PRE-FEASIBILITY REPORT PROPOSED EXPANSION FROM 60 TO 200 KLPD CAPACITY OF GRAIN BASED DISTILLERY UNIT OF

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1 PRE-FEASIBILITY REPORT PROPOSED EXPANSION FROM 60 TO 200 KLPD CAPACITY OF GRAIN BASED DISTILLERY UNIT OF M/S ANKUR BIOCHEM PVT. LTD., DHANBAD, JHARKHAND SUMMARY The proposed project is an expansion of existing grain based distillery unit of M/s. Ankur Biochem Private Limited (ABPL). The capacity of existing unit is of 60 kilo litres per day (KLPD), which will be enhanced to 200 KLPD. The existing unit is located at Tetulia More, Lakheiya Bridge Post Dubi, Dhanbad, Jharkhand, (PIN ). The constructed area (including process, office, waste management, storage, etc) of the existing unit is approximately four acres (~15,050 sq.m.). The proposed unit will be installed within the existing industrial premises. It will require about two and half acres of land (~9,900 sq.m.). The industry has 28 acres of land which is adequate for the proposed expansion. The required raw material and resources such as grains and fuel (coal and rice husk) will be made available from the local market. The machinery required for the unit is also available indigenously. The capital cost of the project is Rs. 11,900 Lakhs of which Rs. 500 lakhs are allocated for environment management purpose. The effluent treatment scheme of existing unit comprised of decantation, evaporation and distillers dry grains with soluble (DDGS) units. Condensate Polishing Unit (CPU) has been provided to treat the vapour condensate from DDGS. The effluent from proposed unit will also be treated by same method but by adequately enhancing the capacity of existing units. During the effluent treatment, DDGS of 115 Tons per day (TPD) is estimated to be generated as a solid waste. DDGS is popularly used as a cattle or poultry feed and will be sold in the nearby markets. Steam condensate from manufacturing process will be recycled as boiler feed water. The treated water from CPU will be recycled in process and irrigation purpose. This way the industry has planned to achieve Zero Liquid Discharge (ZLD) guideline prescribed under CREP norms. M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 1

2 2.1 Project Highlights 1 Name of the Proponent M/s. Ankur Biochem Private Limited (ABPL) 2 Type Large Scale Industry (private limited company ) 3 Project Expansion of grain based distillery unit from 60 to 200 KLPD ( by adding a unit of 140 KLPD) 4 Location of the project Tetulia More, Dubhi, P.S. Nirsa, Duvi, Dist: Dhanbad State: Jharkhand, India ankurbiochem@gmail.com Tel. : / Fax: A Latitude & Longitude 23 47'7.18"N and 86 38'47.49"E (altitude 162m) 5 Environmental Settings of the Area A Nearest National Highway NH-2/AH1 is ~2.7 Km away from site B Nearest Railway Station Kalubatham is ~13 km (towards SE), Dhanbad: ~25Km C Nearest air port Dhanbad: ~25Km, Kolkatta: ~240 Km D National Park, Wild Life Sanctuary, Biosphere Reserves etc.) within 10 km radius None within 10 km radius of the project site E Nearest Town / City Dhanbad: ~ 25Km (towards West) F Nearest River Khudia river ~ 0.8 km towards south G Seismic Zone Seismic zone III as per IS: 1893 (Part-I) : Land Requirement 2.5 acres of land for proposed unit; acres of land is available with project proponent 7 Product and Raw material details A Product Product Production ENA Impure Spirit/Technical alcohol Distillers Dry Grain with Soluble (DDGS) B Operation Days per annum Around the year KLPD KLPD TPD C Main Raw Material Quantity Grain Flour Nutrients DAP and Urea Turkey Red Oil (TRO) TPD ~0.5TPD each As per requirement D Water Requirement 1721 cum / day Water will be drawn from three Source: 1) Ground water (permission available for existing unit), 2) from Maithan reservoir (permission available) and 3) from rivulet Khudia (permission available) M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 2

