Capacity expansion of existing 6 KLPD Molasses/grain based distillery to Phase-1 12 KLPD grain based distillery in existing
plant with no additional land requirement and Phase-2 expansion from 12 KLPD to 65 KLPD (grain based) Distillery Unit along
with 1.5 MW Cogeneration Power Plant
PRE-FEASIBILITY REPORT
Capacity expansion of existing 6 KLPD Molasses/grain based distillery to
Phase-1 12 KLPD grain based distillery in existing plant with no additional
land requirement and Phase-2 expansion from 12 KLPD to 65 KLPD (grain
based) Distillery Unit along with 1.5 MW Cogeneration Power Plant
FOR
SUIDIHI DISTILLERY PRIVATE LIMITED
At
Village –Suidihi, P.O. Lathikata, District – Sundargarh, Odisha
APPLICANT
M/s. Suidihi Distillery Private Limited
Village : Suidihi, Post: Lathikata,. Dist:
Document No.: 2016_VI_000011
1
Capacity expansion of existing 6 KLPD Molasses/grain based distillery to Phase-1 12 KLPD grain based distillery in existing
plant with no additional land requirement and Phase-2 expansion from 12 KLPD to 65 KLPD (grain based) Distillery Unit along
with 1.5 MW Cogeneration Power Plant
Sundergarh, Odisha
1.0 Executive Summary
Earlier, the assessment of the projects was done on Technical feasibility reports and Cost-BenefitRatio which mainly considered financial & technical resources. But no consideration was given to
the environment protection in this evaluation and these flaws became apparent with continuous
deterioration of environment. Thus in order to have more realistic evaluation, and keeping in
view the deteriorating conditions, another dimension was added which is now called as
“Environmental Impact Assessment” (E.I.A.). This forms an integral part of the project and is
taken into account while appraising the project at different stages. Thus in the new
comprehensive approach all considerations like, Technical, Financial & Environmental are given
due weightage.
M/s Suidihi Distillery Private Limited. is proposing for Capacity Expansion from existing capacity
of M/s Suidihi Distillery Private Limited from 6KLPD ( Mollases /grain based) to expansion phase1: to 12 KLPD (grain based only) in existing manufacturing unit with no additional land
requirement and Phase-2 expansion from 12 KLPD to 65 KLPD (grain based) Distillery Unit along
with 1.5 MW Cogeneration Power Plant. As per EIA Notification dated 14th Sept., 2006 and
amended from time to time, the proposed project falls under Category “A”, Project or Activity
5(g).
They have to submit Form-I along with Pre-Feasibility Report and other relevant documents for
getting Environmental Clearance. This pre-feasibility report has, therefore, been prepared by the
consultant to assess the likely impact of the proposed on various factors which may be affected
with the implementation of the program me and to suggest remedial/precautionary measures, if
any.
2.0
INFORMATION OF PROJECT/BACKGROUND INFORMATION
i)
Identification Of Project And Project Proponent Project: M/s Suidihi Distillery Private Limited. is proposing for Capacity Expansion from existing
capacity of M/s Suidihi Distillery Private Limited from 6KLPD (Molasses /grain based) to
expansion phase- 1: to 12klpd (grain based only) in existing manufacturing unit with the same
available plant and machinery and thereafter expansion into a total new plant for the phase-2
for 65klpd (grain based only) Distillery Unit along with 1.5 MW Cogeneration Power Plant.
Project Proponent
Suidihi Distillery Pvt. Ltd. (SDPL) was incorporated on 20.10.2004 having its registered office at
Document No.: 2016_VI_000011
2
Capacity expansion of existing 6 KLPD Molasses/grain based distillery to Phase-1 12 KLPD grain based distillery in existing
plant with no additional land requirement and Phase-2 expansion from 12 KLPD to 65 KLPD (grain based) Distillery Unit along
with 1.5 MW Cogeneration Power Plant
Village:Suidihi, Post: Lathikata, Dist: Sundargarh , Odisha. The company is having two directors
namely Shri Sunil Choudhary, and Shri Moni Poddar. The description of the directors is as below;
1.
Shri Sunil Choudhary, Director,
Age: 46 years
Father’s Name: Late Pawan Kumar Choudhary
Address: F – 9, Civil Township Rourkela – 769004 Orissa, India
Education Qualification: B. E. (ChE) U.S.A University of Louisiana
Experience: 15 years of Industrial Management
2. Shri Moni Poddar, Director,
Age: 68 years
Father’s Name: Late Gourang Poddar
Address: Basanti Colony, Rourkela
Education Qualification: B.Com
Experience: 35 Years of Industrial Management
Besides this, the management team comprises of many other senior members. The company is
managed by well-qualified persons having progressive attitude and qualification.
The promoters of the project have already worked in their small distillery unit, M/s Suidihi Distillery
Pvt. Ltd. at Village Suidihi, Post Lathikata, District Sundergarh, Odisha. This unit is the first grain based
unit in the state of Odisha. The promoters having learnt from the operation of the unit strongly
believe that there is ample scope for a larger integrated grain based distillery in the State of Odisha.
ii) Brief description of nature of project:
The proposed project of M/s. Suidihi Distillery Private Limited is proposing for Capacity Expansion
from existing capacity of M/s Suidihi Distillery Private Limited from 6KLPD ( Mollases /grain based)
to expansion phase-1: to 12klpd (grain based only) in existing manufacturing unit with the same
available plant and machinery and thereafter expansion into a total new plant for the phase-2 for
65klpd (grain based only) Distillery Unit along with 1.5 MW Cogeneration Power Plant at- village
Suidihi, Post- Lathikata, District - Sundergarh, Odisha.
iii)
Need for the Project and it’s importance to the country and or region.
