superheated steam from boiler is passed through a steam turbine and
low pressure goes to Low pressure header, which is used for distillery. While passing
through the turbine, the high pressure and temperature steam rotates the turbine
rotor and an electric alternator mounted on the same shaft. Electric power is
generated by the alternator. This electric power generated is consumed in house i.e.
for running the distillery and utilities like boilers auxiliaries etc.

Steam 42 TPH @ 3.5 kg/cm2 Power 4.80 MW

(Extraction of 4.00 bar(g))
To MSDH - 4.60 TPH
To Dryer - 11.50 TPH
To Distillation - 14.50 TPH
To Hydro heater/Jet cooker - 5.00 TPH
To De-Aerator - 5.00 TPH
To Misc. - 1.10 TPH

vii. Resource optimization/ recycling and reuse

Advantages of Grain Plant over the Molasses Plant
• Water consumption is reduced by 30 to 40% % in the Grain based plant as compare to
Molasses based plant
• Effluent generation is also reduced by 30% in the Grain based plant as compare to
Molasses based plant
• Hydraulic Load is also reduced by 40-50% in the Grain based plant as compare to
Molasses based plant
• By adaptation of Grain based technology for production of Fuel Ethanol, reduction in
pollution load is proven fact. Further the availability of raw material i.e. grain is in
abundance around the proposed site as compare to molasses which is not available
around the site hence selection has been made for grain base technology.
• Centrifuge Decanter is used for separation of suspended solid from the spent wash
coming out of the distillation plant.
• Wet cake has 30-35% w/w solids as removed from the bottom of the Decanter.
Thin slops coming out from decanter will be collected in a tank & transferred for the
partial recycling & remaining for Evaporation. The separated solid shall be converted
as DWGS & DDGS which is protein reach cattle feed having good market value.
Quantity of Raw Materials Requirement and storage facility
Item Type Capacity Requirement Source
(TPD)
Grain / Flour / Others Grain Godown 10000 MT 450-500 TPD Rice mills/
FCI
Rice Husk Husk Yard 1000 MT 271 TPD Rice mills
Coal Cover Shed 1000 MT 217TPD Kandla Port
Antifoam Agent Antifoam Agent 1000 Kg 06 Kg/Kl Nagpur
NaOH (50% concentration) NaOH (50%) 1000 Kg 06 Kg/Kl Nagpur
Enzymes like Enzymes like 1500 Kg 1.70 Kg/Kl Nagpur
Amyloglucosidase, Alpha Amyloglucosidas,
Amylase Viscozyme Alpha Amylase
Viscozyme
Yeast Yeast 500 Kg 3 Kg/Kl. Self gen./
suppliers
H2SO4 (93%) H2SO4 (93%) As per 1Kg/Kl. Indore
requirement

Composition of starch based raw materials

Units in % w/w
Contents Sorghum Corn Rice Wheat Dry Tapioca/
Cassava Chips
Moisture 9-13 8-12 10-12 8-12 10-12
Total Solids 87-97 88-92 88-90 88-92 88-90
Starch 66-70 52-66 65-69 59-63 67-72
Proteins 9-11 7-11 8-10 11-13 1.5–3
Fats/oils 2.2 -3.2 3.5–5.0 0.4 –1.0 1.5–2.0 1 –1.5
Crude Fibers 1.3–2.1 1.5–2.0 0.3 –1.0 2.0 -3.0 2.5–3.5
Inorganic Ash 1.2–2.0 1.0–1.5 0.5 –1.6 1.5–2.5 1.25–2.0
Other organisms 8-12 7-9 4-10 7-10 Not Specified

Compositionsanditsderivatives:
A PaddyFeed Percentages 1000
1 Rice(Whole) 70.00 700
2 Moisture 12.00 120
3 Bran 5.00 50
5 Husk 13.00 130
Total 100.00 1000
B ProductofRiceMilling
1 Rice(Whole) 69.00 690
3 Bran 6.00 60
4 BrokenRice +Germ 7.00 70
5 Husk 18.00 180
Total 100.00 1000
C Feed- BrokenRice+Germ+Bran 1000
1 Starch 39.00 390.00
2 CrudeOil 14.00 140.00
3 Moisture 10.00 100.00
4 CrudeFiber 8.00 80.00
 5 OtherCarbohydrate 6.00 60.00
6 Protein 23.00 230.00
Total 100.00 1000
D Output-BranBasedIndustries(Wet
1 Alcohol 189.93
2 Refined Oil 116.20
3 Lecithin-Animal Feed 2.8
4 Wax 2.1
5 Oryzanol 2.1
6 Fatty Acid 14.7
7 Rice Bran Gluten (Protein) 411.11
Total 738.9411

viii.: Availability of Water its source, energy / power requirement and source:
Water requirement:
Construction Phase – 15 KLD
Operational Phase – Net fresh water requirement will be 803 KL per day
Source: Surface water supplied by MPIDC.
Water and Mass Balance Chart
 Water Balance Of Proposed Fuel Ethanol Unit of 200 KLD & POWER PLANT
Water Type Fresh Water Fresh Water Total Water
required Before required After Recycle
recycle recycle
Process Water 1183 493 690
Soft Water 1192 600 750
De-mineralized Water 860 28 850
TOTAL 2865 1173 1692

ix. Power Requirement:

