Table 1 Salient Features of the Project

Transcription

1 PRE - FEASIBILITY REPORT 1.0 EXECUTIVE SUMMARY (I) Introduction M/s. Shri Gang Industries & Allied Products Limited is proposing 55 KLPD Grain based Distillery along with 2.0 MW of Co-Generation Power Plant at Plot No. B- 2/6 & B 2/7, UPSIDC Industrial Area, Sandila Phase IV, Lucknow Hardoi Road, Tehsil Sandila, District Hardoi, Uttar Pradesh. Grains such as damaged grain feed stock, broken rice, maize, bajra & sorghum will be used as raw material which is easily available from the local market. As per EIA Notification dated 14 th Sep., 2006 and as amended from time to time; the project falls in Category B, Project or Activity - 5(g)(ii) [Non-molasses based distilleries >60 KLD]. S. NO. PARTICULARS Table 1 Salient Features of the Project DETAILS A. Nature & Size of the Project Proposed 55 KLPD Grain Based Distillery along with 2.0 MW Co-Generation Power Plant B. Category of the Project As per EIA Notification dated and as amended from time to time, the project falls in Cat. B, S. No. - 5(g), as capacity is 55 KLPD Grain Based alcohol production. C. Location Details Plot No. B - 2/6 & B 2/7, UPSIDC Industrial Area, Sandila Phase IV, Lucknow Hardoi Road Tehsil District State Latitude Longitude Sandila Hardoi Uttar Pradesh N to N E to E D. Area Details Total Project Area Greenbelt / Plantation Area ha (30.09 acres) 4.0 ha, i.e. ~33% of the project area will be covered under green belt/ plantation E. Environmental Setting Details (with approximate aerial distance & direction from project M/s. Shri Gang Industries & Allied Products Limited 1

2 site) 1. Nearest Village Muradnagar Village (0.8 km in ESE direction) 2. Nearest Town & City Nearest Town: Sandila (~8.0 km in ESE direction) District Headquarters: Hardoi (~46 km in NW direction) 3. Nearest National Highway / SH - 25 (~0.5 Km in North direction) State Highway 4. Nearest Railway station Sandila (~8.0 km in ESE direction) 5. Nearest Airport Chaudhary Charan Singh International Airport, Lucknow (~ 57 km in SE direction) 6. National Parks, Wild Life No National Parks, Wild Life Sanctuaries, Biosphere Reserves, Sanctuaries, Biosphere Tiger/ Elephant Reserves, Wildlife Corridors, Reserved Reserves, Tiger/ Elephant Reserves, Wildlife Corridors, Forests (RF) / Protected Forests (PF) etc. falls within 10 km radius from the project site. Reserved Forests (RF) / Protected Forests (PF) etc. within 10 km radius 7. River / Water Body (within 10 Lucknow Branch Canal (~4.0 km in SW direction) km radius) F. Cost Details Total Cost of the Project Cost for Environment Management Plan Rs Crores Capital Cost: Rs. 10 Crores Recurring Cost : Rs. 1.0 Crores/annum G. Basic Requirements for the project Water Requirement 451 KLPD Source Groundwater Power Requirement 1.8 MW Source Co Generation Power Plant of 2.0 MW Man Power Requirement 60 (Source:- Unskilled / Semi-Skilled - Local Area; Skilled- Local & Outside) H. Product Mix ENA / RS I. Working Days 350 days/annum M/s. Shri Gang Industries & Allied Products Limited 2

