Pre Feasibility Report

For
Grain Based Fuel Ethanol Plant of 200
KLD & 6 MW Co Generation Plant
At
Village –Agariya,
Tehsil-Narsinghpur
Dist.–Narsinghpur(MP)

Proposed By
M/S Mahakaushal Sugar And Power
Industries Ltd
Village-Agariya , Tehsil – Narsinghpur,
Dist .- Narsinghpur , MP- 487001.
1. Identification of project and project proponent
M/s Mahakaushal sugar & Power Industries Ltd (MSPIL) is as limited firm
registered with State Govt and located at Village- Agariya Tehsil- Narsinghpur -
Dist Narsinghpur (MP)

The company is incorporated with main objects to carry on in India or anywhere

else the business as producers, importers, exporters, traders, dealers, processors of
cattle feed, cattle sheep, sea food, river food, meet, meat products, canned food,
canned fruits, vegetables, dairies, dairy products, poultry farming, fisheries, and
preservation and processing of all kinds of food products
M/s. MSPIL is one of the pioneering sugar factories of Madhya Pradesh and is in
its 10th year of operation. MSPIL received its memorandum for manufacturing of
vacuum pan sugar and molasses along with other sugarcane by products from the
Ministry of Commerce & Industry in April 2005. The factory started its crushing
operations in the year of 2006-07. The licensed crushing capacity of the plant is
4500 tonnes per day.
M/s Mahakaushal Sugar and Power Industries Ltd. having following Present
Directors on its Board:
 Mr Nawab Raza, Director
 Mr Asmat Raza, Director
 Mr Sahil Raza, Director
 Mr Saif Raza, Director
Considering the availability of grains in the command area of the company, the
management of the company has taken various steps for setting up of 200 KLPD
Ethanol Plant based on multi grains.
The Company has also received sanction from Ministry of Food and Public
Distribution, Government of India for 6% (or 50% on charged interest) Interest
subvention whichever is lower.
The proposed Ethanol plant of 200 KLPD capacities will employ state-of- art-
technology for production of Ethanol i.e. milling and cooking, fermentation, multi
pressure distillation system, integrated and standalone evaporation section, CPU
and Captive power plant.
Brief Description of Nature of the Project
The unit is in operation for 4500 TCD of sugar manufacturing and Cogen plant of
12.8MW with valid consent of air and water of MPPCB.
The present proposal is for setting up a 200 KLD fuel ethanol plant (Grain based)
with 6MW of cogen plant at Village- Agariya Tehsil & Dist Narsinghpur (MP) in the
State of Madhya Pradesh at an estimated cost Rs. 179.00 Crores. The proposed
project will be set up at adjacent premises of existing sugar unit (4500 TCD &
12.8MW power plant) of M/s MSPIL.
Most of the infrastructure facility is already available with the industry as present
sugar manufacturing operation is being continued from several years.

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.
 Silent Feature of the Project
• Plant can be operated on different Grain feedstock like broken rice, corn,
Sorghum, Millet etc.
• Provided with most efficient Fed batch Fermentation technology
• Distillation operating on Multi-Pressure Technology -a efficiently heat integrated
system, operating on fully automated PLC control system
• On line cleaning system is provided for distillation equipment's to minimize
plant shut down period.
• Process equipment's are designed as per TEMA/ ASME standards
• Indigenous Efficient Grain handling system is considered.
• Closed water recycles system and plant process is designed to minimize fresh
water requirement by recycling various effluents.
• Drier is considered to dry Distillery Wet Grain Soluble (DWGS), a Mixture of
Spent Grain and Evaporated Thick Slops:
• C02 is discharged as a byproduct of the Fermentation process which in turn
can be utilized after further treatment (CO2 Plant) in industrial or food grade
application which further would contribute to enhance Revenue Generation.
• Zero Effluent Discharge norms is applied while designing the plant.
• Distillery plant has been designed with hydrolysable starch content assumed as
68% w/w starch basis during grain-based operations.
• Offered Plant has been proposed on the concept of ZERO LIQUID EFFLUENT
DISCHARGE UNIT with spent wash from Distillation Plant being treated
suitably to produce DDGS (Distillers Dried Grains & Soluble), which is very rich
in fiber and nutrients and has very good demand as high value cattle feed.
• Liquefaction System has been proposed with Jet Cooking System and adequate
retention time in the system to facilitate proper break down of starch through
enzymatic reactions.
• Fermentation system is based on highly successful SSF (Simultaneous
Saccharification and Fermentation) Concept, which simplifies plant
operation, minimizes chances of contamination and ensures better fermentation
efficiencies resulting in higher yields while cutting down on process hardware.
• Distillation Plant is based on Multi-Pressure Distillation Technology, in which
all the Distillation column separate at different internal pressures and the
normal energy cascades from one distillation column to other distillation
column, leading to highly energy efficient system
• Six effects integrate Evaporator System to concentrate thin stillage
(decanted spentwash) to solids concentration of about 30% w/w.
• Two Bed MSDH plant has been proposed for Fuel Ethanol production.

[Link]. Particulate Description

1. Name of the proponent M/s Mahakaushal Sugar And Power Industries Ltd.
2. Project capacity Proposed : 200 KLD Grain based Ethanol Plant with
Cogen plant and 6 MW
3. Khasara No. &Location of the 142/1,142/2, 142/3, 146/8, 142/5
project Total 5.9286 ha at village Agariya District Narsinghpur
M.P.
4. Geographic Location 1. 22°52'34.59"N& 79°18'29.10"E
 2. 22°52'43.11"N& 79°18'29.59"E
3. 22°52'42.82"N& 79°18'28.84"E
4. 22°52'41.92"N& 79°18'28.09"E
5. 22°52'48.00"N& 79°18'26.00"E
6. 22°52'50.02"N& 79°18'26.14"E
7. 22°52'51.09"N& 79°18'27.12"E
8. 22°52'51.14"N& 79°18'29.71"E
9. 22°52'51.77"N& 79°18'30.79"E
10. 22°52'51.78"N&79°18'33.26"E
11. 22°52'51.16"N& 79°18'35.14"E
12. 22°52'49.81"N& 79°18'35.88"E
13. 22°52'48.47"N& 79°18'34.50"E
14. 22°52'48.29"N& 79°18'32.26"E
15. 22°52'44.78"N& 79°18'31.11"E
16. 22°52'44.76"N& 79°18'32.82"E
17. 22°52'34.88"N& 79°18'33.55"E
5. Land requirement Total Available Land Approx 5.9286 ha
Land Earmarked for proposed unit : 3.2618ha
Total Green belt area : 2.00ha
6 Product Product:
Proposed: 200 KLD Grain based Ethanol Plant with
Cogen plant and 6 MW
7. Operation days 330 days
8. Grain Requirement 460-489 TPD
9 Boiler capacity at MCR (100% 50 TPH
Load)
10 Steam Requirement 43-47 TPH @ 3.5 kg/cm2(g)
11 Fuel 130 TPD as rice husk or 110 TPD of coal
12. Source of water Borewell
13. Power Requirement 5555 KWH
14 Total water Requirement 4390 KLD
15 Total Recycling Water 3335 KLD
16 Total Fresh Water Requirement 1055 KLD
16 Spent Wash Generation 1538 TPD
17 Capital Cost for Environmental Proposed : 1822 Lacs
measures MEE, Dryer, ESP for
boiler (proposed)
18 Recurring cost for environmental Recurring charges is envisaged towards monitoring i.e.
Management etc(Proposed) Electrical units consumed shall be payable for
Continuous Stack Emission Monitoring System
(CSEMS) and Effluent Quality Monitoring System
(EQMS) for 24x7 online seamless systems for stack as
well as effluent (Being on ZSD) monitoring.
Proposed : 80 Lacs
19 DG Sets DG sets of 1000 KVAX2,
20. Man-power 82 skilled and unskilled (Direct )
21. Total project cost 179.00 Croes
22 Land acquired 5.9286ha
23 Land earmarked for proposed 3.2618 ha
distillery unit
24 Proposed area for plantation wrt
2.00 Ha
distillery unit
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
Cleaner Environment: As per the ministry of petroleum notification on new
biofuel policy, the proposed 1G ethanol project of DATPL
willproducearound~1.92–1.98Croreliters 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 18700 Lacs. Investment in proposed 1G
ethanol plant will spur infrastructural investment in rural areas.
Indian Outlook for Bio-ethanol