Construction Phase – 100 kw
Power requirement Operating in KW Connected in KW
Liquefaction Section 170 280
Fermentation Section 475 650
Distillation Section (RS) 140 280
MSDH Section 100 200
Integrated Evaporation 600 750
Section
DWGS Dryer 500 600
Decantation (excluding 70 100
decanter centrifuge)
Alcohol Storage 50 100
Evaporation Condensate 180 320
Treatment Plant
Utilities: Cooling Towers, 900 1350
Air Compressor
POWER LOAD FOR 3185 4630
ABOVE SCOPE

Auxiliary Power for Plant

Power requirement Operating in KW Connected in KW
Fire Fighting 70 110
Boiler & STG 650 950
Plant Illumination & Office 100 130
block
CO2 Plant 740 950
POWER LOAD FOR 1550 2140
ABOVE SCOPE

Total Power requirement for running the plant is 4735 KW

During operation phase, the required power will be taken from 4.80 MW cogeneration
power plant. DG set of 01 x 1500 KVA & 01 x 250 KVA shall be kept as standby
arrangement
X. Quantity of wastes to be generated (liquid and solid) and Scheme for their
management/ disposal
For Liquid Waste
During operation, Grain Slops will be taken through Centrifuge Decanters for
separation of suspended solids.
Spent wash 1300 M3 per day will pass through centrifuge decanter for separation of
solid. The part of thin slope from centrifuge will be recycled to process. The remaining
slop will be concentrated through multi effect evaporator.
• The concentrated syrup will be mixed uniformly in the ribbon mixer to form DWGS
(190 MT per day). Final product will be in the form of DDGS at 102 tons per day.
• DDGS powder will be sold as cattle feed.
Treatment Scheme
Decantation Section
• Centrifuge Decanter is used for separation of suspended solid from the spent wash
coming out of the distillation plant.
• Wet cake has 30-35% w/w solids as removed from the bottom of the Decanter.
• Thin slops coming out from decanter will be collected in a tank & transferred for the
partial recycling & remaining for Evaporation.

Evaporation section
The suggested treatment scheme is a Multi Effect Evaporator with thermal
recompression for Thin Slops Evaporation. The following points will elucidate the basic
working principal:
• Shell & Tube type Evaporators with highly efficient liquid distributor working on the
principal of Falling Film Evaporation.
• Analyzer vapors are fed to the 1st effect evaporator shell side at the given pressure &
temperature as the heating medium.
• The Feed is fed from the top of the 1st effect evaporator which is Falling Film
Evaporator-1
• Vapors generated in the 1st effect VLS (Vapour Liquid Separator) are used as heat
source in the 2nd effect. 3rd effect (finisher) is on steam. Vapours generated in the 2nd&
3rd effects VLS are condensed on shell side of Surface Condenser for Evaporator.
• The Total Solid will be obtained at the outlet of the 3rd effect evaporator. A shell &
tube type multi pass surface condenser is employed for condensing the shell side
vapors.
• The operation of the plant will be under vacuum. Vacuum will be created with the help
of a water ring vaccum pump. Cooling water from the cooling tower is used in the
surface condensers for condensing the vapors.
• Spent Lees 277 TPD will be recycle back for Slurry preparation. 829 m3/day of Process
condensate, CT Blow down, WTP Reject is fed to CPU unit.
• 746 m3/day treated water will return back to process for utilization in
liquefaction/fermentation/cooling tower etc. Balance Rejected 83 m3 use in process
for Liquifaction section/fer. cleaning.
• Rainwater will be utilized to recharge the underground resource through scientifically
designed rainwater harvesting system.
• 23 M3/day of boiler blow down will be sent for ash quenching.
Solid And Hazardous Waste Management
Type Of Waste Quantity Storage Utilization/ Disposal
DDGS – ( by 102 TPD Covered shed Sold as Cattle Feed, Poultry &
product) Fisheries
Boiler ash 66 TPD Silo Brick making or land filling
Waste papers/ 1.5-2 TPD Covered shed to recyclers
Boxes
Used Oil < 500 lit per HDPE drums Given to re-cycler authorized by
year in covered MPPCB/MoEF
shed
Spent Resin from <50Kg/Yr HDPE drums Given to re-cycler authorized by
DM Plant in covered MPPCB/MoEF
shed
ETP sludge 55 MT/DAY Covered shed AS MANURE

Details of Air Pollution Control System

S. No. Details of DG
1. Type of Fuel HSD
2. Capacity 1500 KVA & 250KVA
3. Stack Height 30 Mtr
4. Pollution Control Adequate stack height/
Equipment Measures Acoustic

Emission Details of Stack

Parameters Co gen Plant
Boiler Configuration 42 TPH
Type of fuel COAL
Calorific value 4000
Ash content 35 %
Sulphur content 0.4 %
Number of Stacks 01
Common Stack with no. of flues 01
Material of construction RCC
Shape (round rectangular) ROUND
Stack height from ground level(m) 52
Stack Dia. (m) 2.70 MTR OD
Exhaust Gas Temperature(oC) 160
Flue Gas Velocity (m/s) 15
Volumetric flow rate (Nm3/S) <100
APCE (Air pollution control equipment) ESP
Proposed