Due to abundant availability of raw materials being used in the grain based distilleries there has been
a huge demand for grain based extra neutral alcohol for the fast growing IMFL Industries and for
blending in Foreign Liquor outside India which has been a multi-fold surge in demand. Due to
substantial deficiency in supply of grain based ENA and potentiality of the national & international
market M/s. Suidihi Distillery Private Limited have planned for expansion of 6 KLPD grain based
distillery to 65 KLPD grain based distillery unit in the major grain producing area of Odisha. The
Document No.: 2016_VI_000011
3
Capacity expansion of existing 6 KLPD Molasses/grain based distillery to Phase-1 12 KLPD grain based distillery in existing
plant with no additional land requirement and Phase-2 expansion from 12 KLPD to 65 KLPD (grain based) Distillery Unit along
with 1.5 MW Cogeneration Power Plant
proposed expansion of distillery project will play an important role in upliftment of the socio
economic condition of the region particularly nearby villages.
iv) Supply Gap
The total requirement of ENA / IMFL / Ethanol in India is 600 crores litres (25% ENA from grain & 75
% from molasses) and 350 Crore Litres for Ethanol as Fuel whereas, in India, total production of ENA
from molasses and grain is 148 crores litres per annum. Next five year projected ENA from grain 40
% & from molasses 60 %. 275 Crore Litres of alcohol produced from molasses were used by oil
companies in the year of 2014-15. Projection for the year 2015-16 is 50.50 crores litres by the oil
companies. Post 2017 India will require 6.30 billion litres of alcohol mainly from molasses for the use
in petrol by the oil companies. Therefore, the huge demand of ENA made out of grain will arise.
ii) Demand Imports vs. Indigenous Production
Indian producers are not able to meet present alcohol demand. Approx 5-7% of total demand of
alcohol is being imported from other countries. As far as ENA production is concerned, Indian market
play a vital role at both domestic & international level. In this context, there is major requirement of
indigenous grain based alcohol production to reduce the import load and save the revenue.
vi) Domestic/Export Market
There is a huge demand of Indian made grain based alcohol in the national and international market.
vii) Employment Generation (Direct and indirect)
Due to the proposed expansion of distillery project in the region direct and indirect employment
avenues will be created in the nearby areas. In existing 6 KLPD grain based distillery 25 nos. of
manpower is currently employed. An additional 75 nos. of manpower including officers, management
personnel and workers etc. will be employed after the establishment of the 65 KLPD distillery project.
3.0 PROJECT DESCRIPTION
i)
Type of Project including interlinked and interdependent projects, if any
The proposed expansion project of distillery unit is for setting up of manufacturing facilities to
produce Extra Neutral Alcohol (ENA). It is based on primarily agricultural products (grain based).
The project will be equipped with fully diversified processing facilities.
ii) Location (Map showing general location, specific location, and project boundary and project
site layout) with coordinates
Location: Village: Suidihi
Post: Lathikatha District:
Sundergarh
State: Odisha
Document No.: 2016_VI_000011
4
Capacity expansion of existing 6 KLPD Molasses/grain based distillery to Phase-1 12 KLPD grain based distillery in existing plant with no additional land requirement and Phase-2 expansion from 12 KLPD to 65
KLPD (grain based) Distillery Unit along with 1.5 MW Cogeneration Power Plant
Figure 1: Google Image
Document No.: 2016_VI_000011
5
Capacity expansion of existing 6 KLPD Molasses/grain based distillery to Phase-1 12 KLPD grain based distillery in existing plant with no additional land requirement and Phase-2 expansion from 12 KLPD to 65
KLPD (grain based) Distillery Unit along with 1.5 MW Cogeneration Power Plant
Figure 2: Key Plan showing 10 km radius study area
Document No.: 2016_VI_000011
6
Capacity Expansion from existing capacity of M/s Suidihi Distillery Private Limited from 6KLPD (Mollases/grain based) to expansion phase-1: to 12klpd (grain based only) in existing manufacturing unit with the same
available plant and machinery and thereafter expansion into a total new plant for the phase-2 for 65klpd (grain based only) Distillery Unit along with 1.5 MW Cogeneration Power Plant.
Figure: 3 Layout Plan
7
Document No: 2016_VI_00011
Capacity expansion of existing 6 KLPD Molasses/grain based distillery to Phase-1 12 KLPD grain based distillery in existing plant
with no additional land requirement and Phase-2 expansion from 12 KLPD to 65 KLPD (grain based) Distillery Unit along with 1.5
MW Cogeneration Power Plant
iii) Details of alternate sites Considered and the basis of selecting the proposed site, particularly
the environment consideration gone into should be highlighted.
No alternate sites have been considered for the proposed expansion of distillery project as the due
to the existing distillery unit all the facilities are easily available and also has a well-developed
infrastructure. Also, the land was easy available and area is rich in raw material sources with ease of
accessibility.
Advantages of the Project Site
 Required Raw Material (Broken Rice, damaged grains, etc.) & Fuel (Coal) is available easily in
the nearby areas. Raw materials can be easily procured from Grain surplus states such as
Chhattisgarh, West Bengal, Rajasthan, Uttar Pradesh & even Punjab.
 Good availability of Water, Good Quality of Water.