3 1.1 ENVIRONMENT MANAGEMENT PLAN Particulars DETAILS Air Quality Management Possible Boilers, Transportation vehicles, D.G. Sets etc. Sources Emissions ESP/Bag Filters will be installed with the proposed boiler. Adequate boiler stack height will be provided. CO2 produced during the fermentation process will be collected and utilized as an industrial gas. DG Sets will also have adequate stack of height as per CPCB Guidelines. Adequate measures for Fugitive Dust Emissions will be taken. All the internal roads will be asphalted. Development of Green Belt all around the periphery & within the premises of the plant will help in attenuating the pollutants emitted by the plant. Monitoring Online stack monitoring system will be installed. Water Quality Management Ambient air quality will be regularly monitored. Management The proposed Grain based distillery will be based on Zero Effluent Discharge. Fresh water requirement of the project will be met by Ground Water & recycled water. Grain Slops (Spent Wash) will be taken through Centrifuge Decanters for separation of Suspended Solids separated as Wet Cake. Thin Slops from the Decanter Centrifuge are partly recycled back to process (30-35%) and partly taken to Thins Slops Evaporation Plant for concentration of remaining solids to form a Syrup. This Syrup is also mixed into the Wet Cake coming out of Centrifuge and forms part of Cattle Feed. (Also known as Soluble Collectively known as DWGS) DWGS Drier Wet cake / DWGS will be passed through steam tube bundle drier for drying into cake with 10-12% moisture (max.) to give higher shelf life. Solid dry cakes (DDGS) will be obtained finally. The Process condensate will be cooled and collected into a neutralization tank with sufficient residence time. After Neutralization and filtration (UF+RO) this process condensate will be recycled into process use. Rainwater will be collected and recharged into underground resource through M/s. Shri Gang Industries & Allied Products Limited 3

4 Noise Level Management scientifically designed Rainwater Harvesting System. Management Proper maintenance, oiling and greasing of machines at regular intervals. PPEs like earplugs and earmuffs will be provided to the workers exposed to high noise level. Development of Green Belt in 33% of the total project area. D.G sets will be provided with acoustic enclosures to control the noise level within the prescribed limit. Monitoring Regular monitoring of noise levels will be carried out and corrective measures in concerned machinery will be implemented accordingly to the possible extent. Solid Waste Management Management Solid waste generated would be wet cake, yeast sludge and ash from the boiler. Solid waste from the grain based operations generally comprises of fibres and proteins in the form of DDGS, which will be ideally used as cattle feed. Ash from the boiler will be supplied to brick manufacturers & cement plant. The Yeast sludge will be added to the Wet Cake. Used oil & grease generated from plant machinery/gear boxes as hazardous waste will be sold out to the CPCB authorized recycler. Green belt Development/ Plantation Management Out of the total project area ~ 33% of total project area will be developed under green belt/plantation. Plantation will be done as per Central Pollution Control Board (CPCB) Norms. Greenbelt will be developed all along the project boundary and plantation will be done all along the roads which will attenuate noise level, arrest dust and improve the surrounding environment. Native species will be given priority for plantation in consultation with local horticulturist. The plantation would start along with the start of the construction activities of the proposed unit. Odour Management Management Adequate greenbelt all around the periphery of the plant. Efficient CO2 scrubbing to avoid carryover of alcohol vapors & other fumes. DWGS Dryer will be installed for complete drying of solids. Better housekeeping will maintain good hygiene condition by regular steaming M/s. Shri Gang Industries & Allied Products Limited 4

5 of all fermentation equipment. Longer storages of any product/by-products will be avoided & use of efficient biocides to control bacterial contamination. Regular use of disinfectants in the drains to avoid generation of putrefying micro-organisms. 2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION (i) Identification of Project and Project Proponent M/s Shri Gang Industries & Allied Products Limited (SGIAPL) is a company promoted by Mr. Suraj Gupta and family. The promoters have diversified interests in liquor, edible oils, real estate etc. The promoters have the financial and managerial capability to set up and manage large industrial projects. Now, Company is proposing Project comprising of Grain Based Distillery, IMFL & Country Liquor Bottling, Brewery and Co-Generation Power Plant at Plot No. B- 2/6 & B 2/7, UPSIDC Industrial Area, Sandila Phase IV, Lucknow Hardoi Road, Tehsil Sandila, District Hardoi, Uttar Pradesh. It would be an eco-friendly project. We shall adopt zero discharge concepts. (ii) Brief description of nature of the project M/s. Shri Gang Industries & Allied Products Limited is proposing to set up Extra Neutral Alcohol/ Rectified Spirit manufacturing facility with an installed capacity of 55 KLPD & 2.0 MW Co-generation Power Plant along with CO2 & Distillers Dried Grains & Solubles (DDGS) for Cattle/Poultry/Fish or Prawn feed as by-products. For the purpose of setting up the unit, the site is located at Plot No. B- 2/6 & B 2/7, UPSIDC Industrial Area, Sandila Phase IV, Lucknow Hardoi Road, Tehsil Sandila, District Hardoi, Uttar Pradesh. The company will manufacture ENA & RS through grain based process. The proposed site is chosen because of its proximity to the agriculture field surrounding the area & easy availability of food grains like Maize, Bajra, Sorghum & broken rice to the distillery for producing alcohol. (iii) Need for the project and its importance to the country and or region With hundreds of kind of alcoholic beverages being made and consumed in India, the industry can be categorised into four broad groups viz. Indian Made Foreign Liquor (IMFL), Country Liquor (CL), illicit liquor & Beer. IMFL products contain about 42.85% of alcohol. The consumption of CL is slowly on the decreasing trend as some cheap IMFL is available. In spite of this, the CL industry is growing at around 8%. However, government is taking necessary steps to restrict the illicit liquor as it causes loss of revenue and spoils the health of the people, also bad quality may M/s. Shri Gang Industries & Allied Products Limited 5