3 E. Steam and Fuel Coal: Max. 13 TPH i.e. 312 TPD (for 200 KLPD capacity) OR Rice husk: ~13.4TPH i.e. 322 TPD (for proposed only) Considering steam requirement of 51TPH fuel to steam ratio of 1:4 (coal) and 1:3.8 (Rice husk) Source of coal : Local market at Dhanbad Rice husk: markets from Jharkhand, Bengal and Bihar 8 Effluent Treatment System Decantation followed by evaporation followed by dryer For Secondary effluent Primary followed by Ecophoto-X followed by carbon filtration as a tertiary treatment 9 Man power Existing 65, additional about 20 persons = Total Project Cost Rs. 11, Lakhs 12 Capital expenses for environment management Rs lakhs INTRODUCTION 1.2 Project Proponent: M/s. Ankur Biochem Private Limited is a business unit belonging to a business group that consists of M/s. Ankur Chemfood Pvt. Ltd, Gandhidham, Gujarat and M/s. Ankur Salt Marketing. Mr. Mahendra Sharma is the project proponent. Mr. Sharma is also engaged in steel industry as a Director of M/s. Kunj Bihari Steel Pvt. Ltd. Jamuria, West Bengal. His business roots are largely spread over the states of Jharkhand and West Bengal. The average annual turnover of the group is around Rs. 15,000 Lacs employing around 350 persons. M/s. Ankur Biochem Pvt. Ltd. has planned to enhance/expand the existing grain based distillery unit s capacity from KLPD. The industry is registered under the Companies Act 1956, having Corporate Identity Number U24100WB2008PTC The proposed unit will manufacture mainly Extra Neutral Alcohol (ENA) and Impure Spirit using grains as raw material. If needed, the plant will manufacture Rectified Spirit (RS). Distillers Wet Grains with Soluble (DWGS) or DDGS will be a byproduct of the process which has a demand in the market as cattle or poultry feed. 2.3 Need of project and its importance to the country and region In India, mainly three types of alcohol are popularly produced, i.e. rectified spirit (RS), extra neutral alcohol (ENA) and anhydrous alcohol (AA). Of these, RS is used for large number of industrial, scientific, laboratory, medical and many other applications. Thus, demand for the same is immense and it is ever increasing. ENA is used for making liquors and other alcoholic beverages. 2.4 Demand and Supply Gap There are more than 300 distilleries in the country with a total installed capacity of 3,500 million litres per annum. However, it is discouraging to note that in spite of such abundant licensed and installed capacity alcohol production in the country has been lagging behind and is varying only around 1,900-2,000 million litres per annum. Thus, it is not withstanding the great demand for alcohol both for chemical industry and for potable purpose, The target of alcohol demand as projected in the perspective plan for Chemical Industry; Department of Chemical & Petrochemicals, Government of India is 2,710 million litres per annum. M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 3

4 2.5 Import vs. Indigenous production The process is straight line and the technology even for the pollution control/disposal is available indigenously. 2.6 Export Possibility The finished products i.e. Extra Neutral Alcohol has an excellent export potential. 2.7 Domestic / export markets Market places such as Kolkata, major cities of UP, Bihar, West Bengal as well as markets of Delhi are the potential domestic market for ENA. ENA also has excellent export potential. Kolkata is the nearest port for international export. 2.8 Employment Generation Proposed project will generate about 20 new employment opportunities for skilled as well as unskilled persons. Apart from this, the project is anticipated to give plenty of indirect opportunities to transporters, shopkeepers, and various facility providers such as refreshment centres, etc. 3.0 PROJECT DESCRIPTION 3.1 Grain Storage Grains will be procured in bulk and manually unloaded onto pit for bucket elevator. Unloaded grains are pre-cleaned through de-stoner and classifier equipment and further stored in Grain Silos. 3.2 Grain Milling Grains will be milled in to flour of desired quality and mesh size using hammer mill (dry milling process). Different grains such as broken rice, maize, sorghum, millets, etc. can be used in the same mills. However, the flour so obtained is passed through classifiers and screens to retain certain mesh size as desirable by the process. Weighed quantity of Flour is sent into liquefaction process, where the starch is liquefied completely Liquefaction Section In liquefaction process, starch is hydrolyzed to dextrin. The liquefaction is carried out in single stage liquefaction tank. Feedstock flour is transferred to pre-masher and mixed with recycle streams 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 using cooling water supply and transferred to pre-fermentation and fermentation section Saccharification & Fermentation Yeast Activation Yeast seed material is prepared in pre-fermenter by inoculating sterilized mash with yeast. Optimum temperature is maintained by circulating cooling water. The contents of the pre-fermenter are then transferred to fermenter. The purpose of fermentation is to convert the fermentable substrate into alcohol. M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 4