 Well connected by Road / Rail Network
 Proximity of Liquor Consuming Markets
 Well located near Industrial Areas
 Manpower availability
 Land availability for carrying out Project expansion
 Existing infrastructure
iv)
Size or magnitude of operation
This is the expansion project of 6 KLPD grain based distillery unit to 65 KLPD grain based
distillery unit along with 1.5 MW of Cogeneration power plant. 61,750 LPD ENA will be
produced from the proposed expansion (65 KLPD).
v)
Project description with process details: (a schematic diagram/flowchart layout, components
of the project)
The distillery will use grains as raw material in the production of Extra Neutral Alcohol. The
process description of alcohol production in using grain as raw materials is as follows:
A) Process Description of 6 KLPD Distillery Unit
Milling and Flour Handling
The incoming grain is first cleaned with the help of destoner and magnetic separators to
remove stones and other material which may damage the hammers during milling. The grain
is fed to hammer mill in controlled manner. In milling grains are crushed to flour of uniform
size. Oversized screening rejects are segregated with the help of vibratory screen. These are
taken to coarse bin before sending it to mill again. Intermediate hopper is provided for
buffer capacity for flour storage. The flour is metered through a weigh feeder with load cell
arrangement before transferring to the mixing tank for slurry preparation process.
Slurry Preparation / Liquefaction
8
Document No: 2016_VI_00011
Capacity expansion of existing 6 KLPD Molasses/grain based distillery to Phase-1 12 KLPD grain based distillery in existing plant
with no additional land requirement and Phase-2 expansion from 12 KLPD to 65 KLPD (grain based) Distillery Unit along with 1.5
MW Cogeneration Power Plant
In liquefaction process, starch is hydrolyzed to dextrin. The Liquefaction is carried out
in Single stage Liquefaction Tank. Feedstock Flour is transferred to Premasher and
mixed with Recycle Streams and liquefying enzyme. Slurry from Premasher 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 using cooling water
supply and transferred to Pre-fermentation and Fermentation section.
SaccharificationAnd Fermentation
Yeast Propagation
Yeast seed material is prepared in Prefermentor by inoculating sterilized mash with
yeast. Optimum temperature is maintained by circulating cooling water. The contents
of the Prefermentor 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
Prefermentor. 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.
Fermentation
The Fermentation process is engineered to operate in batch mode depending upon
the quality of raw material. The purpose of Fermentation is to convert the
fermentable sugars into alcohol. During Fermentation, sugars are broken down into
alcohol and carbon-dioxide. Significant heat release takes place during Fermentation.
The fermenter temperature is maintained at around 30 – 32oC by forced recirculation
flow through plate heat exchangers. We have given a provision for spent wash
recycled to Fermentation depending on solids concentration in fermented wash.
The carbon dioxide evolved during the process is scrubbed to prevent ethanol
emissions by process water, which is taken to beer well. The flow diagram of process
description of grain spirit production is shown in Fig. 3.1.
9
Document No: 2016_VI_00011
Capacity expansion of existing 6 KLPD Molasses/grain based distillery to Phase-1 12 KLPD grain based distillery in existing plant
with no additional land requirement and Phase-2 expansion from 12 KLPD to 65 KLPD (grain based) Distillery Unit along with 1.5
MW Cogeneration Power Plant
Wash to Extra Neutral Alcohol – Distillation
Distillation system has various 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:
1.
2.
3.
4.
5.
6.
7.
Analyser Column
Degasser Column
Pre-Rectifier Column
ED Column
Rectifier cum Exhaust Column
Recovery Column
Simmering Column
Pre-heated fermented wash will be fed to Degasser column. Fermented wash is
stripped off alcohol by ascending vapors in Analyser column. Rectifier vapors provide
energy to Analyser column through a Thermosyphonreboiler. Vapors of Degasser
column are condensed and taken to Recovery Feed Tank. The condensed Analyser
vapors are taken to Pre-Rectifier Column. Analyser Condensate is concentrated in PreRectifier column, which operates under pressure. Condensing steam provides energy
to pre-rectifier column through a vertical Thermosyphonreboiler. A Technical Alcohol
cut of about 1-2% of total spirit is taken from the Pre-Rectifier column.
Concentrated alcohol draw from Pre-Rectifier column is fed to ED column for
purification. Dilution water in the ratio of 1:9 is added in this column for concentrating
higher alcohol at the top. Top of this column is condensed in its condensers and fed to
recovery feed tank while bottoms are fed to Rectifier cum Exhaust Column for
concentration. Rectifier Column operates under pressure and condensing steam
provides energy to this column through a vertical Thermosyphonre boiler. Technical
Alcohol cut is taken out from the top of this column while ENA draw is taken out from
appropriate upper trays and fed to Simmering Column after cooling. Fusel Oil build up
is avoided by taking fusel oil draws from appropriate trays.
These fusel oils along with the condensate of Degasifying & Extractive Distillation
columns are fed to recovery column for concentration. A technical alcohol cut is taken
out from the top of this column.
Simmering Column is operated under high reflux for better separation of methanol
and di-acetyls. Final ENA product draw is taken from the bottom of this column.
10
Document No: 2016_VI_00011
Capacity expansion of existing 6 KLPD Molasses/grain based distillery to Phase-1 12 KLPD grain based distillery in existing plant
with no additional land requirement and Phase-2 expansion from 12 KLPD to 65 KLPD (grain based) Distillery Unit along with 1.5
MW Cogeneration Power Plant
Decantation & Thin Slops Recycle Section
Decantation section comprises of a Centrifuge Decanter for separation of suspended
solids from Spent Wash coming out of Grain Distillation Plant. Wet cake has 30-32%
w/w solids as removed from bottom of Decanter which can be sold directly in wet
form as cattle feed (DWG).
Thin slops coming out of Decanter are collected in a tank and partly recycled into the
process & further for Evaporation for concentration upto 35-40% w/w solids. The
concentrated thin slops called as Syrup is mixed with Wet cake and sold in wet form as
cattle feed (DWGS) or the entire mixture can be dried in the sun as DDGS Sun Drying
and then sold in dry form as Cattle feed (DDGS).