Emission Rate Calculation

A) Boiler (42TPH) for rice husk
1) The emission rate of Particulate matter (PM)
Feeding rate of husk – 271TPD/11.29TPH
Assuming 15% ash content in husk,
Total ash generated = 0.15 x 11.29 = 1.6935TPH
Further assuming fly ash: Bottom ash to be 60:40 and ESP efficiency to be
99.9%
PM10 emission rate = (1.6935 x 0.6 x 0.1/100) = 0.0010161 TPH
= (0.0010161 x 1000 x 1000)/3600
= 0.28g/sec
2) The emission rate for SO2
Feeding rate of Rice Husk– 271TPD/11.29TPH
Assuming 0.07% Sulphur content in Rice Husk,
Total Sulphur generated = 0.07% x 11.29 = 0.008TPH
Emission of sulphur from the rice husk = S+O2 = SO2 (32+16*2=64)
Hence 32kg of sulphur expected to be release 64kg of SO2
Thus 1kg of sulphur expected to be release = 64/32 = 2kg SO2
Total SO2 generation = 0.008 x 2 = 0.016
= (0.016 x 1000 x 1000)/3600
= 4.44g/sec
B) Boiler (42TPH) for Coal
3) The emission rate of Particulate matter (PM)
Feeding rate of Coal – 217TPD/9TPH
Assuming 35% ash content in Coal,
Total ash generated = 0.35 x 9 = 3.15TPH
Further assuming fly ash: Bottom ash to be 60:40 and ESP efficiency to be
99.9%
PM10 emission rate = (3.15 x 0.6 x 0.1/100) = 0.00189 TPH
= (0.00189 x 1000 x 1000)/3600
= 0.53g/sec
4) The emission rate for SO2
Feeding rate of Coal– 217TPD/9TPH
Assuming 0.4% Sulphur content in Coal,
Total Sulphur generated = 0.4% x 9 = 0.036TPH
Emission of sulphur from the Coal = S+O2 = SO2 (32+16*2=64)
Hence 32kg of sulphur expected to be release 64kg of SO2
Thus 1kg of sulphur expected to be release = 64/32 = 2kg SO2
Total SO2 generation = 0.036 x 2 = 0.072
= (0.072 x 1000 x 1000)/3600
= 20g/sec
1) The emission rate of NOx
Volumetric rate at 160 oC (273oK) = cross sectional area of the stack at the top
(m) x exist velocity (m/sec)
 = (3.14/4) x (2.70)2 x (15) m3/sec = 85.84 m3/sec
Volumetric flow rate at NTP = (85.84 x 298)/433 = 59.08 m3/sec
Hence
Emission rate of NOx = volumetric flow rate at NTP x emission norms of NOx
= (59.08x100) mg/sec = 5.91 gm/sec
Adequacy of Minimum Stack Height for Boiler
The company has installed one number of stacks having height of 42 mt.
(a) Design Calculation
Boiler capacity : 42 TPH
Coal consumption : 9TPH
Coal consumption in kg : 9000kg/hr
Sulphur in Coal : 0.4%
SO2 in flue gas : 0.8%
SO2 Generation : 9000 kg/hr*0.8% = 72kg/hr

Chimney Height: H=14*(Q) 0.3

Where H = chimney height in meter
Q= SO2 in kg/hr
Therefore chimney height = 14*(72)0.3 = 50.50m
Actual height of chimney =52m
Proposed Stack Details
S. no Stack Height Dia Velocity Temp Emission rate (g/s)
(m) (m) m/s (°C) TPM SO2 NOX
1 Stack 1 52 2.70 15 160 0.28 4.44 5.91
(Rice
husk)
Stack 1 52 2.70 15 160 0.53 20.0 5.91
(Coal)

 Air Pollution Control System (for Grain base (200 klpd)

S No Parameters UOM Description
A Boiler Details
Type
Boiler Type Single. / Bi-Drum 490 Deg C Super-heated steam
Boiler Capacity 42 TON Bi- Drum Traveling grate
Boiler Make Not yet Finalies
Fuel Coal/Agrowast
Fuel Grade Indian
Ash Content in Fuel 26 to 35 %
Working Steam Pressure 67
Flue Gas Temperature 160
Fuel Consumption 222 MT
B APC Equipment Details
Layout Boiler>Economizer> APH>MDC>ID Fan>Stack
 Type Coil type MDC
Quantity 1
Make Not yet Final
C ID Fan Detail
Gas Volume 40 Nm3/a
Static Pressure 250
Operating Temperature 160
Type Centrifuge
Motor Rating 1400 RPM/VFD
Quantity 01
 Site Analysis:
• Connectivity
The site is located 21 km way from Jabalpur and can be approached through NH-12
from NH-12, the site is located at about 11.75 KM via village Dungariya through pucca
road.
Particulars Details
Village Umariya
Tehsil - Shahpura& District-Jabalpur
Latitude A. 23°3'3.33"N - 79°46'42.44"E
Longitude B. 23° 2'57.66"N - 79°46'41.88"E
C. 23° 2'58.74"N - 79°46'36.30"E
D. 23° 2'53.75"N - 79°46'38.33"E
E. 23° 2'52.85"N - 79°46'44.70"E
F. 23° 2'59.04"N - 79°46'45.27"E
G. 23° 2'55.71"N - 79°46'54.22"E
H. 23° 2'58.43"N - 79°46'54.36"E
I. 23° 3'2.90"N - 79°46'44.57"E
Elevation range Highest elevation -449 m
Lowest elevation -431 m
Toposheet No. 55M/16,55N/13,55N/9, 55M/12
Nearest National/ State Highway NH 12-11.75 km-N
Nearest Railway Station Jabalpur railway station- 21 km-NE
Nearest Airport Jabalpur airport -45km-NE
Ecological Sensitive Areas (Wild Life
None within 10 km radius
Sanctuaries) within 10km radius.
Nearest hill range within 10km radius None within 10 km radius
Reserved / Protected Forest within 10km Semra reserved forest-0.25 km –SSE
radius Open jungle-0.75 km –ENE
PF-1.00km-WSW
PF-1.75 km-NW
Nearest major city with 100000 population None within 10 km radius
within 10km radius
Nearest Town/City within 10km radius None within 10 km radius
Nearest Village Dugariya -1.00km-NE
Nearest habitation Dugariya -1.00km-NE
Nearest River with 10km radius Narmada river-7.50km-NNW
Nearest Nalla/pond Bargi canal-3.25km –NNW
Pond-3.25km-NNE
Pond -2.25 km-NNW
Mines within 2km radius None within 10 km radius
Industry within 10km radius None within 10 km radius