Progressive Vision and Strong Policy Support

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

Highlights of National Biofuels Policy -

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

Other Major Policy Measures To Support The EBP

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

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

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

GOI is planning to reduce crude import up to 10% by 2022. EBP is one of the
key facilitator of reducing import bill by blending ethanol in gasoline thereby
reducing gasoline requirement and providing sustainable income to farmers.
The above table also depicts the ethanol available and shortfall in M.P and
potential demand going ahead
The following point’s highlight the advantages of establishing such plants in
order to bring sustainability to ethanol blending program –
1. In the current scenario Ethanol supply is dependent on Sugar sector.
2. Major Sugar Cane Crop Production is limited within Maharashtra, Uttar
Pradesh, Bihar and Karnataka. Due to this the major Alcohol Production
is also from these four states only, making imbalance for demand and
supply of other states.
3. Shortage in supply of fuel ethanol post diverting excess sugar.
4. Incremental Price pressure on account of sugarcane FRP increase and
subsequent remunerative pricing of ethanol.
5. Alternative feedstock in the form of surplus grain (rice) is adequately
available
6. Benefits of setting of grain to Ethanol plants :
a. Control on Ethanol supply for non-sugar producing states and even
Sugarcane crop deficit years.
b. Ensuring minimum quantity sustainability of the EBP
c. In case of Grain to Ethanol, ZLD can be achieved with value added -
protein rich DDGS as a co-product.
d. Decentralized units will boost in achieveing 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

 EthanolDemandScenarioEstimationfor2025

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

Estimated Ethanol Supply from Sugar Sector

 As derived from above maximum possible supply from Sugary feedstock is ~
600 Cr Ltrs post diverting 6 MMT surplus sugar
 This clearly denotes that blending targets cannot be achieved only by
diverting sugarcane/sugar to ethanol, so there is dire need for alternative
feedstock.
 Thus, the government is encouraging production of ethanol from other
feedstock like grains (Surplus rice/Maize/Damaged Food Grain (DFG)).
GRAIN FEEDSTOCK SCENARIO
The Government has notified about surplus Grain availability of around
13.5 MMT which can be utilized to produce Ethanol.
Estimated Ethanol Supply from Grains

Existing and Required Capacities–India

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
Particulars Molasses Grain Based 93
Based ([Link].) ([Link])
Supply requirement 660 540 723
 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

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
As above

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

Existing employment at sugar & co gen unit : 100+ 60 no.
Proposed Employment : 82Nos.( skilled and Direct )
Apart from that indirect employment generation is envisaged from the project.
Sr. No. Staff Nos.
1 Distillery manager 2
2 Production manager 3
3 ETP in charge 2
4 Lab chemist 2
5 Operators 5
6 Project Engineer / shift Engineer 2
7 Electrician 10
8 Mechanical Fitters 5
9 Office Peon 8
10 Office assistant 10
11 Excise officer 0
12 Waterman / Pump man 3
13 Other Contractual staff 30
Total 82

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 6 MW through co generation is proposed. CO 2 will also generate as by product from
the fermentation process which is turn can be utilized after further treatment at CO 2
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 5.9286ha of land in village Agariya Dist. –Narsinghpur of MP.
The latitude and longitude of the site is as below:
1. 22°52'34.59"N& 79°18'29.10"E
2. 22°52'43.11"N& 79°18'29.59"E
3. 22°52'42.82"N& 79°18'28.84"E
4. 22°52'41.92"N& 79°18'28.09"E
5. 22°52'48.00"N& 79°18'26.00"E
6. 22°52'50.02"N& 79°18'26.14"E
7. 22°52'51.09"N& 79°18'27.12"E
8. 22°52'51.14"N& 79°18'29.71"E
9. 22°52'51.77"N& 79°18'30.79"E
10. 22°52'51.78"N&79°18'33.26"E
11. 22°52'51.16"N& 79°18'35.14"E
12. 22°52'49.81"N& 79°18'35.88"E
13. 22°52'48.47"N& 79°18'34.50"E
14. 22°52'48.29"N& 79°18'32.26"E
15. 22°52'44.78"N& 79°18'31.11"E
16. 22°52'44.76"N& 79°18'32.82"E
17. 22°52'34.88"N& 79°18'33.55"E

Topographical Base Map

Google Image of the Project area
 Layout of the proposed Unit

iii. Details of Alternate Site:

The green field unit of 200 klpd is proposed at village Agariya with environmental
consideration and in line with guideline issued for setting up of Industrial project .
Hence no alternate Most of the infrastructure is already available at adjacent site where
sugar plant is located . Therefore proposed site suitable for the project configuration.
iv. Size or magnitude of Operation:
 It is proposed to produce 200KLPD of fuel ethanol, 150TPD of CO2 (Recoverable @
75 TPD as a by-product) from grain-based operation. 6 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:
PROCESS DESCRIPTION

Parameter Details
Grain type Convertible Starch Content
For Clean Grain containing minimum 58%
Broken Rice, Corn, Sorghum, Bajraetc.
w/w enzymatically convertible starch.
Plant Capacity 200 KLD Fuel Ethanol on Grain
Thin slop recycle to Liquefaction section 30%
Alcohol Concentration in Fermented Wash 13 % v/v Min
Product Fuel Ethanol
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
Fuel Ethanol Specifications
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
Appearance Clear Colorless Clear Colorless
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

[Link] 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

DETAIL Of MANUFACTURING PROCESS

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 is 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.

Alcohol
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 [6 MW]

Proposed 6 MW co-generation plant consists of high pressure traveling grate water
tube steam boiler & back pressure steam turbine. Fuel in the steam boiler will be
burnt with the help of air in the boiler furnace. Water will be circulated in the boiler
drum and tubes thus getting heated by the flame burning in the boiler furnace.
Water comes out of the boiler drum located at the top of the boiler as steam. Flue
gases rise in the boiler furnace and come in contact with the steam coming out of
boiler drum. Steam after coming in contact with flue gases gets heated up further
thus getting superheated. Super heated steam leaves the boiler in a pipe. Flue
gases after super heating the steam pass through economizer where they pre-heat
the boiler feed water before it enters the boiler drum. After economizer, flue gases
pass through air pre-heaters where they heat the air which is fed to the boiler
furnace for burning the fuel. After air pre heaters flue gases pass through a bag
house filter where the dust particles are collected in filter bags & discharge from
the bottom of the bag house filter. Dust will be collected in the Ash Silo through
pneumatic conveying system.
 High pressure superheated steam from boiler is passed through a steam turbine
and low pressure goes to Low pressure header, which is used for distillery. While
passing through the turbine, the high pressure and temperature steam rotates the
turbine rotor and an electric alternator mounted on the same shaft. Electric power
is generated by the alternator. This electric power generated is consumed in house
i.e. for running the distillery and utilities like boilers auxiliaries etc.
Process Flow Chart (CPP)

Steam 43 TPH @ 3.5 kg/cm2 Power 6MW

To MSDH - 5 TPH
To Dryer -12 TPH
To Distillation - 15 TPH
To Hydro heater/Jet cooker - 5 TPH
To De-Aerator - 5TPH
To Misc. - 1 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 460-489 TPD Rice
mills/FCI
Rice Husk Husk Yard 1000 MT 130TPD Rice mills
Coal Cover Shed 1000 MT 110TPD 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 Amyloglucosidase,
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 8-12 7-9 4-10 7-10 Not Specified
organisms

Compositions and its derivatives:

A Paddy Feed 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 Product of Rice Milling
1 Rice (Whole) 69.00 690
3 Bran 6.00 60
4 Broken Rice +Germ 7.00 70
5 Husk 18.00 180
Total 100.00 1000
C Feed - Broken Rice + Germ + Bran 1000
1 Starch 39.00 390.00
2 Crude Oil 14.00 140.00
3 Moisture 10.00 100.00
4 Crude Fiber 8.00 80.00
5 Other Carbohydrate 6.00 60.00
6 Protein 23.00 230.00
Total 100.00 1000
D Output - Bran Based Industries ( 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 ( Protien) 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 1055 KL per day
Source: Borwell
Water balance and Mass Balance Chart
 Water Balance Of Proposed Fuel Ethanol Unit of 200 KLD
Water Type Fresh Water required Fresh Water required Total Water
Before Recycle After Recycle Recycle
Process Water 1210 240 970
Soft Water 1350 600 750
De-mineralised
1830 215 1615
Water
TOTAL 4390 1055 3335
KL/KL 21.95 5.28 16.68

ix. Power Requirement:

Construction Phase – 30 kw
Power Distribution kWh 5555
Grain Handling and Milling kWh 580
Liquefaction kWh 220
Fermentation kWh 850
Distillation kWh 120
Dehydration kWh 90
Decantation kWh 180
DDGS Dryer kWh 800
Evaporation kWh 340
 Cooling Tower kWh 650
Product Storage kWh 50
Condensate Polishing Unit kWh 120
Water Treatment Plant kWh 130
Boiler and Turbine kWh 650
CO2 Bottling Unit kWh 700
Plant & Yard Lighting kWh 25
Miscellaneous kWh 50
Total