Bio Digestor System
UASB Reactor:
Up-flow Anaerobic Sludge Blanket reactor is provided for anaerobic treatment of
dairy effluent. The UASB reactor shall be constructed in RCC. The reactor consists of
three zones viz. Influent distribution zone, Reaction zone, Gas solid liquid separation
zone.
Influent Distribution zone: The raw wastewater enters into the at the bottom through
influent distribution zone. A sophisticatedly designed piping network is provided for
uniform distribution of the effluent in the tank. The effluent then travels upward in the
reactor.
Reaction Zone: In the reaction zone the anaerobic bacteria are maintained in the form
of sludge blanket. The organic matter in the wastewater comes in contact with the
bacterial population and is degraded anaerobically to methane rich biogas, the end
product of anaerobic digestion. The process of conversion of organic matter in to the
biogas is a two-stage process. In the first stage the organic matter in the raw effluent
is converted in to the volatile acids by acid forming bacteria. In the second stage the
acid produced in the first stage are converted in to methane by another group of
bacteria i.e. methane formers. In UASB process both the stages are completed in
single reactor. The biogas so produced is bubbled through the effluent and is
separated out in the third section i.e. Gas-Solid-Liquid separation zone. The suspended
solids are also separated to prevent escape of solids from the reactor. The UASB
Reactor shall be fabricated in MS and painted with Epoxy paint.
Gas-Solid – Liquid Separation: In gas solid liquid separation a hood fabricated in MS
and duly painted with corrosion resistant paint is provided. The hood separates the
solid from the overflowing reactor content. Gas collectors are provided for collection
11
Document No: 2016_VI_00011
Capacity expansion of existing 6 KLPD Molasses/grain based distillery to Phase-1 12 KLPD grain based distillery in existing plant
with no additional land requirement and Phase-2 expansion from 12 KLPD to 65 KLPD (grain based) Distillery Unit along with 1.5
MW Cogeneration Power Plant
and conveyance of gas. The treated effluent overflows through a launder and will take
to a secondary treatment.
Flare Stack
Flare stack fabricated in MS and painted with Epoxy paint shall be provided for
Burning the Gas generated in UASB Reactor. The flare stack shall be ignited manually.
Gas Holder:
A gas Holder fabricated in MS shall be provided for storing the gas and carrying it
for utilization. The gas holder shall consist of MS floating dome and RCC wet well.
The gas stored in the Holder shall then be pumped to boiler using biogas Blower.
12
Document No: 2016_VI_00011
Capacity expansion of existing 6 KLPD Molasses/grain based distillery to Phase-1 12 KLPD grain based distillery in existing plant
with no additional land requirement and Phase-2 expansion from 12 KLPD to 65 KLPD (grain based) Distillery Unit along with 1.5
MW Cogeneration Power Plant
Figure 4 : Process Block Diagram for 6 KLPD Distillery
B)
Process Description of 65 KLPD Distillery Unit
Grain Processing Section
Grains are unloaded from truck in grain unloading area, and sent to grain pre cleaning section,
where the grains are passed through a series cleaning equipments such as Vibrating Screen,
Destoner and Magnetic Separator to remove dust stones and fines. The flow through these
equipments is under gravity. After cleaning, the cleaned grains are stored in Silos & from there
they are conveyed to grain milling section using Screw Conveyors and Bucket Elevators. In milling
section the particle size is reduced to as required by the process using Hammer mill. From
hammer mill the flour is conveyed to Flour Bin (Intermediate storage for flour). From flour bin the
flour is carried to Premasher unit. In Premasher flour is wetted with water.
Liquefaction
Two Stage Liquefaction: Slurry from pre-masher is taken to Initial Liquefaction tank where
liquefying enzyme is added. This 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 retention
vessel (cook tube) having sufficient capacity to provide the desired retention time at a given
flow rate. The cooked mash is discharged to a flash tank. The cooking process, accomplished
in the above manner, converts the slurry into a hydrated, sterilized suspension (as starch
molecule is solubilized) and is therefore susceptible to enzyme attack for liquefaction.
The gelatinized mash from the flash tank is further liquefied in a liquefaction tank where
liquefying enzyme is added. Then the liquefied mash is cooled in slurry cooler and transferred
to 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 for next batch.
DISTILLATION
13
Document No: 2016_VI_00011
Capacity expansion of existing 6 KLPD Molasses/grain based distillery to Phase-1 12 KLPD grain based distillery in existing plant
with no additional land requirement and Phase-2 expansion from 12 KLPD to 65 KLPD (grain based) Distillery Unit along with 1.5
MW Cogeneration Power Plant
Wash to ENA Mode: Following Columns will be under operation
• Analyser & Degassifier Column
• Pre-Rectifier Column
• Exhaust Column
• Extractive Distillation Column
• Rectifier cum Exhaust Column
• Recovery Column
• Simmering Column
Preheated fermented wash is fed at the top of the De gasifier column. Analyser Column is
provided with reboiler. The alcohol is stripped out in analyser column. The rest of the
fermented wash flows down the Analyser column and is taken out as the spent wash from
Analyser 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 the Pre rectifier column, which further is sent to Extractive Distillation
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
the Rectifier cum Exhaust column.