• Land Form, Land use and Land Ownership

Project Proponent is having 8 ha of land which is possession and diverted for
industrial purposes.
• Topography
 Topography of the area is almost plain.
• Existing Land use pattern
The land use of the project area is pertaining to industrial activity only. Out of project
area is predominantly being used or agricultural purposes.
Land use Break-Up for proposed unit
Particular In sq mtrs/ha
Built up area for plant, building and 27000/2.70
machinery
Area under road 11200/1.12
Area for Raw Material Storage 2400/0.24
Area for Fuel Storage 3000/0.30
Area for Green Belt 26500/2.65
Total
Open land 9900/0.99
Total Area 80000 /8.00

• Existing Infrastructure
The required infrastructure will be in place as proposed site is barren land. National
Highway- 12 is passing at 11.75 km from the industry.

• Soil Classification
The soils in the area are generally of sedimentary type soil .
• Climate data from Secondary Source:
Summary of Meteorological Data March 2021- May 2021
Month Wind Speed (Km/h) Temperature (oC) Relative Humidity (%) Rain Fall (mm) Cloud
Mean Max % of Mean Max. Min Mean Max. Min Tot 24-hours No. of Cover
calm (Dry al Highest rainy (Octas of
Bulb) days sky)
Mean
March, 18 1.0 14.8 84.54 30 38 12 18 72 4 Nil Nil Nil 2
April, 18 3.7 24.2 42.22 36 40 22 16 53 4 Nil Nil Nil 0
May, 18 5.0 117. 43.95 35 44 22 16 51 4 5 5 01 2
1
30 years Climatological Table of Jabalpur IMD (1961 to 1990
 Source: IMD, Climatological Normals, Office of the Additional Director General of
Meteorology (Research), IMD, Pune

• Social Infrastructure available

Social infrastructure like community center, hospital and electricity is available in
Jabalpur (MP)
• Planning Brief:
• Planning Concept:
The grain base unit shall be installed after receiving environment clearance and
consent under air and water act from the MPPCB. 14 Months has been considered
for the same.
• Population Projection:
The project is small in magnitude. No influx of population is expected as labour
shall be deployed from the local villages.

iii Land use planning

As above

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

• Proposed Infrastructure
The major plant & machinery required for the proposed project is as given under.
List of machinery and equipment
 Grain Storage Section –Silo
 Grain Handling Section
 Jet cooking
 Liquefaction Section
 Fermentation Section
 Distillation Section
 Steam Boiler with Accessories
 Power Turbine
 Steam condensers
 Air compressor
 Storage section (Daily Receiver Section, Bulk Storage tanks)
 Centrifugal Machines/Decanters.
 Multiple Effect Evaporation Section
 Standalone Evaporator
 Condensate Policing Unit
 Water Treatment Plant
 Dryer (DWGS)
 DDGS section
 Raw water treatment plant
 R.O. Plant for boiler water
 Fire protection equipment for entire plant
 Weigh bridge
 Water storage tanks
 Treated water storage tanks.
 Electricals
 Piping works
 Lab equipment’s
Sr. Item Technical Specification MOC O S
No.
1. Slurry Mixing Type-Cylindrical/ vertical with
Tank with conical Top & Bottom SS 304 1 0
Agitator Cap.- 100 m3
2. Final Type-Cylindrical/ vertical with SS 304 1 0
Liquefaction conical Top & Bottom,
Tank with Cap.- 200 m3
Agitator
 3. Retention Vessel Type : Cylindrical/Vertical SS 304 1 0
4. Caustic Dosing Type : Cylindrical/ vertical with Mild Steel 1 0
tank flat Top &sloping Bottom
5. Recycle Stream Type : Cylindrical SS 304 1 0
collection tank
6. Liquefying Type :Vertical SS 304 1 0
Enzyme Dosing
Tank
7. Vent Condenser Shell & Tube Type SS 304 1 0