During operation phase, the required power will be taken from 6 MW cogeneration
power plant. Two DG set of 1010 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 (1326 M3 per day) will pass through centrifuge decanter for separation
of solid. The part of thin slope (246 M3 per day) from centrifuge will be recycled to
process. The remaining slop will be concentrated through multi effect evaporator.
• The concentrated syrup will be mixed uniformly in the ribbon mixer to form DWGS
(195 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.
• SpentLees 858 TPD will be recycle back for Slurry preparation. 1599 m3/day of
Process condensate, CT Blow down, WTP Reject is fed to CPU unit.
• 1519 m3/day treated water will return back to process for utilization in
liquefaction/fermentation/cooling tower etc. Balance Rejected 81 m3 use in
process for Liquifaction section/fer. cleaning.
• Rainwater will be utilized to recharge the underground resource through
scientifically designed rainwater harvesting system.
• 45M3/day of boiler blow down will be sent for ash quenching.
Solid And Hazardous Waste Management
Type Of Waste Quantity Storage Utilization/ Disposal
DDGS – ( by product) 102-110 Covered shed Sold as Cattle Feed, Poultry
TPD &Fisheries
Boiler ash 10 TPD Silo Brick making or land filling
ETP sludge 55 Drying Beds Will be used as Manure
MT/DAY
Waste papers/Boxes 1.5-2 TPD Covered shed to recyclers
Used Oil < 500 lit per HDPE drums Given to re-cycler authorized by
year in covered shed MPPCB/MoEF
Spent Resin from DM <50Kg/Yr HDPE drums Given to re-cycler authorized by
Plant in covered shed MPPCB/MoEF

Details of Air Pollution Control System

S. No. Details of DG
1. Type of Fuel HSD
2. Capacity 2X1010 KVA
3. Stack Height 30 Mtr
4. Pollution Control Adequate stack height/
Equipment Measures Acoustic

Emission Details of Stack

Parameters Co gen Plant
Boiler Configuration 50 TPH
Type of fuel COAL
Calorific value 4800
Ash content 30%
Sulphur content 0.4%
Number of Stacks 1
Common Stack with no. of flues 2
Material of construction RCC
Shape (round rectangular) ROUND
Stack height from ground level(m) 46
Stack Dia. (m) 3 MTR
Exhaust Gas Temperature(oC) 160
Flue Gas Velocity (m/s) 19
 Volumetric flow rate (Nm3/S) <100
APCE (Air pollution control equipment) Proposed ESP

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 46 3 19 160 0.183 2.59 9.24
(Rice husk)
2 Stack 1 46 3 19 160 0.033 4.07 9.24
(Coal)

Air Pollution Control System (for Grain based (200 klpd)

S No Parameters UOM Description
A Boiler Details
Type
440DegC Super heated
Boiler Type Bi-Drum
steam
Boiler Capacity 50 TON Bi- Drum Traveling grate
Boiler Make Not yet Finalies
Fuel Coal/Agrowast
Fuel Grade Indonation
Ash Content in Fuel 4 to 5 %
Working Steam Pressure 45
Flue Gas Temperature 160
Fuel Consumption 110-120 MT
Quantity 110-120 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 60
Static Pressure 250
Operating Temperature 200
Type Centrifuge
Motor Rating 1400 RPM/VFD
Quantity 2
1hrs MGLC for PM10
1hrs MGLC for PM2.5
1hrs MGLC for SO2
 1hrs MGLC for NOx

i. Site Connectivity
i. Land Form, Land use and Land Ownership
• Land Form, Land use and Land Ownership
Project Proponent is having 14.65 acres 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
Built up area for plant, building and machinery 20800.84
Area under road 4046.86
Area for Raw Material Storage 2024.00
Area for Fuel Storage 5745.96
Area for Green Belt 20031.94
Total 52649.60
Open land 6636.84
Total Area 59286.44 ( 5.9286 ha)

ii. Existing Infrastructure

The required infrastructure is already in place as proposed site is in operation.
National Highway is passing at 250mtrs from the proposed project.

iii. Soil Classification

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

iv. Climate data from Secondary Source:

Summary of Meteorological Data
Month Wind Speed Temperature (oC) Relative Rain Fall (mm) Cloud
(Km/hr) Humidity (%) Cover
Mea Ma % of Max Avg. Min Ma Mea Min Tota 24- No. of (Octas
n x calm . (Dry . x. n . l hours rainy of sky)
Bulb) Highest days Mean
March, 18 9 22 6.44 39 28 22 49 18 5 2.9 1.6 03 2
April, 18 11 25 6.25 44 33 26 45 13 4 0.1 0.1 01 2
May, 18 13 29 6.06 46 39 27 31 13 4 2.0 0.8 04 2
v.
Source: IMD, Climatological Normals, Office of the Additional Director General of Meteorology (Research), IMD, Pune
vi. Social Infrastructure available
Social infrastructure like community center, hospital and electricity is available in Agariya ,
Agariya well as in Narsingpur (MP)

Planning Brief:
i. Planning Concept :
The Molasses 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.
ii. 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 has already been provided at site.
 The area shall not being used at all by general public.
 A rest shelter is there for workers.
 Guards during day & night has already been 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.

4.0 Proposed Infrastructure

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

Capacity: 56 TPH
Thickness: 6 mm
Grain unloading Platform 1
1. With MS Grating of Size
And receiving Hopper
1000 mm X 2000 mm
MOC-MS
Capacity: 56 TPH
Bucket Elevator I 1
2. Casing Thickness – 6 mm
(For Grain Loading)
MOC-MS
Capacity: 56 TPH
3. Pre-Cleaner Unit Along with the accessories like feeding
2
apparatus, sieve boats
Tech 6 X 10
Aspiration System for Pre Blower Motor for Fan .
4.
cleaner Air Lock geared Motor . 1
MOC-MS with Epoxy Lining
Capacity: 56 TPH
Bucket Elevator II 1
5. Casing Thickness – 5 mm
(For Grain Loading)
MOC-MS
Type: Flat Bottom
Capacity :5000 MT
Along with the accessories like Sweep
auger, Grain spreader, level switch, full
6. Grain Storage Silo floor aeration system, discharge gate, 2
Cat walk etc.
Thickness: Shell Between 1.5 to 3 mm
Roof Thickness: 0.8 mm
MOC-GI
Length : 8.5 mtr
Diameter: 200 mm 2
7. Sweep Auger
Pitch : 200 mm
MOC-MS
Type : LSH – Vibrating Fork Type
8. Level Switches LSL- Vibrating Fork type 4
Fork Length : LSL/LSH
 250/250 mm
Power Supply : 24 V-240 V AC/DC
Capacity : Suitable
Water Gauge pressure : 85 mm 2+2
9. Blower
Motor RPM : 1480
MOC-MS with Lining
Type :Motorised /manual
Silo Discharge –Electro Pneumatic &
Rest Manual
10. Slide Gate Valve Size – 200 X 200 4
Galvanization
Qty : 450 G/m2
MOC-MS & Galvanized
Screw Conveyer 2
11. Capacity : 56 Ton/Hr.
(For Grain Unloading)
12. Interconnecting ducting / piping --- Lot
13. Electrical & Instrumentation MCC and DCS based Lot

Grain Handling And Milling Section

Bucket Elevator Capacity: 30 TPH 1

1.
(for grain) MOC-MS
Receiving Hopper Capacity: 30 TPH 1
2.
With Rotary Valve MOC-MS
Capacity : 30 TPH
3. Vibrating Screen 1
MOC-MS
Capacity : 1500
4. Air Blower I nm3/hr. 1
MOC-MS
Capacity : 30 TPH
5. Bag Filter for Vibrating Screen 1
MOC-MS
Capacity: 30 TPH
6. Magnetic Separator 1
MOC-MS
Capacity: 30 TPH
7. De-stoner 1
MOC-MS
Capacity : 1500
8. Air Blower II nm3/hr. 1
MOC-MS
Capacity : 30 TPH
9. Bag Filter for De-stoner 1
MOC-MS
Buffer Hopper I for Grain With Capacity : 30 Tons
10. 1
Rotary Valve MOC-MS
Capacity: 12TPH
11. Hammer Mills 3+1
MOC-STD
Capacity: 30 TPH
12. Flour Screw Conveyer 1
MOC-MS
Bucket Elevator Capacity: 30 TPH
13. 1
(for flour) MOC-MS
 14. Flour Sifter Capacity : 30 TPH 1
Capacity : 150 Ton
15. Flour Silo 1
MOC-CS
Capacity: 20 TPH
16. Flour Screw Conveyer 1
MOC-MS
Bucket Elevator Capacity: 20 TPH
17. 1
(for flour) MOC-MS
Buffer Hopper for Flour with Rotary Capacity : 20 Ton
18. 1
valve MOC-MS
19. Weighing Machine Capacity: 20 TPH 1
Capacity: 20 TPH
20. Flour Screw Conveyer 1
MOC-MS
Dust Collection System for Milling ---
21. 1 ENZ
Section
22. Interconnecting ducting / piping --- Lot YMA
23. Electrical & Instrumentation MCC and DCS based Lot TIC
HYD
ROLYSIS / LIQUIFICATION SECTION