The Rectifier/Exhaust column concentrates the alcohol. 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). Recovery column where the 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:The Thick slops (bottoms) from the distillation section are sent to decantation section. In
decantation, thick slops are separated into thin slops and wet cake, based on their density
difference. The thin slops separated are reused in liquefaction and distillation sections. The
thin slops is sent to evaporation section for further concentration
EVAPORATION:The suggested treatment scheme is (integrated) working on the principle of falling film
Evaporation. Alcohol vapors are used as Heat Source & are fed to the first effect evaporator
shell side. The Feed at predetermined temperature is fed to tube side from the top of First
effect evaporator. Vapors generated in 1st effect VLS (Vapor Liquid Separator) are used as heat
source in the 2nd effect & so on. Finally vapors from last effect are condensed in Surface
Condenser. A Shell & tube type Multi-pass Surface condenser is employed for condensing the
shell side vapors. The product at the desired concentration is obtained. Each effect is provided
14
Document No: 2016_VI_00011
Capacity expansion of existing 6 KLPD Molasses/grain based distillery to Phase-1 12 KLPD grain based distillery in existing plant
with no additional land requirement and Phase-2 expansion from 12 KLPD to 65 KLPD (grain based) Distillery Unit along with 1.5
MW Cogeneration Power Plant
with recirculation cum transfer pump. The condensate from surface condensers is collected in
a common Process Condensate pot. The Process Condensate is transferred to further battery
limits by using centrifugal pump. The Pure steam condensate is collected in Steam Condensate
Tank and further it will be pumped as per battery limits. The system operates under vacuum.
Water-ring vacuum pumps will be used to maintain a desired vacuum. Cooling water from
cooling tower is used in the surface condensers for condensing the vapors.
DWGS DRYER SECTION: Wet distiller’s grains shall be fed into the dryer housing at controlled rate through a
suitable feeding system. The Rotary Tube Bundle is enclosed in an insulated dryer
housing and on its outer flights are fixed. Dry saturated steam is to be supplied to the
tube bundle through rotary joint at one end & the condensate is discharged through
rotary joint mounted of another end
 During the course of rotation, these flights pick up the material and shower them on to
the tube bundles. The heat transfer is primarily by conduction. The water vapors are
exhausted through an Exhaust Blower & passed through a cyclone separator for
separating fines.
 Dry product partially recycled back to feed conditioner for feed conditioning through
Product Screw & Recycle Conveyor. Entire operation of the Dryer is controlled
through Control panel.
15
Document No: 2016_VI_00011
Capacity expansion of existing 6 KLPD Molasses/grain based distillery to Phase-1 12 KLPD grain based distillery in existing plant
with no additional land requirement and Phase-2 expansion from 12 KLPD to 65 KLPD (grain based) Distillery Unit along with 1.5
MW Cogeneration Power Plant
Figure 5 : Process Flow Chart for 65 KLPD Grain Based Distillery
Power Co-generation 1.5 MW
Operations
The unit proposes to set-up boiler and power turbine. In this proposed expansion project a 25
TPH boiler will be installed and based on Rice Husk/Coal and as available fuel options. This Boiler
will operate mainly to feed steam to grain based operations and 1.5 MW power generations
from Turbine.
Proposed 1 . 5 MW co-generation plant consists of a high pressure water tube steam
boiler extraction cum condensing steam turbine. Fuel in the steam boiler will be burnt with
the help of air in the boiler furnace. Water will be circulated in the boiler drum and tubes
thus getting heated by the flame burning in the boiler furnace. Water comes out of the
boiler drum located at the top of the boiler as steam. Flue gases rise in the boiler furnace and
come in contact with the steam coming out of boiler drum. Steam after coming in
contact with flue gases gets heated up further thus getting superheated. Super heated
steam leaves the boiler in a pipe. Flue gases after super heating the steam pass through
economizer where they pre-heat the boiler feed water before it enters the boiler drum.
After economizer, flue gases pass through air pre-heaters where they heat the air which is
fed to the boiler furnace for burning the fuel. After air pre heaters flue gases pass through
Bag Filter/ESP where the dust particles are collected.
High pressure superheated steam from boiler will be passed through a steam turbine, which
will be used for distillery process operations. While passing through the turbine, the high
pressure and temperature steam rotates the turbine rotor and an electric alternator
mounted on the same shaft. Electric power will be generated by the alternator. This
electric power generated will be consumed in house i.e. for running the distillery and
utilities like boilers auxiliaries etc.
16
Document No: 2016_VI_00011
Capacity expansion of existing 6 KLPD Molasses/grain based distillery to Phase-1 12 KLPD grain based distillery in existing plant
with no additional land requirement and Phase-2 expansion from 12 KLPD to 65 KLPD (grain based) Distillery Unit along with 1.5
MW Cogeneration Power Plant
Figure 6: Process Flow Chart for Cogeneration Power Plant
vi) Raw Material required along with estimated Quantity, likely source, marketing area of final
products, mode of Transport of raw material & finished product.
Table 1: Raw Material Requirement
S. No.
Particular
Source of the Raw Material &
Mode of Transportation
Requirements
6 KLPD Unit
12 KLPD Unit
65 KLPD
1
Grains
17 MT/day
35 MT/day
162-164
MT/day
Nearby Market, by closed
trucks
2
Steam
1.45 TPH
3.00 TPH
7.3 TPH
From it’s own boiler of 25 TPH
Chemicals
3
Sodium Hydroxide
4.05 Kg/day
As per
requirement
As per
requirement
Nearby market
4
Sulphuric Acid
5 Kg/day
As per
requirement
As per
requirement
Nearby market
Enzymes
5
Saccharifying Enzyme
7kg/day
As per
requirement
As per
requirement
Nearby market
6
NH2-CO-NH2
(Urea;46%N2)
8Kg/Day
As per
requirement
As per
requirement
Nearby market
Fuel Requirement
7
Coal
Nil
Nil
15 MT
Nearby market
8
Rice Husk
15MT
18 MT
25 MT
Nearby market
vii) Resources optimization/recycling and reuse envisaged in the project, if any, should be briefly
outlined.