5 3.5 Distillation Pre-heated fermented wash will be fed to degasser column. Alcohol is stripped off from fermented wash by ascending vapours in analyser column. Rectifier vapours provide energy to analyser column through a thermosyphon reboiler. Vapours 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 pre-rectifier column, which operates under pressure. Condensing steam provides energy to pre-rectifier column through a vertical thermosyphon reboiler. 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. 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. 3.6 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% solids (w/w) as 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 and further for evaporation for concentration up to 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 a DDGS Dryer and then sold in dry form as cattle feed (DDGS). 3.7 DWGS DRYER WITH COOLING AND CONVEYING SYSTEM 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 its outer flights are fixed. Dry saturated steam is to be supplied to the tube bundle through rotary joint at one end and the condensate is discharged through rotary joint mounted on 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 vapours are exhausted through an exhaust blower & passed through a cyclone separator for separating fines. Dry product is partially recycled back to feed conditioner through product screw and recycle conveyor. M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 5

6 Fig 1: Flow Diagram of manufacturing process Boiler Grain Cleaning, Milling And Flour Handling Section Water Storage Steam & Water Supply Turbine Slurry Preparation & Liquefaction Section Power Generation House FERMENTATION SECTION Spirit Storage Section (ENA/TA) Multipressure Distillation Section Decanta tion Section EVAPORATION PLANT Wet cake Process Condensate Treatment & Recycle Conc. Syrup DWGS Dryer DDGS M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 6

7 3.6 Raw materials Table 1: Availability raw materials & finish good product and transport mode Raw materials Estimated quantity /day Source/ market Grain 530MT Damaged grain and surplus grain from markets of Jharkhand, West Bengal, Bihar, Uttar Pradesh Nutrients N, P Turkey Red Oil (TRO) As per requirement As per requirement Local market at Dhanbad, Ranchi, Kolkatta Local market at Dhanbad, Ranchi final product Estimated quantity KL/day 200 KLPD 10KLPD Source/ market Transport mode ENA + Major markets Surface transport Impure of India using track Spirit (Technical alcohol) from West Bengal, and Tankers Bihar, Uttar DDGS 115TPD Pradesh Surface transport using Trucks/ Tempo Surface transport using Trucks/ Tempo 3.7 Resource optimization / recycle and reuse envisaged in the project, if any, briefly describe Optimum utilization of the available resources is strived by the management. These resources include land, coal, steam, grain and power. 3.8 Availability of water and its source a) Source: Water required for the proposed capacity will be 1,721 cum for day-to-day operations. It will be drawn from (a) bore well, (b) rivulet Khudiya and (c) from reservoir at Maithan. The permissions for water drawl from respective authorities are available with project proponent. Power: Power requirement for the proposed capacity (i.e. 200KLPD) will be of 4000kWh. Captive power will be used. Presently, turbine of 2 MW is installed, in addition to which a new turbine of 4 MW will be installed. These two turbines together will fulfill the power requirement of the proposed distillery capacity. Fuel: Coal or rice husk will be use as a fuel for the steam generation activity. If coal (Indian) is utilized, its requirement will be maximum 13 TPH i.e. 312 Tons per day. If rice husk is utilized its requirement will be Max TPH i.e. 322 TPD for the operation of distillery at proposed capacity (i.e. 200 KLPD). This is based on steam requirement of 51 TPH and fuel (coal and rice husk) to steam ratio of 1:4 for coal and 1:3.8 for rice husk. M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 7

8 3.9 Quantity of waste to be generated & its disposal scheme A) Liquid waste Daily water intake will be of 1,721 m 3 /day. Reduction in water requirement will be due to recycling of (i) condensate water at 40TPH i.e. 960 m 3 /day as well as spent lees of 600m 3 (considering 3 L of lees per liter of ENA). Thin slope can be treated by decantation followed by multi effect evaporation followed by dryers. The DWGS can covert in to the DDGS and sold in the market as cattle or poultry feed. Fig 2 Flow diagram of Thin liquor and effluent stillage treatment Thin Liquor re-circulated to Distillery Wet cake Effluent grain stillage Decantat ion Section EVAPORATION PLANT Conc. Syrup DWGS Dryer Process Condensate Treatment & Recycle DDGS 115 TPD M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 8