Type : Screw Mixer,

1. Pre-masher Capacity :68 m3/hr. 1
MOC-SS304
Type :Vertical /
Cylindrical, 1
2. Hot water Tank
Capacity : 20 m3
MOC-SS304
Type: Centrifugal,
Capacity : 60 m3/hr.
3. Hot water Pumps 1+1
MOC- Wetted Parts
CF8
Type :Vertical /
Cylindrical, 1
4. Slurry Tank
Capacity : 65 m3
MOC-SS304
Type: Centrifugal,
5. Slurry Transfer Pumps Capacity : 65 m3/hr. 1+1
MOC- SS304
Type: Propeller
6. Agitator For Slurry Tank : top Entry 1
MOC- SS304
Type: Venturi,
7. Jet Cooker Capacity : 65 m3/hr. 1
MOC- SS304
Type: Tubular,
8. Retention Vessel Capacity – 20 m3
MOC-SS304
Type: Vertical /
Cylindrical,
9. Flash Tank
Capacity: 5 m3
MOC-SS304
 Type: Shell & Tube
10. Primary Flash Condenser HTA : 67 m2 1
MOC-SS304
Type: Shell & Tube
HTA : 47 m2
11. Secondary Flash Condenser 1
MOC-SS304
Thickness-3 mm
Type: Vertical /
Cylindrical,
12. Liquefaction Tank 1
Capacity: 128 m3
MOC-SS304
Type: Centrifugal,
13. Liquefied Slurry Transfer Pumps Capacity: 64 m3/hr. 1+1
MOC- Wetted Parts CF8
Type: Propeller
14. Agitator For Liquefaction Tank 1
MOC-SS304
Type: Plate Heat
Exchanger,
15. Slurry Cooler Wide gap 1+1
MOC-SS316 EPDM
Gasket
Type : Vertical /
Cylindrical
16. Alfa Amylase Enzyme Dosing Tank 1
Capacity :0.2 m3
MOC-SS 304
Type : Metering
17. Alfa Amylase Enzyme Dosing Pump Capacity :0.2 m3/Hr. 1+1
MOC-HDPE / PP
Type : Vertical /
Alfa Glucosidase Enzyme Dosing Cylindrical
18. 1
Tank Capacity :0.2 m3
MOC-SS 304
Type : Metering
Alfa Glucosidase Enzyme Dosing
19. Capacity :0.2m3/Hr. 1+1
Pump
MOC-HDPE / PP
20. Piping and Valves ––– Lot
21. Electrical & Instrumentation MCC and DCS based Lot

FERMENTATION SECTION

1. Pre-fermenter Type: Vertical/Cylindrical 2

Capacity: 220 m3
MOC: SS 304
2. Culture Transfer Pump Type: Centrifugal / Horizontal 1+1
Capacity: 220m3/hr.
MOC: Wetted Parts SS 304
3. Pre-Fermenter Coolers Type: Plate Heat Exchanger, 1
MOC: SS 316 Plate, Wide Gap
 EPDM Gasket
4. Fermenters Type : Vertical / Cylindrical with 4
Conical Bottom
Capacity: 1350 m3
MOC: SS 304
5. Agitators for Fermenters Type: Top Entry, Propeller 4
MOC: SS 304
6. Cleaning Nozzles Type : 360 degree Spray Type 6
MOC: SS 304
7. Fermented Wash Coolers Type: Plate Heat Exchanger 4
Wide gap PHE
MOC: SS 316 Plate, EPDM Gasket
8. Fermented Wash Type: Centrifugal / Horizontal 4
Recirculation Pumps Capacity: 680 m3/hr.
MOC: Wetted Parts SS 304
9. Air Sparger Type : Suitable 2
for Prefermenter MOC: SS 304
10. Safety system Type: Breather Valve 4
MOC: SS 304
11. Buffer Tank with Agitator Type : Vertical / Cylindrical 1
Capacity:1350 m3
MOC: SS 304
12. Distillation Feed Pump Type: Centrifugal/ Horizontal 1+1
Capacity: 85 m3/hr.
MOC: Wetted Parts SS 304
13. Air Filter Type: HEPA Type 1
MOC: CS
14. Air Blowers with Liquid Type: Water Ring 1+1
separator Capacity: 450 m3/hr.
Pressure: 1.5 kg/cm2(g)
MOC: CS with SS Internals
15. CO2 Scrubber Type: Sieve Tray 1
Diameter: 1000 mm
Tray Spacing: 250 mm
No of Trays: 6
MOC: SS 304
16. Water Header As per CPEPL standards 1
MOC: MS
17. Air/CO2 Header As per CPEPL standards 1
MOC: SS 304
18. Nutrient Tank with agitator Type: Vertical / Cylindrical 1
Capacity: 2 m3
Thickness: 3 mm
MOC: SS 304
19. Nutrient Dosing Pump Type: Metering 1+1
Capacity: 1 m3/hr.
MOC: SS304
20. CIP Tank Type: Vertical / Cylindrical 1
Capacity: 20 m3
 Thickness: 3 mm
MOC: SS 304
21. CIP Pump Type: Centrifugal/ Horizontal 1+1
Capacity: 20 m3/hr.
MOC: Wetted Parts SS 304
22. Piping Process Fluid - Lot
a. Fermented Wash : SS 304
b. Steam : MS ‘C’
c. Water : MS ‘B’
d. Process Air : MS ‘B’
e. CO2 :SS 304
f. Nutrient : SS 304
g. TRO : SS 304
23. Valves Process Fluid - Lot
Ball Valve/Butterfly Valves a. Fermented Wash
b. Steam
c. Water
d. Process Air
e. CO2
f. Nutrient
g. TRO
MOC: SS304/CI
24. Piping and Valves ––– Lot
25. Electrical & MCC and DCS based Lot
Instrumentation
26. Piping Process Fluid - Lot
a. Fermented Wash : SS 304
b. Steam : MS ‘C’
c. Water : MS ‘B’
d. Process Air : MS ‘B’
e. CO2 :SS 304
f. Nutrient : SS 304
g. TRO : SS 304
27. Piping and Valves ––– Lot

MULTIPRESSURE RS DISTILLATION SECTION

1. Mash Column Diameter : 3300 mm 1

No. of trays : 26+1
Tray Type : Grid Type
Tray Spacing : 750 mm
Material : SS 304

2. RS Rectifier cum Diameter : 2700 mm 1

Stripping Column No. of trays : 62
Tray Type : Bubble Cap
Tray Spacing : 250 mm
Material : SS 304
3. Recovery cum Diameter : 1500 mm 1
Aldehyde Column No. of trays : 35
Tray Type : Bubble Cap
+ Sieve
Tray Spacing : 250 mm
Material : SS 304

REBOILERS

1. Mash Column HTA : 500 m2 2+1

Reboiler Type : Shell & Tube
Material : SS 304
Tube OD : 31.75 mm
Tube Length : 3000 mm

2. Rectifying cum HTA : 450 m2 1

Stripping Reboiler Type : Shell & Tube
Material : SS 304
Tube OD : 25.4 mm
Tube Length : 3000 mm

CONDENSERS & COOLERS

1. Analyser Column vent HTA : 65 m2 1

Condenser Type : Shell & Tube
Material : SS 304
Tube OD : 25.4 mm
Tube Length : 3000 mm
2. RS Rectifying column Vent HTA : 65 m2 1
condenser –I Type : Shell & Tube
Material : SS 304
Tube OD : 25.4 mm
Tube Length : 3000 mm
3. Rectifier column PCV HTA : 10 m2 1
condenser Type : Shell & Tube
Material : SS 304
Tube OD : 25.4 mm
Tube Length : 3000 mm
4. Aldehyde Column HTA : 50 m2 1
condenser - I Type : Shell & Tube
Material : SS 304
Tube OD : 25.4 mm
Tube Length : 3000 mm
5. Aldehyde Column HTA : 12 m2 1
condenser - II Type : Shell & Tube
Material : SS 304
Tube OD : 25.4 mm
 Tube Length : 3000 mm
6. Fusel Oil Cooler HTA : 7 m2 1
Type : Shell & Tube
Material : SS 304
Tube OD : 25.4 mm
Tube Length : 3000 mm

OTHER EQUIPMENTS
1. Vapour Liquid Separator Type : Gas LiquidSeparator 1
Material : SS 304