6 lead to death of consumer. The major consumption of alcohol as of now is for alcoholic beverages. Ethyl alcohol has the potential to become the fuel of the future relegating gasoline to a secondary place. The ethanol produced from the grains is superior in quality as compared with that from molasses. It is estimated that IMFL market will require around 3000 million litres in the year 2014 and expected to grow more than 50% in next 3 years. As Government declares 5% mandatory mixing of fuel ethanol in the gasoline thus there is great potential for new distillery establishment. (iv) Demand- Supply Gap Not required in this Project. This depends on excise Department. (v) Import vs. Indigenous Production Indian market could not meet present alcohol demand. So they import alcohol 5-7% of total demand. As far as ethanol production is concerned, Indian market play a vital role at both domestic & international level. So they require to produce more alcohol to meet the demand. (vi) Export Possibility Export of Alcohol is currently governed by Govt. policy. (vii) Domestic / Export Markets Sales and Marketing division has always been a key focus area for our company. Over the years we have reached a number of key customers through our initiatives. We have a thrust on institutional Buyers which is a paradigm shift from the tradition of selling to wholesale market. (viii) Employment Generation (Direct and Indirect) due to the project For smooth functioning of the plant, the company needs a team of 60 persons. These persons are responsible towards their respective department such as Process Plant, Boiler Operating Plant and administrative block. Here is the detailed description of the manpower requirement of the company. M/s. Shri Gang Industries & Allied Products Limited 6 Table 2 Manpower Requirement S. No. Units Requirement 1. Process Plant Raw material and Product handling Boiler House Plant 8 4. Administrative Plant Others 10

7 Total PROJECT DESCRIPTION (i) Type of Project including interlinked and independent projects, if any. There are no interlinked projects related to this proposed project. (ii) Location (map showing general location, specific location, and project boundary & project site layout) with coordinates M/s. Shri Gang Industries & Allied Products Limited 7

8 Figure - 1: Location Map M/s. Shri Gang Industries & Allied Products Limited 8

9 (ii) Plant Layout Figure - 2: Plant Layout M/s. Shri Gang Industries & Allied Products Limited 9

10 (iii) Environmental setting map of 10 km radius study area Figure - 3: Environment setting map of 10 km radius study area M/s. Shri Gang Industries & Allied Products Limited 10

11 (iv) Details of alternative sites consideration and basis of selecting the proposed site, particularly the environmental considerations gone into should be highlighted. No alternative site has been taken into consideration as the proposed site has been acquired by the company keeping in mind following mentioned factors: Grant of state excise permissions (LOI) for setting up distillery in the district/state. Proposed project is located within UPSIDC Industrial Area. Raw material availability & markets for both products & by-products within the state. Nearness to SH - 25 (~0.5 Km in North direction) makes it easier to transport raw materials & final product to market. (v) Size or magnitude of operation The total proposed capacity of Grain Based Distillery is 55 KLPD & Co-generation Power Plant is 2.0 MW. The process includes basic raw material requirement, sizing of equipment, utilities & services, infrastructure facilities & sources of waste generation, their quantity, treatment & safe disposal of the waste. S. No. Units Capacity 1. Distillery (ENA/ RS) 55 KLPD 2. Co-Generation Power Plant 2.0 MW (vi) Project Description with Process Details Process Description of Grain Based Operation A) Grain Receipt and Storage: The process of the production of alcohol begins with the procurement of grain which is received at the factory in trucks and generally in bags. These are unloaded in the grain unloading section and the grain pre-cleaned through a system of bucket elevators and suitable equipment like destoners and others and transferred to the Grain Silos meant for the storage of Grain. Silos are generally made of GI Sheet having all internals to handle and keep the grain cool and maintain the right moisture content through blowers etc. B) Milling The grains after being cleaned of its impurities are then passed to the milling section. The cleaned grains are then milled using dry milling process through special hammer mills which grind the grain down to the size suitable for the process of conversion of starch to sugar and finally to alcohol. Grain after milling is passed through a mesh which grades the flour and passes on the M/s. Shri Gang Industries & Allied Products Limited 11