9 Other wastewater such as process condensate, boiler blow down, etc. will be treated in effluent treatment plant (condensate polishing unit CPU). The quantity of this effluent would be about 589 cum. Treated water will be recycled to process, cooling tower makeup and gardening. Figure 3: Flow sheet for Secondary treatment Air emission and its control measures From the proposed project, flue gas emissions would be in the form of PM, SOx and NOx due to use of coal or rice husk as a fuel for boiler. Adequate capacity of ESP along with 45 metres height of chimney will be provided to control the PM level below 100 mg/m 3. Solid waste The proposed industrial activity will generate solid waste in the form of ETP sludge, Yeast sludge and boiler ash. Generated DDGS can be sold to the market as a cattle feed as well as poultry feed. The sludge from ETO has the biodegradability in nature hence it used to prepared manure. The ash can sold to the brick manufacturers. M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 9

10 Table 2: Solid waste generation and disposal # Waste Quantity/day Treatment Disposal Remark 1 DDGS 115 MT --- To sell as cattle feed or poultry feed Organic 2 Yeast sludge 1.2 MT Compost Mixed with DDGS Organic 3 ETP sludge MT Compost Mixed with DDGS Organic 4. Ash (Bottom + fly ash) 125 MT (for coal) Or 80.5MT (for rice husk) - Nearby brick manufacturing unit Inorganic Fig 4: Schematic representation of the feasibility drawing which give information of EIA purpose Expansion of grain based distillery from 60 to 200 KLPD capacity Categorization as per EIA notification Sep and its amendment till the date Category A; project activity 5 (g) Application (Form I) and Pre- Feasibility study as project proposal Submitted to Ministry of Environment and Forest (MoEF), Govt. of India for obtaining Environmental Clearance M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 10

11 4. SITE ANALYSIS 4.1 Connectivity Table 4: Connectivity of the project Location of the project Nearest City/Town Within existing distillery premises at Tetulia More, Lakheiya Bridge Po- Dubhi, Dist: Dhanbad, Jharkhand, India Dhanabad 25 Km Asansol (West Bengal) ~50 Km Road Railway Station Air Port State Boundary NH km away towards north Dhanabad 25 Km & Asansol (West Bengal state) -40 Km Kolkata, 250km from project site West Bengal approx 20 km towards south and 35km towards east 4.2 Land form, land use and ownership The land required for the proposed distillery expansion (along with ancillary units) is two and half acre (i.e. ~ 9,990 sq.m.). The industry already has 28 acres of land. The proposed distillery unit along with ancillary units for treatment and disposal of wastewater as well as solid waste will be established within existing industrial premises. Hence, there will not be any change in the existing land use. The land is already procured by the project proponent Information of District Information about Dhanbad Dhanbad is famous for its coal mining and has some of the largest mines in India. Tata steel, BCCL, ECL and IISCO (Indian Iron And Steel Company) are some of the companies having coal mines in the district. The Indian School of Mines is located in Dhanbad. Among the rail divisions of Indian Railway, Dhanbad Rail Division is the second largest in terms of revenue generation after Mumbai division Geographical features The location of proposed grain based distillery project of Ankur Biochem Private Limited, is at village Dubhi, Nirsa, District Dhanbad Jharkhand. National highway 2 (NH2) which was earlier known as Grand Trunk road is about 1.5 km away towards the north of the site. The site is situated on a flat terrain. There are no hills or hillocks in the surrounding of the site. There are approx 75 villages in the 10 km radius of the site. The surrounding land use is mainly agricultural and residential. The main crops of the district are rice, ragi, maize, wheat, red gram, etc. The geographical coordinates of the site are N and E; the proposed site region is at elevation of 155m above the mean sea level. The nearest surface water body is a rivulet Khudia, situated at a distance of 0.8 km from the site towards south M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 11

12 4.4 Existing land use pattern of Nirsa block Land use of the Nirsa block was distributed as, out of total area, ha is under forest, ha is under culturable waste, ha is under unculturable wasteland (Area not available for cultivation) The irrigation is done on, ha with Government canal, ha with well (without Electricity), ha by well (with Electricity), ha with tube-well (without Electricity), ha with Tank, ha with River, 7.15 ha with Lake, ha with Others Total Irrigated Area: Total Unirrigated Area: ha Since, the project will be requiring 4 ha of unculturable land, which is ha, in the said block (Nirsa). Therefore, the land use change under the head uncultivable land will be % of the total land. 4.5 Existing Infrastructure Land 19 acres of land available with sugar factory of which 10 acres will be used for capacity expansion of distillery and ancillary units as well as greenbelt Water Power Source: from 1) rivulet Khudia and 2) existing bore/tube well Captive power supply from 3.0 MW TG set Road approach road of 1.5 KM connecting to National Highway 2 (NH 2) Medical, facilities Education banking Easily available at Nirsa and Dhanbad Available at village Dubhi, Nirsa as well as at Dhanbad Telephone, cell phone, post office, etc are available 4.6 Soil classification The region mainly comprises soils developed on granite gneiss (32.6%) and granite schists (14.2%). There is practically no problem of soil salinity or flooding. Soil acidity problem (ph <5.5) is observed in some areas of the district. The land surfaces being uneven are subject to sheet and gully erosion, causing loss of soil and plant nutrients. The soils of the region have very poor water holding capacity. These soils contain less 'Humus' organic matter. The soil and ph of the soil are suitable for cultivation of cereals such as rice, sorghum, etc. 4.7 Climate The climate of the region ranges from dry semi-humid to humid semi arid type. During summer, the climate is hot and humid. Rains during June to September are occasionally heavy. Summer season is M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 12