2. Fusel Oil Separator Type : Decanter 1

Material : SS 304
3. Vat Scrubber Type : Column Type 1
Material : SS 304
4. Reflux Collectors and Type : Cylindrical/Vertica 3
Collection Tank l
Material : SS 304
Capacity : 1 m3
5. Steam Condensate Tank Type : Cylindrical/Vertica 1
l
Material : MS
Capacity : 2 m3
6. CIP tank for Evaporation Type : Cylindrical/Vertica 1
and Distillation l
Material : SS
Capacity : 10 m3
7. Fermented Mash Pre-heater Type : PHE 1+1
Material : Plates SS 316
Gaskets EPDM
8. Rectifying Feed Pre-heater Type : PHE 1
Material : Plates SS 316
Gaskets EPDM
9. Vacuum water recycle Tank Type : Cylindrical/Vertica 1
l
Material : SS304
Capacity : 0.5 m3
10. Vacuum water recycle Pump Type : Centrifugal 1+1
Material : Wetted Parts CF8
Capacity : 6 m3/hr.
11. Vacuum water recycle PHE Type : PHE 1
Material : Plates SS 316
Gaskets EPDM
12. Process Pump Type : Centrifugal 5+5
Material : Wetted Parts CF8
Capacity : Suitable
13. CIP tank Pump for Type : Centrifugal 1+1
Evaporation and Distillation Material : Wetted Parts CF8
 Capacity : Suitable
14. Vacuum Pumps Type : Water Ring Type 1+1
Material : Wetted Parts CF8
15. Header Cylindrical Type 1
Material : Carbon steel
1. Cooling Water Header (Supply)
2. Cooling Water Header (Return)
3. Process Water Header and
Steam Header
16. Safe & Tester Type : Glass Tube Type 2
17. PIPING Fluid : MOC Lot
F. Mash : SS 304
[Link] : SS 304
Sp. Lees : SS 304
Alcohol : SS 304
Steam : MS C Class
Water : MS C Class
Instru. : GI
Air
Fusel Oil : SS 304
18. VALVES Fluid : MOC Lot
(Butterfly / Ball / Globe / F. Mash : SS internal
Gate Valves) [Link] : SS internal
Sp. Lees : SS internal
Alcohol : SS internal
Steam : CI / CS
Water : CI / CS
Fusel Oil : SS internal
19. PLC: -
It will consist of marshalling cabinets, two work stations; printer and voltage
safety stabilizers, memory backup and UPS battery backup.
The Distillation plant will be monitored using the PLC system.
Also a few important data from utilities will also be drawn and displayed on the
PLC

Redundancy factor for I/O will be provided adequately.

FUEL ETHANOL SECTION

1. Super-heater HTA : 54 m2 1
Type : Shell &Tube
Material: SS304
2. Regeneration HTA : 470 m2 1
Condenser Type : Shell &Tube
Material: SS304
3. Product Condenser HTA : 162 m2 1
Type : Shell &Tube
Material: SS304
4. Molecular Sieve Drums Type : Cylindrical/Vertical 2
Material: SS 304
Capacity: 18 m3
5. Molecular Sieves Type : 3A Type/Zeolite 28 MT

6. Supporting Media Type : Ceramic Balls Lot

Size : 10 &25 mm
7. Product Cooler HTA : 75 m2 1
Type : Shell &Tube
Material: SS304
8. Regeneration Cooler Type : PHE 1
Material: SS304
9. Vacuum Eductor Size: Suitable 1
10. Product Receiver Type : Cylindrical/Vertical 1
Material: SS 304
Capacity: 1 m3
11. Regeneration Receiver Type : Cylindrical/Vertical 1
Material: SS 304
Capacity: 1m3
12. Product Pump Type : Centrifugal 1+1
Material: Wetted PartsSS 304
Capacity: 10 m3/hr.
13. PLC:
It will consist of marshalling cabinets, One work station; printer and
voltage safety stabilizers, memory backup and UPS battery backup.
The Ethanol plant will be monitored using the PLC system.
Also a few important data from utilities will also be drawn and
displayed on the PLC.
Redundancy factor for I/O will be provided adequately
14. PIPING Fluid MOC
Alcohol : SS 304
Sp. Lees : SS 304
Ethanol : SS 304 / MS B
Steam : MS C Class
Water : MS B Class
Instru. Air : SS304
15. VALVES Fluid MOC
(Butterfly / Ball / Globe Alcohol :SS 304 internal
/ Gate Valves) Sp. Lees :SS 304 internal
Ethanol :SS 304 internal
Steam :CI / CS
 Water :CI / CS
Instru. Air :SS 304 internal

16. Electrical and Instrumentation

DECANTATION SECTION
1. Decanter Type : Decanters 4+1
Capacity: 20m3/hr
MOC- SS316
2. Spent wash Tank Type : Vertical / Cylindrical 1
Capacity: 60 m3
MOC- SS 304
3. Thin Slop Tank Type : Vertical / Cylindrical 1
Capacity: 240 m3
MOC-SS 304
4. Spent wash Transfer Type : Centrifugal/ Horizontal 1+1
Pumps Capacity: 65m3/hr.
MOC: Wetted parts CF8
5. Thin slop Transfer Pumps Type : Centrifugal/ Horizontal 1+1
Capacity: 60 m3/hr.
MOC: Wetted parts CF8
6. Piping and Valves -- Lot
7. Electrical & MCC and DCS based Lot
Instrumentation

INTEGRATED EVAPORATION PLANT

4 Falling Film Effect plus 2

Scheme No.
Forced circulation effect
Thin Slop Feed to Evaporator TPD 1117
Solids in Thin Slop % w/w 6
Product Rate TPD 223
Product solids % w/w 30
Water Evaporation Rate TPD 894
Operation Hours Hr. 23
Analyser Column Top Vapor (70
Heating Media -- °C)
DDGS Dryer Vapors (80 °C)
Shell : SS 304
Material of Construction --
Tubes : SS 304
 S NO NAME OF EQUIPEMENT TECHNICAL SPECIFACTION
QUANTITY
1. Feed Tank Type : Cylindrical/Vertical 1
MOC : SS 304
Capacity : 2 m3
2. Feed Pump Type : Centrifugal 1+1
Material : Wetted Parts CF8
Capacity : 54 m3/hr.
3. Falling film Evaporator HTA : 1160 m2 4
Type : Falling Film
Material : SS 304
Tube OD : 50.8 mm
Tube Length: 12000 mm
4. Vapour Liquid Separator Type : Gas Liquid Separator 4
for falling film Material : SS 304
evaporator
5. Recirculation Pump- Type : Centrifugal 4
Falling Film Material : Wetted Parts SS 304
6. Forced Circulation HTA : 750 m2 2
Evaporator Type : Forced
Circulation
Material : SS 304
Tube OD : 38 mm
Tube Length: 12000 mm
7. Flash Vessel for forced Type : Gas Liquid Separator 1
circulation evaporator Material : SS 304
8. Recirculation Pump- Type : Centrifugal 1
Forced Circulation Material : Wetted Parts CF8
9 Surface Condenser HTA : 950 m2 1
Type : Shell & Tube
Material : SS 304
Tube OD : 25.4 mm
Tube : 6000 mm
Length
10 Conc. Spent Wash Tank Type : Cylindrical/Vertical 2
Material : SS 304
Capacity : 1 m3
11 Conc. Spent Wash Pump Type : Centrifugal 2+1
Material : Wetted Parts SS 304
Capacity : 12 m3/hr.
12 Vacuum Pump Type : Water Ring type 2+1
Material : SS Internals
13 Process Condensate Tank Type : Cylindrical/Vertical 1
Material : SS 304
Capacity : 1 m3
14 Process Condensate Type : Centrifugal 1+1
Pump Material : Wetted Parts CF8
Capacity : 45 m3/hr.
15 Piping and Valves
16 Electrical and Instrumentation

DDGS DRYER
1. Steam Tube Bundle dryer
1 No Rotating Tube Bundle DDGS dryer suitable model Area approximate: 1300 m2 X 2
Nos. Suitable to dry moisture of wet cake and evaporation slurry using steam as the
heating medium.
2. Parameters:
a) Name of product : DDGS
b) Specific Production rate : 0.45 Ton/KL of alcohol for Broken Rice
c) Colour of product : Light yellowish to brownish
d) Moisture of product : Less than 10 %
e) Temp of product : 40 °C to 45 °C
f) Final vapour Temp : From Dryer 75 °C(Dry Bulb)
Steam Pressure: 3.5 kg/cm (g), 150 to 160 °C (Minimum)
2

3. A) Tube Bundle
a. Tube Sheet: Q345R.
b. Head: Q245R.
c. Heating Tube : CS, Seamless, Dia -51 mm.
d. Main Shaft : Carbon steel 20#, III grade forging. Centre shaft – Carbon Steel
/Stainless steel.
e. Angle hold bar: drawn steel.
f. Shovels : SS316 , ( with bolt +Washer + lock washer).
g. Rest : Carbon Steel

B) Housing Parts
a. Shell : SS316.
b. End Plates : Material Carbon Steel Q235B, liner SS316, Thickness : 5 mm .
c. Vapour Hood : Carbon Steel.
d. Inspection Doors : SS316
e. Discharge Hopper : Carbon Steel
f. Insulation with LRB (Thickness: 50 mm, density: 140 Kg/m3), Cladding
Aluminium Thickness 1 mm.
g. Dryer base : Carbon steel /Channel Beam .