12 larger grain and re-circulates the larger grain back to the milling section for grinding it to the requisite size. This section is equipped with all relevant dust collectors, back filters to contain the dust or any other foreign particle like stones, metals etc. The flour is then stored in a flour silo from where it is transferred to a slurry tank through another screw conveyer (Pre masher) for the slurry preparation. C) Slurry Preparation, Cooking & Liquefaction Section Grain flour and processed water are fed at controlled rate in slurry mixing cum liquefaction tank as per the requirement. The liquefying enzymes are also added in the slurry at this stage. 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 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 solubilised) and 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. D) Saccharification & 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. Fermentation: 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. The fermentation process is engineered to operate in batch mode depending upon the quality of raw material. 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 C by forced recirculation flow through plate heat exchangers. There is a provision for spent wash recycling to fermentation depending on solids concentration in fermented wash. M/s. Shri Gang Industries & Allied Products Limited 12

13 At the start of the cycle, the fermenter is charged with mash and contents of the Yeast Activation Vessel (Pre Fermenter) once the yeast has got activated. Contrary to tradition today yeast is available readymade and one has to only activate the same and not develop it. Thus in normal course of today s fermentation we can do without yeast vessels and we can start the process at the pre-fermenter stage itself. Significant heat release take place during Fermentation, being an exothermic reaction. This is removed by passing the mash through heat exchangers to maintain an optimum temperature. The re-circulating pumps also serve to empty the Fermenters into Beer Well for Distillation of Alcohol. CO2 which is released during fermentation is passed to the CO2 recovery section after the recovery of alcohol from the scrubber. After emptying of Fermenter, it is cleaned with CIP using cleaning nozzles. After CIP, fermenter is ready for next batch to be filled for the next cycle. This whole process of fermentation from filling to emptying to cleaning and restart takes about 72 hours. E) Multi-Pressure Distillation:- Multi Pressure Distillation system has Seven 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:- 1. Analyser Column 2. Degasifying Column 3. Pre-Rectifier Column 4. Extractive Distillation Column 5. Rectifier cum Exhaust Column 6. Recovery Column 7. Simmering Column Pre-heated fermented wash will be fed to Degasifying column. Fermented wash is stripped off alcohol by ascending vapours in Analyser column. Rectifier vapours provide energy to Analyser column through a Thermo-siphoned-boiler. Vapours of Degasifying column are condensed and taken to Recovery Feed Tank. The condensed analyser Vapours are taken to Pre-Rectifier Feed Tank. Analyser Condensate is concentrated in Pre- M/s. Shri Gang Industries & Allied Products Limited 13

14 Rectifier column, which operates under pressure. Condensing steam provides energy to pre-rectifier column through a vertical Thermo-siphoned-boiler. A Technical Alcohol cut of about 1-2% of total spirit is taken from the Pre-Rectifier column. Concentrated alcohol drawn from Pre-Rectifier column is fed to an Extractive distillation 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 Thermo-siphon re-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 fuse 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 diacetyls. Final ENA product draw is taken from the bottom of this column. Benefits of Multi-pressure Distillation:- Multi-pressure Distillation system has lower steam consumption as it is designed for maximum heat integration to conserve energy Energy efficient Multi-pressure Distillation system with a steam consumption of 3.2 kg/lit of Total Spirit (depending on mode of operation) Vacuum operation nearly eliminates scaling problem in Analyser column and ensures better separation of impurities, which results into better quality product. Well-engineered plants with high efficiency trays to ensure elaborate separation and removal of impurities ensuring superior quality of Neutral Alcohol. Proper care in design of calming zone on trays, large area of down-comers, gasliquid separators with tangential entry and vapour bottles ensures proper gasliquid disengagement and eliminates chances of liquid carryover. Analyzer column with Hyper-stat Rh-Grid trays ensure high turbulence on tray, this minimizes chances of scaling. Also, this special construction of trays and access to each tray helps in easier cleaning column internals. Condensers are designed with multiple passes to ensure high velocity and to M/s. Shri Gang Industries & Allied Products Limited 14