13 observed during mid of March to May, there is a steady increase in the temperature, with maximum temperatures of the year occurring in April and May. It is very pleasant during the cold weather from November to February. Thereafter the climate becomes warm. It remains hot until the monsoon breaks towards the middle of June. With the setting in of rains the temperature falls and humidity rises, July to October are the rainy months. The monsoon winds from Bay of Bengal bring rains to the region. July and August are the wettest months. The average annual rainfall in the Dhanbad district is approximately 1400mm.The sky is generally clear during non-rainy season 4.8 Social Infrastructure available Infrastructure such as roads, schools, electricity supply, health centers/hospitals, transportation, banking, market, communication and postal facilities are available to the local people easily. Table 8: Summery of demography The study area encompasses total 75 villages of Nirsa and Gobindpur block. The population details for Nirsa block are as follows Community Children LiteratesWorkers All 921 Population Total SC ST Others Total Main Margi-Nonnal Worker SC 927 Below 7 Years Total Male Female Table 9: Basic infrastructure ST Other Childs964 Name of Block Primary School Middle School Total Dhanbad Govindpur Nirsa s. Within 10km Area There is no tropical forest There is no biosphere reserve There is no national park There is no wildlife sanctuary There is no coral formation No defense installations; No historically important site, monument, structure, etc (Declared by Archeological Survey of India) No recreational site or pilgrimage centre etc. M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 13

14 5.0 PLANNING 5.1 planning concept Type of industry: Manufacturing industry (Expansion of existing grain based distillery unit from 60 to 200 KLPD) Facilities for the drinking water: Water filtration units have been provided in the existing unit. The main sources of water in Nirsa Block are 27 Tap Water schemes, 215 Well Water, 155 Tank Water, 47 Tube well water, 158 Hand pump, 3 Canals Facilities for transport: Grand Trunk road i.e. National Highway 2 (NH 2) Highway 1.5 KM away from Industry. Telephone as well as mobile phone services are available in the region. This block is linked with 13 Bus Services, 3 Railway Services, 1 Navigable water way including River, Canal etc. Post & Telegraph: There are 18 Post Office, Telephone connectivity is also available in the region. Power Supply: Captive power will be used in the proposed project. I Town and country planning / Development authority classification The project site came under the jurisdiction of Belkupa Gram Panchyat. The Gram panchayat has issued No Objection Certificate letter on dated 02/06/2014 for this proposed capacity expansion of grained based distillery from 60 to 200 KLPD. 5.2 Population projection: The proposed expansion activity is generating approx 85 opportunities. Sons of the soils will be preferred while selecting the employee. Thus, migration of sizable population near the project will automatically avoid. Skilled and semi-skilled workers could be easily available in the district, since engineering college as well as ITI are available in the district and surrounding areas. Thus, influx of population could be negligible. 5.3 Land use Planning: The proposed distillery will be within the existing industrial premises. Table 10: Land allocation for proposed unit Unit Land (in Acres) Existing distillery unit including storage of raw material, finished products, solid and liquid waste handling and disposal, etc. Proposed unit Greenbelt (33% of built-up area) open space Total Land available M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 14