C) Driving system
a. Gear box:
b. Fluid Coupling
c. Gear Wheel:
d. Bearing Housing

D) Other Parts
 a. Rotary Joints
b. Flexible Hoses
Note:
1. CS tubes to be expanded /full welded with CS Tube sheet
2. Each dryer have 2 rupture disc for safety
3. Final product temp before cooler – 95 to 100 deg C
4. All Internal nut/bolt of 2 Cr 17 Ni materials
5. Each dryer to have 4 manholes on dish end, maximum size 350 X 450 mm for
maintenance & inspection doors on top housing, Size 800 X 650 mm.
6. Housing SS 316
7. Along with each dryer gear box with coupling, Gear Wheel, Pinion, Insulation,
Vapour hood, inspection doors, discharge hopper, rotary joints, flexible hoses,
Bearing housing etc.
8. Final vapour temperature from dryer -80 -85 °C (Dry bulb)

EQUIPEMENTS
S No SPECIFICATIONS QUANTITY
NAME
Type: Screw conveyors
Capacity: 4500 Kg/hr.
Diameter : 400 X 6000 mm
1. Wet Cake Conveyor
Solids : 30 % 2
Density : 1200 kg/m3
MOC- CS
Type: Screw conveyors
Capacity: 11000 Kg/hr.
Diameter : 560 X 1500 mm
2. Feeding conveyors 2
Solids : 60 %
Density : 1300 kg/m3
MOC- CS
Type: Screw conveyors
Capacity: 7500 Kg/hr.
Discharge Diameter : 500 X 7000 mm
3. 2
Conveyors Solids : 90 %
Density : 360 kg/m3
MOC- CS
Type: Screw conveyors
Capacity: 6000 Kg/hr.
Diameter : 500 X 9000 mm
4. Recycle conveyors 2
Solids : 90 %
Density : 360 kg/m3
MOC- CS
Type: Paddle Type
Capacity: 10000 Kg/hr.
5. High Speed Mixer Diameter : 876 X 2920 mm
2
Solids : 60 %
Density : 1300 kg/m3
 MOC- CS
Type : Tangential Vapour Nozzle Entry,
Dryer Vapour Diameter 1250 mm X 5000 mm Lg
6. 2
Cyclone Shell Thickness: 4 mm
MOC :CS
Type : vertical /cylindrical
Tray type : Sieve tray
7. Wet Scrubber Shell Thickness: 4 mm 2
Diameter : 1000 MM
MOC- SS304
Type : Tangential Vapour Nozzle Entry,
Cyclone - I for Shell Thickness: 3 mm
8. 2
Pneumatic Conveying Diameter : 1000 mm
MOC- CS
Type : Tangential Vapour Nozzle Entry,
Cyclone - II for Shell Thickness: 3 mm
9. 2
Pneumatic Conveying Diameter : 1100 mm
MOC- CS
Type : Tangential Vapour Nozzle Entry,
Cyclone for Air Diameter 1600 mm X 3500 mm Lg
10. 2
Cooler Shell Thickness: 3 mm
MOC : CS
Type : Tangential Vapour Nozzle Entry,
Capacity : 25 Tons
11. Product Storage Silo 2
Shell Thickness: 6 mm
MOC- CS
Type : Tangential Vapour Nozzle Entry,
Diameter 1000 mm X 1250 mm Lg
Steam Condensate
12. Capacity :1 M3 2
tank
Shell Thickness: 4 mm
MOC- SS304
Type: Vertical /cylindrical
Sealing Tank for Shell Thickness: 3 mm
13. 2
Wet Scrubber Capacity : 1 m3
MOC- SS304
Type ; Centrifugal
Drive : Direct coupled
Impeller :Radical curved backwards
Fluid : Air +Water Vapours
Dryer Vapour Fan Pressure : 3500 Pa
14. along with motor and Along with accessories Vibration isolator, 2
it’s accessories. motor mounting slide rail, locking and
motor alignment bolts, common base
frame, damper belt-pulleys, belt guard,
bearings, cleaning door, drain plug,
heatslingers, isolation bellows.
 Type ; Centrifugal
Drive : Direct coupled
Impeller :Radical curved backwards
Fluid : Air Vapours
Air cooler Fan (Bag
Pressure : 3720 Pa
Filter Fan) along with
15. Along with accessories Vibration isolator, 2
motor and it’s
motor mounting slide rail, locking and motor
accessories.
alignment bolts, common base frame,
damper belt-pulleys, belt guard, bearings,
cleaning door, drain plug, heat slingers,
isolation bellows.
Type ; Centrifugal
Drive : Direct coupled
Impeller :Radical curved backwards
Fluid : Air Vapours
Fan for pneumatic
Pressure : 9000 Pa
conveying along with
16 Along with accessories Vibration isolator, 2
motor and its
motor mounting slide rail, locking and motor
accessories.
alignment bolts, common base frame,
damper belt-pulleys, belt guard, bearings,
cleaning door, drain plug, heat slingers,
isolation bellows.
Type : Horizontal double deck cooler
To cool the product DDGS from
17 Product cooler 2
95 °C to 45 °C
Capacity : Suitable
Type : Vertical /cylindrical
Solids : 90 %
18 Bag Filter 2
Density : 400 kg/m3
MOC- CS
Type : Vertical /cylindrical
Diameter : 1000 mm
19 Chimney 2
Height : 7000 mm
Thickness : 3 mm
Type : Centrifugal/ Horizontal
Steam Condensate
20 Capacity :10 m3/hr. 1+1
Pumps
Head : 25 MWC
One (1) number of semi-automatic bagging
21 Bagging Machine systems along with bag top stitching 2
facilities

Sr. Equipment Name Technical Specification Quantity

On the stationary end cover on the feed, there is an
exhaust port, which is to be connected to a centrifugal
22. Vapour Ducting
blower for exhaust the Vapours to the atmosphere.
Vapours duct and centrifugal blower are in SS304
 A 4 pole motor rotates the dryer at 8 rpm [Link] a
drive train of pulley’s-belts, gearbox, flexible coupling
23 Drive Arrangement
and pinion /girth gear assembly. All drive components
are mounted on a common M.S. base frame.
To discharge dust /Water Particle from
Cyclone at dryer Material Handled :
AIR + Dust of DDGS + Water
Particle Size : <660 micron (0.6mm)
Rotary Air Lock valve Bulk density :450 Kg/m3
24 2
for dryer cyclone Temp : 85 °C
Discharge Capacity:25 Ltr/rev @ 100
%
Filling
MOC : SS 304
To discharge dust /Water Particle from
Cyclone at Air cooler cyclone
Material Handled : AIR + Dust of DDGS
+
Water
Rotary Air Lock valve
25 Particle Size : <660 micron (0.6mm) 2
for Air cooler cyclone
Bulk density :360 Kg/m3
Temp : 85 °C
Discharge Capacity:10 Ltr/rev @ 100
%
Filling, MOC : CS
26 MCC Panel As per Standard 1
27 Motors As per Standard, Non Flameproof Lot
As per Standard, will be confirmed
28 Cables after Lot
detailed engineering
29 Cable Trays GI Cable trays Lot
As per Standard, will be confirmed
30 Earthing Strips after Lot
detailed engineering
Instrumentation
As per Standard, will be confirmed
Control valve, Flow
31 after Lot
meters, Transmitters,
detailed engineering
Instrument cable
32 Piping As per Standard Lot
33 Valves As per Standard Lot

2 . UTILITIES SECTION

[Link] Tower for Fermentation

 a. Design Conditions
Flow Rate Capacity : 1400 m3/hr.
Inlet Temperature : 34 °C
Outlet Temperature : 32 °C
Design Wet Bulb Temperature : 28 °C
b. Cooling Tower Specifications & Type
Type : Cross Flow Type, Induced Draft
c. Pumps And Motor
Pump Capacity : 700 m3/hr.
Quantity : 2+1
2 Cooling Tower for Distillation, Ethanol & Evaporation
d. Design Conditions
Flow Rate Capacity : 2000 m3/hr.
Inlet Temperature : 40 °C
Outlet Temperature : 32 °C
Design Wet Bulb Temperature : 28 °C
e. Cooling Tower Specifications & Type
Type : Cross Flow Type, Induced Draft
f. Pumps And Motor
Pump Capacity : 1000 m3/hr.
Quantity : 2+1
3. Cooling Tower for Liquefaction
g. Design Conditions
Flow Rate Capacity : 350 m3/hr.
Inlet Temperature : 40 °C
Outlet Temperature : 32 °C
Design Wet Bulb Temperature : 28 °C
h. Cooling Tower Specifications & Type
Type : Cross Flow Type, Induced Draft
i. Pumps And Motor
Pump Capacity : 350 m3/hr.
Quantity : 1+1
j. Piping and Valves
k. Electrical and Instrumentation

AIR COMPRESSOR:

[Link]. Description Specifications

1. Air Compressor Type : Screw Compressor
Capacity : 150 CFM
Op. Pressure : 7.5 kg/cm2 (g)
Quantity : 1+1
2. Air Dryer Capacity : Suitable
Quantity : 1
3. Air receiver Type : Vertical/Cylindrical
Capacity : 2000 lt
Op. Pressure : 10 kg/cm2 (g)
 Quantity : 1