15 minimize scaling inside tubes. Fusel oil decanters after Rectification column ensure proper separation of fusel oils. F) Decantation & Thin Slops Recycling:- Decantation section comprises of a Centrifuge Decanter for separation of suspended solids from Spent Wash coming out of Grain Distillation Plant. Wet cake has 28-32% 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 up to 35% w/w (min) 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). G) Evaporation System- Integrated Evaporation Scheme:- The suggested treatment scheme is a TWO Effect (Integrated) plus TWO Finisher effect working on the principle of falling film Thin Slop Evaporation Plant. The following points will elucidate the basic working principle: a) Shell & Tube type Evaporators working on the principle of Falling film. b) Analyzer vapours is fed to the first effect evaporator shell side and steam is fed to shell side finisher at the given pressure and temperature as the heating medium. c) The Feed is at predetermined temperature is fed from the top of First effect evaporator, and then it is follow the following flow path. d) Vapours generated in 1st effect VLS (Vapour Liquid Separator) are used as heat source in the 2nd effect. e) The vapours from Stand alone falling film effect E-3 are also added to stand- alone effect- 4 Jacket to increase the steam economy. f) Vapours generated in stand-alone 4th effect VLS (vapour Liquid Separator) are added to integrate second effect. g) Vapours from 2nd Effect are condensed in Surface Condenser. A Shell & tube type Multi-pass Surface condenser is employed for condensing the shell side vapours. h) The product at the desired concentration 35% is obtained at the outlet of the Fifth effect. i) Each effect is provided with recirculation cum transfer pump. j) The condensate from surface condensers is collected in a common condensate M/s. Shri Gang Industries & Allied Products Limited 15

16 pot. The condensate is transferred for further treatment/ drain by using centrifugal pump. k) The Pure steam condensate is collected in receiving vessels and can be pumped to desired battery limit. l) Highly efficient operating pumps have been provided for pumping the required fluid. m) The plant is having high level of automation to get consistent output at required concentration. n) The system operates under vacuum. Water- ring vacuum pumps are used to maintain a desired vacuum. o) Cooling water from cooling tower is used in the surface condensers for condensing the vapours. H) Dryer Section:- The wet grain received from the Decanter and the thick slops received from the Evaporator are mixed in a ribbon mixture to make DWGS which has about 70% moisture. This material can then be disposed of as cattle feed or sent to the DDGS Dryer for drying. The Dryer works on the principle of steam being used as a heating medium and passed through tubes and the DWGS mixture of Wet Grain from the Decanters and the syrup from the evaporator is fed to the Dryer. The DWGS at 70% moisture is dried to about 10% moisture to give DDGS which is sold as Cattle Feed. DDGS has a good market potential in India as well as abroad and is also a major source of revenue. I) Effluent Treatment:- The first step to achieving a zero discharge is through recycling of different streams and the following streams are recycled into the process to economize on the usage of fresh water as also achieve a zero discharge in the process:- a) Thin slops emerging from the decanters are recycled to the process in varying quantities depending on what the process can take from 10-25%. b) The balance thin slops are passed on to the evaporator and then to the Mixer for making of DWGS and then to the Dryer to make DDGS thereby making the entire effluent zero and getting a valuable by product cattle feed. c) Spent less which is the waste zero alcohol liquid coming from different distillation columns is also recycled to the process. d) Steam and process condensate is also reused with primary condensate going back M/s. Shri Gang Industries & Allied Products Limited 16

17 to the boiler and the process condensate being used as a makeup at different points including the Cooling Tower and so on. e) All washings etc. which cannot be reused are passed through a small treatment plant and the clear liquid obtained sent back to the process. f) The reject of the treatment plant is generally used for ash quenching or for gardening. g) We are thus able to achieve zero discharge which is the objective of this treatment process. M/s. Shri Gang Industries & Allied Products Limited 17