M/s. Suidihi Distillery Private Ltd. will make optimum utilization, recycling and reuse. These
resources include Land, Fuel (Rise husk and coal), Grain, Water and Electricity. Wastewater
generated from Boiler and cooling tower blow down will be treated and recycled for further
process, domestic & green belt development uses.
i)
Availability of Water its source, Energy/Power requirement and source should be given
A) Water Requirement
17
Document No: 2016_VI_00011
Capacity expansion of existing 6 KLPD Molasses/grain based distillery to Phase-1 12 KLPD grain based distillery in existing plant
with no additional land requirement and Phase-2 expansion from 12 KLPD to 65 KLPD (grain based) Distillery Unit along with 1.5
MW Cogeneration Power Plant
Table 2: Water Requirement
S.No.
Particulars
Existing
Requirement
1
Water
87.6
Additional Requirement
Phase: 1: 16.4 KLD
Total
Source
310 KLPD
Ground Water
Phase 2: 206 KLD
B)
Power Requirement
Details of power consumption in the distillery are shown in Table 3.
Table 3 Power requirement
S.No.
Particulars
Details
Source
1
Power Requirement for Existing 6 KLPD
Distillery Unit +Phase I
0.25 MW
2
Power Requirement for Expansion (Phase 2)
1.25 MW
Total
1.50 MW
WESCO (Western
Electricity Supply
Company of Orissa and
captive co-generation
of electricity)
Captive Power Generation
1.5 MW
C) Steam Requirement
Steam is required in the processes such as generation of Power, Liquefaction Process,
Distillation and sterilization. Total steam requirement for the proposed project is shown in
the table below:
Table 4: Steam Requirement
S. No.
1
(ix)
For Existing 6 KLPD
Phase 1: 12 KLPD grain
Phase 2: 65 KLPD Grain
Distillery Unit
based Distillery Unit
based Distillery Unit
1.45 TPH
3.00 TPH
7.3 TPH
Source
From it’s own
boiler of 25 TPH
Quantity of waste to be generated (Liquid and solid) and scheme for their management.
Waste water generation & treatment
Most of the water will be recycled back. Spent Wash generated will be passed through
decanter for separation of soluble. The remaining from decanter is sun-dried to obtain DWGS.
Effluent from washing and blow down process will be treated in existing ETP. Treated water
will be used for green belt development. Domestic waste will be treated in septic tanks
followed by soak pits. Rainwater would be utilized to recharge the underground water source
through scientifically designed rain water harvesting system in coming day.
Air Pollution
18
Document No: 2016_VI_00011
Capacity expansion of existing 6 KLPD Molasses/grain based distillery to Phase-1 12 KLPD grain based distillery in existing plant
with no additional land requirement and Phase-2 expansion from 12 KLPD to 65 KLPD (grain based) Distillery Unit along with 1.5
MW Cogeneration Power Plant
The following air pollution control systems are to be installed in this project to reduce the
anticipated adverse impacts: Air quality marginally may get affected due to
emissions
generated from burning fuel In boiler and D.G. sets; they are Particulate matter and small
amount of SOX an NOX. To mitigate the impact, stack of appropriate height of 30 meters
provided for 8 TPH boiler. To reduce particulate matter concentration multicyclone dust
collector is being installed. Green belt is developed in 1.5 acres area. Additional 33% area will
be developed as Green belt for proposed expansion which will acts like adsorbent of air
pollutants. To combat fugitive emissions roads are paved and regularly swept. Water
sprinklers are provided for suppression of dust. Vehicular exhaust is being maintained by
providing regular maintenance and servicing of vehicles. Same will be continued for future
also.
Solid Waste Management
All the solid waste generated will be managed as under:
Table 5: Solid Waste Generation
Name of the Solid Waste Quantity
Management
Boiler Ash
Existing: 3.75MT/day
Land fill and fly ash brick make
Proposed Phase I: 4.5 MT/Day Fly ash brick manufacturing and land fill.
Phase 2: 10.75 MT/day
DDGS
Existing : 4MT/day
Will be used for the cattle feed
Proposed Phase 1 : 6-7
MT/day
Phase 2: 40MT/day at 90%
w/w solids
ETP Sludge
Existing: 0.5mt/day
Will be used for the agriculture
Proposed: Nil
Evaporation and Dryer mixed with
DDGS
4. SITE ANALYSIS
i)
Connectivity
The Plant site is located at village Suidihi, Post: Lathikata, Dist: Sundergarh, Odisha,
approximately 1 KM from nearest National Highway (NH-23). The nearest Railway Station
is Rourkela Railway Station approximately 16 km in North direction from the project site.
The nearest town is Lathikata Town approximately 3 km in South direction. Sundergarh
district headquater is approximately 110 km in North-west direction from the project
site.
ii)
Land form, Land Use and Land Ownership
The existing land for 6 KLPD unit is 5.56 Acres. The land is completely acquired. Land papers
are enclosed as Annexure 1. An additional land of 6.67 Acres is required for setting up 65
KLPD Distillery Unit. This area will be enough for the following areas of working:1. Storage for raw material and finished goods.
2. Plant and Machinery
3. Storage
4. Offices
19
Document No: 2016_VI_00011
Capacity expansion of existing 6 KLPD Molasses/grain based distillery to Phase-1 12 KLPD grain based distillery in existing plant
with no additional land requirement and Phase-2 expansion from 12 KLPD to 65 KLPD (grain based) Distillery Unit along with 1.5
MW Cogeneration Power Plant
5. Toilets
6. Water storage tanks
Open space will be landscaped and trees will be planted in due course of time.