PRODUCT RECEVING AND BULK STORAGE SECTION

Sr. No Name of Equipment Technical Specifications Quantity
Ethanol Daily Receiver Type : Cylindrical/Vertical 3
Material : MS
Capacity : 200 m3
Fusel Oil Receiver Type : Cylindrical/Vertical 1
Material : MS
Capacity : 5 m3
Ethanol Bulk Storage Tank Type : Cylindrical/Vertical 3
Material : MS
Capacity : 2000 m3
Fusel Oil Storage Type : Cylindrical/Vertical 1
Material : MS
Capacity : 25 m3
Ethanol Transfer Pump Type : Centrifugal type 1+1
Material : Wetted Parts SS 304
Capacity : 60 m3/hr.
Fusel Oil Transfer Pump Type : Centrifugal type 1+1
Material : Wetted Parts SS 304
Capacity : 5 m3/hr.
Vent Condenser HTA : 15 m2 2
Type : Shell & Tube
Material : SS 304
Alcohol Flow Meters Type : Positive 2
Displacement
Piping and Valves Lot
Flame Arrestor Lot

Condensate Polishing Unit

The proposed unit is to treat the Process Condensate, Spent Lees, WTP Reject, Cooling
Tower Blowdown, Dryer Condensate from the plant to reuse as Process Water for
Liquefaction & Fermentation & make-up water in Cooling Tower.
Design Data & Performance Projections
This Wastewater Treatment plant is designed for following parameters & will perform as
under upon reaching steady state of its operation:

PARAMETERS RAW WASTE WATER TREATED WASTEWATER

Flow (m3/day) 1600 1519
pH 3.9 – 4.2 7.0 – 8.0
BOD (mg/l) 2000 -2500 < 30
COD (mg/l) 3000 – 3500 < 250
Temperature -- Ambient

DETAILS OF TREATMENT UNITS

No. Treatment Unit MOC Mechanical Equipments
1 Mixing Chamber RCC M-25 SS Flash Mixer
2 Buffer Tank RCC Lined UASB Feed Pumps
3 Oil & Grease Trap RCC M-25 --
4 UASB Reactor RCC M-25 GLSS-MSEP, Feed Distribution
5 Extended Aeration Tank RCC Lined 2 No. Fixed Aerator
6 Secondary Tube Settler RCC M-25 Sludge Recirculation Pumps
Sludge Drying Beds
7 Brick Work --
(Optional)
8 Flash mixer RCC-M 25 Agitator
9 Flocculator RCC M-25 Flocculator Mechanism
10 Lamella Clarifier RCC M-25 Tube Dek
Chlorine Contact
11 RCC M-25 Chlorine Dosing Assembly
Chamber
12 Dual Media Filter -- --
Brick Work /RCC --
14 MCC Room
M-20

LIST OF EQUIPMENTS
Sr. No Equipments Qty BO/SITE/SHOP
1 SS “Mixer in Mixing Chamber 1 No BO
2 Dosing Pump with Dosing assembly 4No BO
3 UASB Feed Pumps 2 No BO
4 GLSS System for UASB Reactor 1 Lot BO
Feed Distribution System for UASB
5 1 No BO
Reactor
6 Flare Stack & Accessories 1 Lot. BO
7 Gas Holder and Accessories 1 Lot BO
8 15 HP Surface Aerator for Aeration Tank 2 No BO
9 Secondary Clarifier Mechanism 1 No BO
10 Sludge Recirculation Pumps 2 No. BO
11 Flash Mixer Agitator 1 No BO
12 Clari-flocculator Mechanism 1 No BO
13 Chlorine Dosing Assembly 2 No BO
14 Dual Media Filter Feed Pumps 2 No BO
15 Dual Media Filter 1 No BO
16 Activated Carbon Filter 1 No BO
17 Interconnecting Piping & Valves 1 Lot BO
18 Pressure Gauges 1 Lot BO
19 MCC Panel, Earthing& Cabling 1 Lot BO
20 High Pressure Pumps 2 No BO
21 Dosing Arrangement 1 No BO
22 Antiscalant Arrangement 1 No BO
WATER TREATMENT PLANT - 1600 m3/Day

Sr. No. Description Specifications

HRSCC Clarifier Type : Solids contact type

Material : RCC with MS Internals Quantity : 1 No.

Accessories for Clarifier Half fixed bridge with walkway, draft tube,
scrapper arms with neoprene squeegees, Quantity
:1 set

Drive Mechanism and Gear Suitable

box for Clarifier Quantity :1 set

Multi Grade Filter Material : MS with Epoxy painting,

Type : Solids contact type Media : Pebbles &
Graded silica sand Quantity : 1 No.

Accessories for Multi Grade Complete with frontal piping, valves and Rota
Filter meters at the inlet of the unit. Quantity :1 set

Activated Carbon Filter Material : MS with Epoxy painting,

Type : Solids contact type Media : Pebbles and
Activated Carbon Quantity : 1 No.

Accessories for Carbon Complete with frontal piping, valves and Rota
Filter meters at the inlet of the unit. Quantity :1 set

Base Exchange Softener SA 515 / 516, Gr. 60 / 70 Boiler Quality,

Supporting Media : Gravels &Silex,
Quantity : 1 set Brine measuring tank : 2 m3,
MOC : MS Epoxy, Mode of Brine injection :
Ejector, Quantity : 1 No.

Accessories for Base Complete with frontal piping, valves and Rota
Softener meters at the inlet of the unit. Quantity : 1 set

DM Exchange Supporting Media : Gravels &Silex,

Quantity : 1 set Brine measuring tank : 2 m3,
MOC : MS Epoxy,
Mode of Brine injection: Ejector, Qty:- 1.

Accessories for DM Plant Complete with frontal piping, valves and Rota
meters at the inlet of the unit. Quantity : 1 set

Sr. No. Description Specifications

Polyaluminium Chloride Tank with Agitator,

(PAC) Dosing System Material : M S with Rubber lined,
 Material of construction of agitator SS 304,
Location of dosing : lamella

Dosing Pump for PAC Type : Electro mechanical,

system Material: PP, Quantity: 1 + 1.

Polymer Dosing System Tank with Agitator,

Material : M S with Rubber lined,
Material of construction of agitator SS 304,
Location of dosing : lamella

Dosing Pump for Polymer Type : Electro mechanical,

Material: PP, Quantity: 1 + 1.

NaOCl Dosing System Tank Material : FRP

Quantity: 1 No.
Location of dosing : lamella

Dosing Pump for NaOCl Type : Electro mechanical,

Material : PP, Quantity : 1 + 1 Nos.

Feed Pump Type : Centrifugal Type,

Material : Casing and impeller : CI / CS,
Quantity : 1 + 1 Nos.

Intermittent Pump Type : Centrifugal Type,

Material : Casing and impeller : CI / CS,
Quantity : 1 + 1 Nos.

Water Transfer Pump Type : Centrifugal Type,

Material : Casing and impeller : CI / CS,
Quantity : 1 + 1 Nos.

Piping & Valves

Electricals and Instrumentation.

MULTIFUEL FIRED BOILER - 50 TPH

Design Basis
No of boilers 1 No.
Make of boiler Standard
Design basis Standard Travelling Grate Boiler
Boiler Architecture
Type of boiler Travelling Grate, Water tube boiler
Drum Bi drum
Type of circulation Natural circulation
Type of draft Balance draft
Supporting arrangement Top supported.
Installation Semi outdoor.
Bunker location Front of boiler.
Feeding system location Front side of boiler.
Boiler Design Parameters
Unit Value at 100 % MCR
Super-heated steam flow rate at main steam Kg/hr. 50000
stop valve
Super-heated steam pressure at main steam Kg/cm2(g). 45
stop valve
Super-heated steam temp. at main steam °C 440 ± 5
stop valve
Feed water temperature at economizer inlet °C 110
Feed water temperature at de-aerator outlet °C 110
Super heater steam temperature control % 60 to 100
range
Spray Water temperature for attemperator °C 110
Flue Gas outlet temperature at out of boiler °C 160
Mode of operation - Constant pressure
Peak generation
Unit
Peak generation Applicable
Peak generation capacity Kg/hr. 55000
Duration and interval of peak generation ½ Hour once in 8 hours
shift.
Use of steam For Power generation
Saturated steam Purity at Drum Outlet
Total dissolved solids Ppm 0.1
Silica Ppm 0.02
Saturated steam purity mentioned above is
based on feed water TDS of 0.1 ppm and
silica 0.02 ppm
Site Condition
Plant Location
Environment Safe & non-hazardous/non
corrosive
Ambient dry bulb temperature
a) Minimum °C 3
b) Maximum °C 48
c) For performance trial °C 30
d) For Electrical design °C 50
Relative Humidity
a) Minimum % *(client to confirm)
b) Maximum % *(client to confirm)
c) For performance trial % *(client to confirm)
 d) For Electrical design % *(client to confirm)
Plant elevation above MSL m *(client to confirm)
Importance factor - 1.5
Soil foundation factor - 1
Seismic zone - *(client to confirm)
Basic wind speed m/sec *(client to confirm)

FUEL FIRING
Individual fuel Maximum capacity
Rice Husk/bagasse/Indonesian 100 %
Coal
Fuel Analysis (% age weight as received basis)
Ultimate analysis Rice Husk Bagasse Indonesian Coal
Carbon (%) 36.7 23.5 56.99
Hydrogen (%) 3.0 3.25 3.85
Nitrogen (%) 0.4 0.0 0.74
Sulphur (%) 0.08 0.0 0.16
Ash (%) 18.8 1.5 4.1
Moisture (%) 10 50 18
Oxygen (%) 32.02 21.75 16.23
GCV (Kcal/Kg) 3150 2272 5500

Flue Gas Emission

Unit O2 level Dry / Wet basis Value

Dust concentration at
Mg/Nm3 At actual Wet basis 50
ESP outlet

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
It is proposed to develop green belt over 4.95 acres out of total land of 14.65 acres in next
03years of time.