18 Fig. 4: Process flow chart For Grain Based Distillery M/s. Shri Gang Industries & Allied Products Limited 18

19 (vii) Raw material required along with estimated quantity, likely source, marketing area of final products, mode of transport of raw material and finished product. (a) Raw Material Requirement List of raw materials & Chemical required, their source along with mode of transportation are given below: Table 3 Raw Material Requirement for Grain Based Distillery S. No. Name of Raw Material Requirement per day Storage Source & Mode of Transportation 1 Grains 129 to 135 TPD Silo & Godowns Through vendors / By road 2 CHEMICALS Sodium Hydroxide (Caustic) Kgs Solid form packing in 50 kg bags & Stored Godown Nearby areas via road Nutrients 125 Kgs Solid form packing in bags & Stored Godown Enzymes 125 Kgs Liquid form packed in cane & Stored Godown Antifoam Agent 60 Kgs Semi Solid form packing in drum & Stored Godown Yeast (Active Dry Yeast/Distiller s Yeast) 55 Kgs Solid form packing in bags & Stored Godown (b) Fuel Requirement Rice husk or Indian coal will be used for the proposed boiler of 18 TPH. Details regarding fuel requirements are given below. Table 4 Fuel Requirement Name of Raw Material Quantity (MT per day) Source Of Materials Rice Husk or 120 Through Local vendors / By road Indian Coal 85 From Authorized Dealers By road (viii) Resources optimization/ recycling and reuse envisaged in the project, if any, should M/s. Shri Gang Industries & Allied Products Limited 19

20 be briefly outlined. Water as a resource will be recycled at each possible step of the process and latest technology and methodology will be adopted to conserve and reuse the resources. (ix) Availability of water it s source, energy /power requirement and source should be given. (a) Water Requirement and Source The total water requirement for proposed unit will be 1674 KLPD. After recycling, the fresh water requirement will be 451 KLPD which will be sourced from Ground water. Water as a resource will be recycled at each possible step of the process and latest technology and methodology will be adopted to conserve and reuse the resources. The process condensate will be cooled into a neutralization tank with sufficient residence time. After neutralization and filtration (UF + RO) this process condensate will be recycled into process use. TOTAL WATER INPUT S. No. Section Water Consumption (KLPD) 1. Process water in Liqn & Fermentation DM water for RS Dilution DM water for Boiler feed Soft Water for Analyser Flash Tank Soft Water For Vacuum Pump & Others Soft Water Make Up For cooling Tower Misc. Washing water Other Domestic Usage 10 Total 1647 TOTAL WATER OUTPUT S. No. Section Water Consumption (KLPD) 1. Steam Condensate Spent Lees PR Spent Lees Rectifier Spent Wash (Grain Slops) Soft Water For Vaccum Pump & Others Water in Wet Cake (By-Product) CT Evaporation & Drift Losses Misc. Washing water Domestic Consumption 10 Total 1647 M/s. Shri Gang Industries & Allied Products Limited 20

21 Recycle & Utilization Streams S. No. Section Water Consumption (KLPD) 1. Lees Recycle for RS Dilution Steam Condensate Recycle for Boiler Spent Lees Recycle to Process Thin Slops Recycle to Liqn Process Thin Slop Recycle Flash Tank Process Condensate to Cooling Tower Vaccum Pump Recirculation Total Recycling /Re-utilisations of water per day 1196 TOTAL FRESH WATER INPUT 451 TOTAL FRESH WATER REQUIREMENT 8.2 KL/KL M/s. Shri Gang Industries & Allied Products Limited 21