Sr. Item Technical Specification MOC O S

No.
1. Premasher Ribbon Mixer Type AISI 304 1 0
Slurry Transfer Type : Centrifugal Wetted part: 1 1
2. Pump with motor CF8
3. Steam Jet Cooker PRAJ Std. SS 304 1 0
Agitator for Slurry 1
4. tank &Liquefaction Type :Top Entry AISI 304 eac 0
tank h
5. Caustic Type :Centrifugal CI 1 1
dosingpump
6. Final Liquefaction Type : Centrifugal Wetted Parts - 1 1
tank pump CF8
Recyclestream Type : Centrifugal Wetted Parts -
7. collectiontank CF8 1 1
transferpump
8. Slurry cooler Type : PHE Frame - MS, 1 1
Plate - AISI
316
9. Liquefying Enzyme Type : Metering Standard 1 1
dosing pump

SACCHARIFICATION &FERMENTATION
Sr. Item Technical MOC O S
No. Specification
1. Air Filter Frame Mild Steel 1 0
2. CO2 Scrubber Tray Type :Sieve SS 304 1 0
3. Liquid SS 304 1 0
Separatorfor Air
Blower
Saccharifying & Type :Cylindrical, 1
4. Nutrease Enzyme vertical Shell with Flat SS 304 ea 0
Dosing Tank Top & Bottom ch

Sr. Item Technical Specification MOC O S

No.
CIP Tank for Type :Cylindrical,
Fermentation Vertical, Conical Top &
1. (Common for Sloping Bottom, MS Epoxy 1 0
Fermentation &
Liquefaction Section)
Pre fermenter/Yeast Type: Cylindrical,
2. Activation Vessel with vertical, Conical Top & SS 304 2 0
Air sparger Flat Sloping Bottom
;Gross Cap –160 m3
Type: Cylindrical,
3. Fermenter vertical, Conical Top & SS 304 4 0
Flat Sloping Bottom
Gross Capacity – 1350
m3
Type: Cylindrical,
4. Beer well/Wash Vertical, Conical Top & SS 304 1 0
charger/ wash holding flat Sloping Bottom
Gross Capacity – 1350
m3
Sealing water TankAir Type: Cylindrical,
5. Blower vertical, Conical Top & Mild Steel 1 0
Flat Sloping Bottom
Sealing water Tankfor Type: Cylindrical,
6. Process Pump vertical, Conical Top & Mild Steel 1 0
Flat Sloping Bottom

Sr. Item Technical Specification MOC O S

No.
1. Agitator for Pre- Type: Side Entry SS 304 1 0
Fermenter with Motor
Agitators for
2. Fermenters with Type :Side Entry SS 304 3 0
Motors
3. Agitators for Beer well Type :Side Entry SS 304 1 0
with Motors
Fermenter Wetted Parts -
4. Recirculation Pump Type :Centrifugal Type CF8 3 0
with Motors
Prefermentor/YAV Wetted Parts -
5. transfer pump with Type :Centrifugal Type CF8 1 0
Motors
6. Wash Transfer Pump Type :Centrifugal Type
Wetted Parts - 1 1
with Motors CF8
7. Air Blower with Motors Type :Water Ring Air CI 1 1
Blower
8. Filter for Air Blower HEPA MS Frame 1 0
CIP Pump for Type :Centrifugal Type Wetted Parts -
 9. fermentation with CF8 1 1
Motors
Saccharifying & Wetted Parts -
10. Nutrease Enzyme Type :Metering Pump CF8 2 0
Dosing Pump
11. Cleaning Nozzles for Self-Operated with SS 304 3 0
Fermenters 360 degree rotation
12. Cleaning Nozzles for Gyro Type SS 304 1 0
Prefermentor
Cleaning Nozzle for
13. Beer well/wash Self-Operated with SS 304 1 0
charger/ wash holding 360 degree rotation
tank
14. Fermented Wash Type : WIDE GAP PHE Frame: MS, 3 0
Coolers Plates: SS 316
15. Prefermentor Cooler Type : Plate Heat Frame: MS, 1 0
Exchanger Plates: SS 316
16. Sealing water cooler Air Type :Plate Heat Frame: MS, 1 0
blower Exchanger Plates: SS 316
17. Sealing water cooler Type : Plate Heat Frame: MS, 1 0
Process pump Exchanger Plates: SS 316
18. Fermenter Safety Breather Valve SS 304 3 0
System

DISTILLATION - WASH TO RSMODE

Sr. Description Tech. Specs. MOC QTY

No.
Column Dia.: 2900mm
1. Analyser Column No of trays – 22 no. Tray AISI 304 1
Type :Rh Grid Tray
Spacing: 750 mm
Column Dia.: 1350 mm
2. Degasifying Column No of trays – 5 no. AISI 304 1
Tray Type :Sieve
Tray Spacing: 750 mm
Column Dia.: 2800 mm
No of trays – 56 no. Tray
3. Rectifier Column Type: combination of AISI 304 1
Sieve & Bubble Cap
Tray Spacing: 250 mm
4. Alcohol Scrubber As per PRAJ Standard AISI 304 1

Reboiler:
Sr. Description [Link] M.O.C. Qty.
No
1. Reboiler for Shell and tube type/ AISI 304 1
AnalyzerColumn Falling Film type
2. Reboiler for Shell and tube type AISI 304 1
 RectifierColumn