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

v Connectivity
Site is well connected with by State Highway and national highway .
Project Site Settling
1 Locations
A. Village Agraiya
B. Tehsil Narsingpur
C. District Narsingpur
D. State Madhya Pradesh
Toposheet No. 55N1 & 55N5
Latitude 22°52'34.59"N -22°52'51.78"N
Longitude 79°18'26.00"E 79°18'35.88"E

2 Latitude  22°52'34.59"N & 79°18'29.10"E

Longitude  22°52'43.11"N & 79°18'29.59"E
 22°52'42.82"N & 79°18'28.84"E
 22°52'41.92"N & 79°18'28.09"E
 22°52'48.00"N & 79°18'26.00"E
 22°52'50.02"N & 79°18'26.14"E
 22°52'51.09"N & 79°18'27.12"E
 22°52'51.14"N & 79°18'29.71"E
 22°52'51.77"N & 79°18'30.79"E
 22°52'51.78"N & 79°18'33.26"E
 22°52'51.16"N & 79°18'35.14"E
 22°52'49.81"N & 79°18'35.88"E
 22°52'48.47"N & 79°18'34.50"E
 22°52'48.29"N & 79°18'32.26"E
 22°52'44.78"N & 79°18'31.11"E
 22°52'44.76"N & 79°18'32.82"E
 22°52'34.88"N & 79°18'33.55"E
3 General ground level Highest elevation – 387 m
Lowest elevation- 382 m
4 Nearest Highway SH-22 -4.70 NNE
NH 26 – 0.25 km - W
5 Nearest Railway Station Narsinghpur Railway Station – 11.50 km
6 Nearest Airport Jabalpur-83.85km
7 Nearest Tourist Place
None
within 10km radius
8 Archaeological Important
None within 10 km Radius
Place within 10km radius
9 National park/Wild Life
Sanctuaries within 10km None within 10 km Radius
radius
10 Reserved / Protected Protected forest-0.50 km –SSE
Forest within 10km radius Bachai- RF -3.0 km
(Boundary to boundary Reserved forest -1.25 km-SSW
distance) Datadongri Reserved forest-2.25- km SSW
Kishanpur Reserved forest -3.50 km-SSW
Bakori reserved forest – 5.85 km-ESE
Open jungle – 5.75 km- E
 Bhaduar reserved forest – 7.75 km –E
Dense Jungle - 6.50 Km –ESE
11 Nearest major city with None within 10 km Radius
100000 population within
10km radius
12 Nearest Town / City within Narsinghpur -16 km
10km radius
13 Nearest Village Khoriya – 0.50 KM - NE
14 Nearest River Sher river- 5.25 km- ESE
Maheshwar river – 6.25 km – ESE
15 Nearest Lake/ Ponds Canal – 0.05 km –NW
Pond – 0.50 km – SW
Pond – 1.75 km -W
Pond – 2.10 km – W
Pond -5.10 km –WNW
Pond – 1.75 km –E
Pond – 2.75 km –ESE
Pond -3.50 km - E
Bachai dam – 1.25 km – SE
Pond -7.75 km – ENE
Pond – 8.75 km –ENE
Pond – 8.25 km – E
Pond – 7.50 km - ESE
16 Nearest Nadi / Nala Nala -0.10 km – ENE
Nala – 2.25 km – WSW
Nala – 2.50 km – NW
17 Nearest Hill Ranges None within 10 km Radius
18 Industry located within Mahakuashal sugar & power industries ltd. –
10km radius 0.10 km –SSE

vi Drinking water management

Drinking water will be supplied through borewell with proper RO system.

vii Sewerage System

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

viii Industrial waste management

As described earlier.

ix Solid waste management

As described earlier.

x Power Requirement and supply / source

As described earlier.
7.0 Rehabilitation & Resettlement Plan
No R & R plan is required.

8.0 Project Schedule and Cost estimate

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

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

Based on the capital cost break up worked out inthe project cost summary for the
project is given in the following table:
 Project Cost

Particulars Rs in Lacs
Land 200.00
Civil works & Buildings and Site Development works 2431.00
Indigenous Plant and Machinery 11200.00
Miscellaneous Fixed Assets 424.00
Prelim & Preoperative Expenses 750.00
Contingencies (2.40%) 550.00

Add: GST 2345.00

Total 17900.00

Means of Finance:
Financing Pattern % (Rs in Lacs)
MSIPL’s Own Contribution 8.38% 1500.00
Term Loan 91.62% 16400.00
Subsidy (Not Taken in Project)
Total 100.00% 17900.00
Note: - Madhya Pradesh offering Capital Subsidy as per Investment promotion &
policy on Investment @40% of Total Investment on Plant, Machinery & Building
which is come in 7 Equal Installment at the end of the every year after the
successful minimum 40% production.
Project Cost
 Land & Site Development
The cost of Land, levelling, filling, internal roads, fencing, green belt development,
sewerage and drainage, etc. has been estimated at Rs 700.00lacs, as detailed below
Sr. No. Particulars Amount, Rs. Lacs
 1 Land, Levelling and grading 275.00
2 Compound with Fencing, Street light & Gate 125.00
3 Internal Roads & Culverts 125.00
5 Sewerage and Drainage 175.00
6 Total 700.00

 Buildings and Civil Works

The buildings and machinery foundations for 200 KLPD Ethanol plant is estimated at
Rs. 2000.00 lacs, as given below:

[Link]. Particulars Amount Rs. Lacs

1 Ethanol Building Foundation 75.00
2 Raw and treated water storage, WTP Building & Foundations 150.00
3 Spent wash Storage Lagoons 150.00
4 Tank Foundation 100.00
5 RS/Ethanol Storage Tank Foundations 90.00
6 Grain Silo Foundation 35.00
7 Boiler & Auxiliaries Civil work 125.00
8 Turbine & Auxiliaries Foundations 68.00
9 Ash & Fuel Handling System, civil work 55.00
10 CPU Civil work 90.00
11 Ethanol handling Office 40.00
12 Under Ground Water Reservoir 80.00
13 Handling System Civil 50.00
14 Grain Handling System Civil 50.00
15 Fermentation, Liquefaction Mill Section Civil 173.00
16 Grain Storage Godown 200.00
17 Administrative & Site Residence Building 200.00
18 Sub-total 1731.00
19 Add : GST 269.00
20 Total 2000.00

 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. 13200.00 lacs inclusive 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 Particulars Amount,
 No Rs. Lacs
1 Turnkey supply of 200 KLPD Ethanol based on Multi Grain,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 11200.00
receiver /Alcohol/Ethanol / Syrup Storage Tanks and Staging Structure
for Ethanol plant. 50 TON Boiler & 6 MW Turbine, Chimney, auxiliaries
and fuel & ash handling with buildings and machinery foundations for
200 KLPD Ethanol etc as per quotation.
Add GST 2000.00
Total 13200.00

Miscellaneous Fixed Assets

Company proposes to acquire following miscellaneous fixed assets: estimated at Rs.
500.00 lacs
[Link] Particulars Amount In Lakh
1. Office furniture and fixtures 20.00
2. Cabling and Power distribution, Plant Lightning cost 120.00
3. Lab Equipment 50.00
4. Water Treatment system with RO 50.00
5. Fire fighting system 40.00
6. Yard and utility piping for raw and treated Water, steam, steam 144.00
condensate, process condensate and spent wash
7. Total 424.00
8. Add: GST 76.00
9. Sub Total 500.00

 Preliminary & Preoperative Expenses

The preliminary and preoperative expenses have been estimated at Rs 750.00 Lacs
S. No Particulars Amount in Rs Lakh
1. Project Report/TEV Study 5.00
2. Legal Fees and Other Expenses 5.00
3. Establishment Charges 10.00
4. Rent, Rates & Taxes 3.00
5. Travelling Exp 5.00
6. Government Clearances 20.00
7. Start up Expenses including wages & Salaries 15.00
8. Technical Consultant fees 15.00
9. Architect Fees 10.00
 10. Project insurance during construction 5.00
11. Interest During Implementation 613.91
12. Mortgage Expenses, Bankers Charges, Stamp Duty 43.09
Etc
13. Sub Total 750.00

 Contingencies
The contingency has been provided at 2.4% on costs at Rs 550.00 lacs.

 Capital Investment for proposed Environment Protection

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 (2 Hact) 5.80
6 Occupational Health & Safety ( 85 no) 8.50
7 Misc RWH etc 7.0
Total 1821.30 @ 1822

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 programmed shall be executed through the group discussion and need base
programmed will be proposed for the area, by which people of the area will be benefitted.
Layout of the proposed plant