iii) Topography (along with map):
Geographically, the district is not a compact unit and consists of widely, dissimilar tracts of
expansive and fairly open country, dotted with isolated peaks, inaccessible forests, river
valley and mountainous terrain. Broadly speaking it is an undulating tableland of different
elevations broken up by rugged hill ranges and cut off by torrential hill streams and the river
lb and Brahmani. The general slope of the district is from north to south. There is a open wellcultivated plain country along the valley of the lb river particularly in the south. The rest of
the Sadar sub-division consists of undulating table-land about 700 ft. in average height,
dotted here and there with hills and peaks rising to about 2000ft., in the western most tracts
at Hemgiri P.S. in the north there is a gradual rise to the table-land of Chhotanagur. The
portion occupied by Bonai sub-division to the southeast has rugged forest and hills
intersected by gorges and passes and having a narrow valley of the Brahmani River and its
tributaries. For a short spell of time during the rainy season the rapid current of the hillstreams cut off communication. The east and west of the brahmani valley is filled with high
range of mountains, ft.) Chheliatoka (3331 ft.) and Bichakani (2964 ft.) in the east. The last hill
has acquired importance as it contains million of tonnes of iron-ore for use in Rourkela steel
plant. The territory of Sundargah and Panposh sub-divisions comprising the ex-states of
Ganagpuris about 700 ft. above the sea level. Bonai sub-division comprising ex-State of Bonai
is about 800 ft. above the sea level. The forest of the district is of northern tropical dry
deciduous type, mainly containing Sal, Assan and Kurum. The eastern half of Bonai and
Rajagangapur contain better quality of vegetation. The forest area is mostly studded with rich
mineral deposits, like iron ore, manganese, limestone, lead; also forest products like bamboo,
timber and kendu leaf which are export-oriented. The district was a very inaccessible tract
having no proper communication. The tribal people living in the area used to subsist for the
most part of shifting cultivation which resulted in denudation of forest The forest occupy an
area of 3534.92 sq.kms which includes 2664.64 sq. kms. under reserved forest and 612.07
sq.kms. under protected forest. The forests are of northern tropical dry deciduous type. Sal is
the dominant species. The eastern half of Bonai contains better quality of vegetation. The
plant is proposed to be located near town Rourkela, of Sundargarh district in the state of
Odisha.
20
Document No: 2016_VI_00011
Capacity expansion of existing 6 KLPD Molasses/grain based distillery to Phase-1 12 KLPD grain based distillery in existing plant
with no additional land requirement and Phase-2 expansion from 12 KLPD to 65 KLPD (grain based) Distillery Unit along with 1.5
MW Cogeneration Power Plant
Figure 7: District Map of Odisha
vi)
Climatic Data
The climate of this District is characterized by extremely hot summers and cool
winters. Climate is hot and moist sub humid. Normal rainfall of the District is
approximately 1230 mm, but there is a deviation in receipt of rainfall pattern which is
influencing crop production. Maximum temperature in the district goes up to 48ͦ C and
minimum temperature goes down to 6ͦ C.
Table 6 : Rainfall status of 2016 of Sundergarh District
S.No Months
Average Rainfall in mm
1
January
6.0
2
February
18.6
3
March
11.6
4
April
0.0
5
May
23.3
6
June
90.4
7
July
330.1
8
August
307.1
9
September
233.6
10
October
31.3
11
November
0.0
12
December
0.0
vii)
Social Infrastructure Available
The entire social infrastructure, as mentioned below, is available within 10 - 20
Km. of proposed distillery Project Site.
• Schools (Primary as well as secondary)
• Colleges (Science, commerce, Arts, engineering, medical, pharmacy,
education)
21
Document No: 2016_VI_00011
Capacity expansion of existing 6 KLPD Molasses/grain based distillery to Phase-1 12 KLPD grain based distillery in existing plant
with no additional land requirement and Phase-2 expansion from 12 KLPD to 65 KLPD (grain based) Distillery Unit along with 1.5
MW Cogeneration Power Plant
S. No.
1
a)
b)
c)
d)
e)
f)
2
3
4
• Health centers, dispensaries, hospitals
• Electricity
• Drinking water supply
• Banks (Cooperative as well as nationalized) and credit societies
Table 7: Details of 10 km radius study area
Particulars
Details
Location
Village/ Town/Plot No.
Suidihi
District
Sundergarh
State
Odisha
Latitude
22°9’4.706” to 22°9’18.371” N
Longitude
84°52’29.89” to 84°52’42.04” E
Toposheet No.
73B/16
Elevation
610 ft
Land use at the project site
Industrial
Climatic Conditions
Temperature
Min:10oC, Max:45oC
Rainfall
1451.2 mm (average)
Relative Humidity, %
Min: 30% and Max: 80% at 8:30 hrs
5
6
Nearest highway
Nearest Railway Station
7
Nearest airport
8
Nearest city/settlement
10
i)
ii)
iii)
Iv)
Features with 10 km :
Defence installations
Archaeological important places
Wild life sanctuaries
Reserved/Protected forest
vi)
Rivers
vii)
Hill ranges
viii)
State Boundary
5. PLANNING BRIEF
Min: 25% and Max: 80% at 17:30 hrs
NH-23, 1 KM approx.
Rourkela Railway Station, approx 16 km North
direction from the project site.
Ranchi Airport, 190km in NE direction from the
project site.
Lathikata Town, approx 3 km in South direction
from the project site.
Nil
Nil
Nil
No Reserved/Protected forest within 10KM of
Project unit area.
Suidihi Nala – 0.5 km- South direction
Brahmini River-3 km - West direction
Nil
Nil
22
Document No: 2016_VI_00011
Capacity expansion of existing 6 KLPD Molasses/grain based distillery to Phase-1 12 KLPD grain based distillery in existing plant
with no additional land requirement and Phase-2 expansion from 12 KLPD to 65 KLPD (grain based) Distillery Unit along with 1.5
MW Cogeneration Power Plant
i) Planning concept (type of Industries, facilities, transportation etc) Town and country
planning/Development authority classification.