Condensers, Coolers:
S. Description Tech. Specs. MOC QTY
No.
5. Degasser Column Condenser I Shell and tube AISI 304 1
type
6. Degasser Column Condenser II Shell and tube AISI 304 1
type
7. Analyser vent condenser Shell and tube AISI 304 1
type
8. Analyser Reboiler vent Shell and tube AISI 304 1
condenser type
9. Rectifier LFO/HFO Cooler Shell and tube AISI 304 1
type

S. No. Description M.O.C. QTY

1. Analyser Condensate Tank AISI 304 1
2. Rectifier Reflux tank AISI 304 1
3. Analyser Bottom Transfer Pump CF 8 ( wetted parts only) 1+1
4. Analyser condensate Transfer CF 8 ( wetted parts only) 1+1
Pump
5. Rectifier Reflux Transfer Pump CF 8 ( wetted parts only) 1+1
6. Rectifier lees Transfer Pump CF 8 ( wetted parts only) 1+1
7. FO Washing Tank AISI 304 1
8. FO Washing Transfer Pump CF 8 (wetted parts only) 1+1
9. Steam Condensate Tank (Common MS 1
for Evaporation and Distillation)
10. Steam Condensate Transfer Pump CI 1+1
11. Vacuum Pump CI 1+1
12. Vacuum pump water recycle (one MSEP Tank , PHE & 1 set
system one CI pump)
13. Rectifier Feed Preheater PHE 1
14. CIP Tank (Common for Evaporation AISI 304 1
and Distillation)
15. CIP Pump (Common for CF 8 ( wetted parts only) 1
Evaporation and Distillation)

MSDH SECTION:
A. COLUMNS:
Sr. Description [Link] M.O.C. Qty.
No.
Sieve Bed 1 Type :Cylindrical Shell
1. with Top and Bottom SS 304 1
DishedEnd
Sieve Bed 2 Type :Cylindrical Shell
2. with Top and Bottom SS 304 1
Dished End
B. CONDENSERS ANDCOOLERS:
Sr. Description [Link] M.O.C. Qty.
No.
1. Super heater Type :Shell& Tube AISI 304 1
2. Regeneration Condenser Type :Shell& Tube AISI 304 1
3. Product Condenser Type :Shell& Tube AISI 304 1
4. Regeneration Preheater Type :Shell& Tube AISI 304 1
5. Feed Filter Bag Filter AISI 304 1
6. Regeneration Filter Bag Filter AISI 304 1
7. Product Filter Bag Filter AISI 304 1

C. TANKS &MISCELLANEOUS:

Sr. Description [Link] M.O.C. Qty.

No.
1. Regeneration Receiver Cyl/ Vert shell Top & AISI 304 1
bottom Dished
2. Product Receiver Cyl/ Vert shell AISI 304 1
Top & bottom Dished,
Piping & Valves As specified in
3. Instrumentation., RespectiveAnnexure - Lot
Electrical

DECANTATION SECTION
Sr. Description [Link] M.O.C. Qty
No.
1. Decanter Centrifuge Suitable AISI 304 2+1
(Client Scope) Internals
2. Decanter Feed Tank Cap 220 m3 SS 304 1

3. Decanter Feed Pumps Centrifugal Type Wetted parts 1+1

CF8
4. Thin Slop Collection Tank Vertical Type AISI 304 1
(Under the Decanters) Gross Cap – 15 m3
Thin Slops Transfer Wetted parts CF8
5. PumpWith non-flame Centrifugal Type 1+1
proof motor
6. Ribbon Mixer Ribbon type AISI 304 1

INTEGRATED EVAPORATION PLANT:

Sr. Equipment Description Material of Qty
No. Construction
 Designed based on falling Shell: SS 304
1. Falling Film Evaporator filmprinciple; Tubes : SS304 4
Construction: Shell& Tube sheet:SS
Tube Type. 304
Designed based on Forced Shell: SS 304
2. Forced Circulation Circulation principle ; Tubes : SS304 1
Evaporator Construction: Shell & Tube sheet:SS
Tube Type. 304
Construction: Vertical,
3. Vapor Liquid Separators with tangential entry for Shell : SS 304 5
effective vapor separation.
4. Shell and Tube heat Shell : SS 304 1
Surface Condenser exchanger
5. Concentrated Product Cylindrical / Vertical SS 304 1
Tank Shell with Dished Ends
6. Cylindrical / Vertical SS 304 1
Process condensate Tank Shell with Dished Ends
7. Thin Slops Holding Tank Cylindrical / Vertical MS Epoxy 1
(During CIP) Gross Cap 400 m3
8. Type - Centrifugal Pump Wetted Parts : 1+1
Feed Pump CF8
9. Recirculation cum Type - Centrifugal Pump Wetted Parts : 4
Transfer Pump For FF CF8
10. Recirculation cum Type - Centrifugal Pump Wetted Parts : 1
Transfer Pump For FC CF8
11. Type - Centrifugal Pump Wetted Parts : 1+1
Process condensate pump CF8
12. Product (Thick Syrup) Type - Centrifugal Pump Wetted Parts : 1+1
transfer pump CF8
13. Effluent holding transfer Type - Centrifugal Pump Wetted Parts : 1+1
pump CF8
14. Dryer vapor integration PRAJ Standard SS 304 1
system Unit
15. Vacuum Pump System Water Ring Type CI 1+1
16. Sealing waterRecycle (One MS Tank, PHE & one CI pump) 01
system set