15 5.4 Assessment of infrastructure Demand (Physical & Social) The infrastructures such as land, roads, power, water, transportation, etc are easily available for the proposed unit. Raw material and fuel will also be available locally. As explained earlier, very minor influx of population is anticipated due to the project. Available social infrastructure such as schools, colleges, market, medical facilities, etc. is adequate to support the probable minor population increase. 5.5 Amenities/ Facilities The following amenities/facilities are available industry Canteen Medical facility Separate dedicated parking facility for goods vehicle and personal vehicles at site Provision of street light within premises as well as on approach road Rest room Security check post and round the clock security persons on duty Fire extinguishing facilities Drinking water Diesel generator as a backup facility Fresh water and wastewater treatment plants 6.0 PROPOSED INFRASTRUCTURE Social Infrastructure: The road developed for the existing distillery unit will remain available for the local population. 6.1 Connectivity Table 11: Connectivity of the project Nearest City/Town Road Railway Station Air Port Dhanabad 25 Km Asansol (Weast Bangel state) -50 Km NH km away towards north Dhanabad 25 Km & Asansol (West Bengal state) 50 Km Kolkata, 250km from project site 6.2 Drinking water Management: The industry has installed fresh water treatment plant to treat the water for drinking purpose and supplies it to employees. Sewage Management: Available system of septic tank and soak pits for sewage management will be used even after expansion of the unit. 6.3 Power Requirement and source M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 15

16 Daily requirement of power is about 4000 KWh. Power will be made available through own captive power generation system. 7.0 Industrial waste management The proposed unit will produce thin liquor slope and grain stillage which usually treated by decantation followed by concentration followed by drier. During this treatment, DWGS is converted in to the DDGS. This DDGS can be sold as a cattle feed and poultry feed. Thin Liquor re-circulated to Distillery Effluent grain stillage Decantation Section Wet cake EVAPORATION UNIT Conc. Syrup Process Condensate Treatment & Recycle DWGS Dryer DDGS Effluent treatment plant for spent lees and condensate from evaporators: The effluent from the evaporation unit and spent lees will have collective volume of ~589 cum per day and will be treated in condensate polishing unit (ETP). Table 9: ETP Units for spent lees and condensate combined effluent Unit Primary Settling Tank Bag filter unit Ecophoto-X unit Purpose To remove suspended and colloidal solids (settle able) To remove the suspended particles form wastewater For photo oxidation of organic matter of condensate and other wastewater Carbon filtration To filter the treated water 7.2 Solid waste management: The proposed industrial activity gives solid waste in the form of yeast sludge, boiler ash which is biodegradable. The solid waste will uses as a filler materials in the composting process. The quantity and disposal technique is brief in following table M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 16

17 Table 10: Solid waste generation, treatment & disposal # Waste Quantity/day Treatment Disposal Remark 1 DDGS 115 MT --- To sell as cattle feed or poultry feed Organic 2 Yeast sludge 1.2 MT Compost Mixed with DDGS Organic 3 ETP sludge MT Compost Mixed with DDGS Organic 4. Ash (Bottom + fly ash) 125 MT (for coal) Or 80.5MT (for rice husk) - Nearby brick manufacturing unit Inorganic 8.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN The required land is already available with project proponent hence; there is no question of rehabilitation and resettlement (R & R) Plan. 9.0 PROJECT SCHEDULED & COST ESTIMATES 1. Date of start of construction (tentative) March Date of completion (estimated) Dec Project cost Rs. 11, lakhs 4. EMP cost Rs Lakhs 10.0 ANALYSIS OF PROPOSAL I) Benefits The process is eco-friendly. The effluent problems are non-existent in the case of a grain-based distillery. A grain-based distillery has no dependence on the supply of molasses as raw material, having high elasticity and sensitivity of demand and supply. The manufacturing technology is indigenously available. The project is flexible and can handle a variety of raw materials like cereal grain, vegetables rich in starch like potatoes, cassava, etc. A high protein source in the form of distiller s wet or dry grain with soluble (DWGS/DDGS) can be produced in the distillery. This can be sold as a cattle feed. Additional revenue can be generated by selling DWGS/DDGS. M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 17

18 The promoter can take up the grains on contract farming from the nearby farmers. However in order to minimize dependency of the project on the farmers, grains from outside markets can be procured. Grain alcohol is superior in quality to molasses alcohol. Nowhere in the world, the molasses alcohol being termed as Indian whisky, brandy etc. if they are produced from molasses alcohol, they are termed as Indian Spirits. Grain based CO 2 is food grade. Therefore, in future, there is a scope to put-up a food grade / beverages grade CO 2 plant. It is also possible to go for liquor project (Country liquor or IMFL) in future, which will further improve the economic viability of the project. II) conclusion a) This project will help to improve the economic conditions of local people b) The candidate site is suitable as per general MoEFCC expectations c) Water, power, raw material and market is found available with ease d) Full precautions will be taken for pollution control, resource conservation and environmental protection e) This is cost effective and sustainable development M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 18

19 M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 19