Type of Industry
As per EIA Notification dated 14th Sept., 2006 and amended from time to time, the proposed project falls
under Category “A”, Project or Activity 5(g).
ii) Population Projection
Unskilled Man Power required for the proposed expansion Project will be met from the local villages
completely. Qualified semi-skilled man power requires will be met from local villages if available.
Hence there will not be much population increase in the area.
iii) Land Use Planning
The existing 6 KLPD plant is set up in an area of 5.09 Acres. The proposed 65 KLPD Distillery plant will
be set up in an area of 22.69 Acres. The land use break up is as follows:
Table 8: Land Use Break Up for Expansion Project of 65 KLPD
S.No
Land Usage
Area in Acres
1
Distillery Plant
6.50
2
Power Plant
1.00
4
Effluent Treatment Plant
0.50
7
Green Plantation
4.36
8
Rain Water Harvesting System
0.5
9
Internal Road
0.37
Total Area
13.23
i) Amenities/Facilities
Facilities like canteen, rest rooms and recreation facilities will be provided in the proposed expansion
project. No other additional facilities are proposed.
6. PROPOSED INFRASTRUCTURE
The following plant and machinery will be installed in the Industrial processing area.
Table 9: List of Plant & Machinery
S.No.
Description
1.
Grain storage section
2.
Grain Handling Section
3.
Liquefaction Section
4.
Fermentation Section
5.
Distillation Section
6.
Steam Boiler with accessories
7.
Steam Turbine
8.
Steam Condensers
9.
Air Compressors
10.
Storage Section
23
Document No: 2016_VI_00011
Capacity expansion of existing 6 KLPD Molasses/grain based distillery to Phase-1 12 KLPD grain based distillery in existing plant
with no additional land requirement and Phase-2 expansion from 12 KLPD to 65 KLPD (grain based) Distillery Unit along with 1.5
MW Cogeneration Power Plant
11.
Centrifugal Machines
12.
DDGS Drying Section
13.
Multiple Effect Evaporator Section
14.
Raw water Treatment
15.
R.O Plant for Boiler water
16.
Fire Protection Equipments for entire Plant
17.
Water Storage Tanks
18.
Electricals
19.
Piping works
20.
Lab Equipments
ii) Residential Area
Facilities like canteen, rest room and indoor games facilities will be provided in the proposed project.
iv) Green Belt
Green belt is developed in 1.5 acres area. Additional approximately 33% area will be developed as
Green belt for proposed expansion project.
Social Infrastructure
Social infrastructure will be developed as per need based in the Villages.
vi) Connectivity
The Plant site is located at village Suidihi, Post: Lathikata, Dist: Sundergarh, Odisha, and approximately
1 KM from nearest National Highway (NH-23). The nearest Railway Station is Rourkela Railway Station
approximately 16 km in North direction from the project site.
vii) Drinking water management
Proper Drinking water will be made available to the workers by RO within the plant premises.
viii) Sewerage System
Domestic waste will be treated in septic tanks followed by soak pits.
viii) Industrial Waste Management
Waste water generated from the proposed Project will be treated in Effluent Treatment Plant.
ix)Solid Waste Management
All the solid waste generated will be managed as under:
Name of the Solid Waste Quantity
Management
Boiler Ash
Existing: 3.75MT/day
Land fill and fly ash brick make
Proposed Phase I: 4.5 MT/Day Fly ash brick manufacturing and land fill.
Phase 2: 10.75 MT/day
DDGS
Existing : 4MT/day
Will be used for the cattle feed
Proposed Phase 1 : 6-7
MT/day
Phase 2: 40MT/day at 90%
w/w solids
ETP Sludge
Existing: 0.5mt/day
Will be used for the agriculture
Proposed: Nil
Evaporation and Dryer mixed with
DDGS
24
Document No: 2016_VI_00011
Capacity expansion of existing 6 KLPD Molasses/grain based distillery to Phase-1 12 KLPD grain based distillery in existing plant
with no additional land requirement and Phase-2 expansion from 12 KLPD to 65 KLPD (grain based) Distillery Unit along with 1.5
MW Cogeneration Power Plant
x) Power requirement & Supply / Source:
The power requirement shall be met from WESCO supply of 250 KVA. The remaining will be sourced
from its own turbine.
7.0 REHABILITATION & RESETTLEMENT PLAN
No rehabilitation or resettlement plan is proposed as there are no habitations in the in the Plant site.
8.0 PROJECT SCHEDULE & COST ESTIMATES
The project will start only after obtaining Environmental Clearance and all other required
clearance and will complete after two years of commencement. The Capital Cost of the
expansion project will be 40 crores.
9.0 ANALYSIS OF PROPOSAL (Final Recommendations)
With the implementation of proposed expansion project, the socio-economic status of the local
people will improve substantially. The land rates in the area will improve in the nearby areas due
to the proposed activity. This will help in upliftment of social status of the people in the area.
Educational institutes will also come up and will lead to improvement of educational status of
the people in the area. Primary health centers will also come up and medical facilities will
certainly improve due to the proposed project.
Socio-Economic Developmental Activities
The management is committed to uplift the standards of living of the villagers by undertaking
following activities / responsibilities.
• Health & hygiene
• Drinking water
• Education for poor
• Village roads
• Lighting
• Creating harmonious relationships
• Helping locals to conduct sports
• Training to the unskilled manpower
Health &Hygine
1. Personal and domestic hygiene,
2. Maintaining clean neighborhood,
3. Weekly health camps offering free-check up& medicines
4. Ambulance services
5. Education & drug de-addiction, aids.
Drinking Water
Making drinking water available at centralized locations in the village,
Supporting Education
1. Providing books to all poor children,
2. Conducting annual sports festival in the village schools,
3. Providing amenities like fans, lavatories
-----@@@@@------Document No: 2016_VI_00011
25