DWGS DRYER, COOLING, CONVEYING, DDGS SILO &BAGGING:

S. N. Equipment MOC Qty

(I) DWGS DRYER
Dyer lower & upper trough in SS 304.
EndcoveroftroughMSwithSS304cladding
1. Dryer Housing Outer supports are in MildSteel Base 1 Set
frame in Mild Steel
 Tubes in MS Seamless(3mmthickness)
Rotating Steam Tube Tube Sheet in MildSteel, dish ends in
2. Bundle with shovels & Mild Steel, Shovels are in SS316 and 1Set
shovels carryingangle shovel carrying angles are in SS 304.
3. Set of Rotary Joints Housing in Cast Iron with standard 1
rotary joints for steam inlet & outlet
4. Steam Trap Cast Steel with standard supply Lot
Gear Wheel & Pinion arrangement driven
5. Drive Arrangement by a set of drive comprising Gear Box & 1 Set
Motor mounted on MS base frame
6. Feed screw Main screw flight with trough and end 1 Set
covers in SS 304 and support parts in
MS
7. Feed conditioner Main screw flight with trough and end 1 Set
covers in SS 304 and support parts in
MS
8. Conveying screw Main screw flight with trough and end 1 Set
covers in SS 304 and support parts in
MS
9. Dosing screw Main screw flight with trough and end 1 Set
covers in SS 304 and support parts in
MS
10. Haul off Screw Main screw flight with trough and end 1 Set
covers in SS 304 and support parts in
MS
11. Discharge screw Main screw flight with trough and end 1 Set
covers in SS 304 and support parts in
MS
12. Vapor ducting MS / SS 304 as per application. Lot
13. Cyclone Separator SS 304 1 Set
14. Rotary Air lock Valve Mild Steel 1 Set
15. Exhaust Vapor fan Mild Steel 1 Set
16. Rupture Discs SS 304 1 Set
17. Steam Condensate Tank MS 1
18. Steam Condensate Centrifugal MOC: CI 1+1
transfer pump
19. Instrument Air Std. 1
Compressor
(II) Cooling And Conveying
1. Cooling &Conveying System comprising Air Blower with 1 Set
Rotary Valve, etc. in Mild Steel
2. Pulverizer for DDGS 1
 (III) DDGS STORAGE
Product (DDGS) Storage
1. Silo along with required Capacity :- 50 MT ; MOC – Mild Steel 1
Accessories, bin
activator
(IV) SEMI Automatic DDGS Bag filling System
1. Semi-Automatic DDGS Type :- Semi Automatic 1
Bag Filling system

PROCESS CONDENSATE TREATMENTPLANT

Sr. Description Specification MOC Qty.
No.
1. Equalization tank Horizontal Centrifugal, Wetted 1+1
transfer pump Gland pack parts:SS304
2. Alkali Dosing System - Pump: PP 1+1
Dosing pump ; -Tank Tank: MSEP
FeCl3 Dosing System Pump: PP 1+1
3. -Dosing pump -Tank and Suitable Tank: HDPE 1
agitator Agitator: MSRL 1
Poly Dosing System Pump: PP 1+1
4. -Dosing pump Suitable Tank: HDPE 1
-Tank and agitator Agitator: SS304 1
5. Filter feed pump Horizontal Centrifugal, Wetted parts: 1+1
Gland pack SS304
6. Tube settler bottom Horizontal Centrifugal, Wetted parts: 1
sludge pump Mechanical seal SS304
Down flow type, Vertical,
cylindrical with dished
7. Dual Media filter - 1 ends and packed bed of MSEP 1
media inside.
Down flow type, Vertical,
cylindrical with dished
8. Pressure sand filter ends and packed bed of MSEP 1
media inside.
9. Filter backwash pump Horizontal Centrifugal, Wetted parts: 1
Gland pack SS304
10. RO priming pump Horizontal Centrifugal, Wetted parts: 1+1
Gland pack SS304
10 µm rating, Spun Housing: SS304
11. RO cartridge filter -1 wounded, with manual Cartridge: PP 1
cleaning
5 µm rating, Spun Housing: SS304
12. RO cartridge filter -2 wounded, with manual Cartridge: PP 1
cleaning
 13. RO Chemical Dosing Pump: PP 1 lot
System Tank: FRP
Vertical Multi-stage,
14. RO high Pressure pump inline SS304/ SS316 1
8” Dia ,Horizontal skid
15. RO pressure vessel mounted with piping FRP 1 lot
interconnection
8” Dia, Spiral wounded
16. RO membrane element Sea water membrane Polyamide 1 lot
element
17. RO skid MS shop Fabricated MSEP 1
Pump wetted
18. RO cleaning System parts: SS304 1
Tank: FRP
5 µm rating, Spun Housing: SS304
19. RO CIP cartridge filter wounded, with manual Cartridge: PP 1
cleaning
20. Nutrient (DAP/Urea) Tank: FRP 1
Dosing System
-Tank ; - Agitator
Hypo Dosing System Pump: PP Tank:
21. -Dosing pump FRP 1
-Tank
22. Air blower for aeration CI 1+1
tank
23. Aeration tank feed pump Horizontal Centrifugal, Casing: CI, 1+1
Gland pack Impeller: SS304
24. Fixed Type Air Diffuser Fixed at tank bottom SS304 1 lot
Grid System
25. Clarifier Mechanism MSEP internals 1 lot