22 Figure 5: Water balance for Grain based Operation M/s. Shri Gang Industries & Allied Products Limited 22

23 (b) Power Requirement and Source The power requirement is 1.8 MW, which will be sourced from proposed 2.0 MW Co- Generation Power Plant via a straight back pressure turbine. (c) Steam Requirement Steam consumption for the process and boiler de-aeration is 14.9 TPH, which will be sourced from Boiler (18 TPH). Table 6 Steam requirement S. No. Purpose Steam Requirement TPH 1. Cooking & Liquefaction Multi-pressure Distillation & Evaporation (Integrated) DWGS Drier Boiler De-aeration 2.2 Boiler Details Total 14.9 A Boiler of 18 TPH capacity with ESP/Bag filter as APCE is sufficient to meet the requirements. Others details regarding this are mentioned in the table given below: S. No. Details Table 7 Boiler details 1. Type of Fuel Rice Husk/ Indian Coal 2. Capacity of Boiler 18 TPH 3. Stack Height Adequate stack height 4. Pollution Control Equipment Measures ESP/Bag Filter Details regarding the D.G. Sets 2 Number of D.G. sets of 750 KVA & 500 KVA will be installed for the power backup. Details regarding the D.G. Sets are mentioned in the table given below: Table 8 Details Regarding the D.G. Sets S. No. Details 1. Type of Fuel HSD 2. Capacity 750 KVA & 500 KVA 3. Stack Height (above roof level) As per CPCB/SPCB norms 4. Pollution Control Equipment Measures Adequate stack height/ Acoustic (x) Quantity of waste to be generated (liquid and solid) and scheme for their M/s. Shri Gang Industries & Allied Products Limited 23

24 management/disposal The proposed project is based on ZERO EFFLUENT DISCHARGE. Grain Slops (Spent Wash) will be taken through Centrifuge Decanters for separation of Suspended Solids separated as Wet Cake. Thin Slops from the Decanter Centrifuge will be partly recycled back to process (30-35%) and partly taken to Thin Slops Evaporation Plant for concentration of remaining solids to form a Syrup. This Syrup is mixed with the Wet Cake coming out of Decanter Centrifuge and forms part of Cattle Feed. (Also known as Distillers Wet Grain Solubles - Collectively known as DWGS). DWGS is taken to a dryer operating on steam and is dried to make it DDGS Distillers Dried Grain Solubles. The process condensate is cooled and collected into a neutralization tank with sufficient residence time. After Neutralization, this process condensate will be recycled into process and is used for green belt development within the complex. Solid waste from the Grain based operations generally comprises of Fibres and proteins in the form of DDGS, which will be ideally used as Cattle Feed. Ash from the Boiler will be sold to Brick manufacturers and Cement manufactures. Yeast sludge will be sent to the Sludge Drying Beds or may be added to the Wet Cake. Used oil & grease generated from plant machinery / Gear boxes & D.G. Set will be 4.0 SITE ANALYSIS partly used in oiling & greasing as lubrication of external parts of machinery & partly will be sold to the CPCB authorized recycler. (i) Connectivity The project site is well connected to State Highway SH - 25 (~0.5 Km in North direction). The nearest railway station is Sandila Railway Station (~8.0 km in ESE direction) and nearest airport is Chaudhary Charan Singh International Airport, Lucknow (~ 57 km in SE direction). The site is suitably located with respect to availability of raw material, water, road network, skilled/semi skilled/unskilled and professional manpower etc. All communication facilities such as telephone, telefax & internet are available in the vicinity of the project site. ii) Land from Land use and Land ownership Total plant area is ha (30.09 acres) and the same has been acquired by the company. (iii) Topography M/s. Shri Gang Industries & Allied Products Limited 24

25 Topography of the core zone of the proposed project is almost flat. (iv) Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area under CRZ), shortest distances from the periphery of the project to periphery of the forests, national park, wild life sanctuary, eco sensitive areas, water bodies (distance from the HFL of the river), CRZ. In case of notified industrial area, a copy of the Gazette notification should be given Table 9 Environmental Settings of the Area S. NO. PARTICULARS DETAILS 1. Nearest Village Muradnagar Village (0.8 km in ESE direction) 2. Nearest Town & City Nearest Town: Sandila (~8.0 km in ESE direction) District Headquarters: Hardoi (~46 km in NW direction) 3. Nearest National Highway / State SH - 25 (~0.5 Km in North direction) Highway 4. Nearest Railway station Sandila (~8.0 km in ESE direction) 5. Nearest Airport Chaudhary Charan Singh International Airport, Lucknow (~ 57 km in SE direction) 6. National Parks, Wild Life Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors, Reserved Forests (RF) / No National Parks, Wild Life Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors, Reserved Forests (RF) / Protected Forests (PF) etc. falls within 10 km radius from the plant site. Protected Forests (PF) etc. within 10 km radius 7. River / Water Body (within 10 km Lucknow Branch Canal (~4.0 km in SW direction) radius) 8. Soil Type Loamy soil, silty loam soil and loamy sand soil 9. Seismic Zone Seismic Zone - III as per IS: 1893 (Part-I): (v) Existing Infrastructure Proposed project is new project. There are no existing infrastructures. (vi) Soil classification Soils in the area exhibit a wide variation in composition texture and appearance. The major position of the area is occupied by Loamy soil, silty loam soil and loamy sand soil. M/s. Shri Gang Industries & Allied Products Limited 25