26. Clarifier Sludge Horizontal Centrifugal, All CI 1+1

Recirculation Pump Gland pack
Transfer pump to cooling Horizontal Centrifugal, Casing: CI, 1+1
27. tower cum filter Gland pack Impeller: SS304
backwash pump
28. RO reject transfer pump Horizontal Centrifugal, Wetted parts: 1+1
Gland pack SS304
29. Piping & Fittings As per PRAJ standard 1 lot

30. Electrical As per PRAJ standard 1 lot

ETHANOL / ALCOHOL STORAGE SECTION

 Sr. Description [Link] M.O.C. Qty
No.
1. AA Receivers Gross Capacity : 260 m3 MS 3
2. IS Receivers Gross Capacity : 25 m3 MS 2
3. AA Bulk Storage Tank Gross Capacity : 2000 m3 MS 3
4. IS Bulk Storage Tank Gross Capacity : 300 m3 MS 1
5. FO Bulk Storage Tank Gross Capacity : 20 m3 MS 1
6. Vent condenser Shell & Tube HE MS Lot
7. Flame Arrestor Standards MS Lot
8. AA transfer cum issue Centrifugal Wetted parts: CF 1+1
Pump with flameproof 8
motor
IS transfer cum issue Centrifugal Wetted parts: CF
9. Pump with flameproof 8 1+1
motor
10. FO transfer cum issue Centrifugal Wetted parts: CF 1
Pump with flameproof 8
motor
11. Issue Flow meter with PD Type Standard 2
Totalizer
12. Piping & Fittings As specified in Respective Annexure 1 lot

13. Electrical As specified in Respective Annexure 1 lot

&Instrumentation

ii Residential area (Non-Processing area)

As the local people from nearby villages shall be engaged in project activity. Therefore,
no housing / building is proposed.
iii Greenbelt
Approx 26500 sq mtrs area shall be covered with the good green belt in next 02 years
of time.
iv Social Infrastructure
Company shall evaluate the need base program under CSR and shall execute as per
the given plan.
v Connectivity
Site is well connected with by National Highway-12, which is 11.75 km away from
proposed site
vi Drinking water management
Drinking water will be supplied through bore well with proper RO system.
vii Sewerage System
The domestic waste shall be taken to STP.
 viii Industrial waste management
As described earlier.
ix Solid waste management
As described earlier.
x Power Requirement and supply / source
As described earlier.
7.0 Rehabilitation & Resettlement Plan
No R & R plan is required.
• Project Schedule and Cost estimate
• Likely date of start of construction and likely date of completion
After obtaining environmental clearance and water / air consent the company shall
start the project. Proposed date shall be June 2022 (subject to clearances).
• Estimated project cost along with analysis in terms of economic viability of the
project
Estimated Investment:
Estimated Investment for Design, Engineering, Manufacture, Supply, Erection and
Supervision of commissioning for 200 KLPD of total spirit (Grain Based) Plant as per
the sections mentioned below are as follows:
Cost Summary
Based on the capital cost break up worked out in the project cost summary for the
project is given in the following table:
 Project Cost
Particulars Rs in Lacs
Land (Freehold) 660
Site Development 100
Indigenous Plant and Machinery& 18400
Pre-Operative Exp 200
Contingencies 2% 220
Misc. Fixed Assets 1000
Civil works & Buildings 3000
Working Capital Margin 5000
Total 28580
 Plant and Machinery & Buildings and Civil Works
The erected cost of plant and machinery for 200 KLPD Ethanol plant including boilers
and turbines with buildings and machinery foundations for 200 KLPD Ethanol is
estimated at Rs. 22400 lacsinclusive GST based on the Quotation received & Final
discussions with the machinery suppliers. The detail breaks up of cost of plant and
machinery is given below:
S No Amount,
Particulars
Rs. Lacs
1 Turnkey supply of 200 KLPD Ethanol based on multi feed, Grain,
Handling & storage, Milling, Jet cooking, Liquefaction, Fermentation,
Distillation, MSDH, Integrated and Standalone evaporation ,
Condensate Polishing Unit (CPU), Plant electrical, auxiliary cooling
 tower, storage , structure, dryer, Effluent treatment, Air Compressor,
Product day receiver /Alcohol/Ethanol / Syrup Storage Tanks and
Staging Structure for Ethanol plant. 42 TPH Boiler & 4.80 MW Turbine,
Chimney, auxiliaries and fuel & ash handling with buildings and
machinery foundations for 200 KLPD Ethanol etc. as per quotation.
Total 22400

Capital Investment for proposed Environmental Protection (Rs. in Lacs

S. No. Particular Proposed Cost
1. Bag Filter/ESP 200
2 M.E.E 500
3 Waste Water Treatment Plant for Process Condensate 300
4 Decanter & Dryer 800
5 Green Belt development 7.68
6 Occupational Health & Safety 29.25
7 MiscRWH etc 5.0
1841.93@ 1842
Total

9.0 Analysis of Proposal (Final Recommendation)

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