26 (vii) Climatic data from secondary sources The area falls in a humid subtropical, with extremes of climate in summer and winter. Dust storms are common during the summer months in the area and it experiences severe heat during May and June, with the highest temperatures hovering around 45+3 o C and minimum temperatures touching lows of the order 3 o C. The Southwest monsoon period between June and September is the main rainy season of the area when about 85% of the annual precipitation occurs. The mean annual rainfall is about 904 mm. The coefficient of variation is fairly low at 15 mm and the corresponding dispersion of mean rainfall is 20% with a 90 mm standard deviation. The air over this area is generally dry for most part of the year. (viii) Social Infrastructure available There are primary schools, dispensaries, small hospitals, places of worship in nearby area of the project site. 5.0 PLANNING BRIEF (i) Planning Concept (type of industries, facilities, transportation etc.) Town and country Planning/ Development authority classification. The proposed project is a distillery unit. Facilities required for the proposed project will be provided as per requirement. Transportation of raw material and final product will be done via existing road network and cement concrete road will be developed within the proposed project area. (ii) Population Projection Temporary influx of people will be there as the managerial and supervisory staff will generally be outsider. A projection may be made by a governmental organization, or by those unaffiliated with a government. (iii) Assessment of infrastructure demand (Physical & Social) The Company will assess the demand of infrastructure (Physical & Social) in nearby area of the proposed site and will be developed in under corporate social responsibilities programs (iv) Amenities/Facilities The Company will be developed the Amenities/Facilities in nearby area of the proposed project site as per requirement of local people of the nearby area under corporate social responsibility programs. 6.0 PROPOSED INFRASTRUCTURE (i) Industrial Area (Processing Area) M/s. Shri Gang Industries & Allied Products Limited 26

27 12.17 ha (30.09 acres) area will be required for proposed Distillery unit. (ii) Residential area (Non Processing area) Residential colony is not proposed for proposed project. The local labor will be preferred for employment opportunities. (iii) Green Belt Greenbelt will be developed in 33% of the total area of the proposed project. (iv) Social Infrastructure Proposed project will result in growth of the surrounding areas by increased direct and indirect employment opportunities in the region including ancillary development and supporting infrastructure. (v) Connectivity The proposed project is well connected with Road. (vi) Industrial Waste management The proposed Grain based distillery will be based on ZERO DISCHARGE. (vii) Solid Waste Management Solid waste from the Grain based operations generally comprises of Fibres and proteins in the form of DDGS, which will be ideally used as Cattle/Poultry/Fish or Prawn Feed. Ash from the Boiler will be sold to Cement and Brick manufacturers. Yeast sludge will be sent to the Sludge Drying Beds or may be added to the Wet Cake. (viii) Power requirement and source The total power requirement for the proposed project will be 1.8 MW, which will be sourced from Co generation power plant of 2.0 MW & D.G Sets (750 KVA & 500 KVA) (for emergency). 7.0 REHABILITATION AND RESETTLEMENT (R& R) PLAN (i) Policy to be adopted (Central/State) in respect of the project affected persons including home oustees, land oustees and landless labourers (a brief outline to be given). Any rehabilitation and resettlement plan is not applicable in this case since the proposed project will be done within the UPSIDC Industrial Area. 8.0 PROJECT SCHEDULE AND COST ESTIMATES (i) Likely date of start of construction and likely date of completion (time schedule for the project to be given). M/s. Shri Gang Industries & Allied Products Limited 27

28 The project will start only after obtaining Environmental Clearance and all other required clearance and will complete within 3 to 5 years of commencement. (ii) Estimated project cost along with analysis in term of economic viability of the project. Total cost of the Project: Rs Crores Cost for Environment Protection Measures: Capital Cost: Rs. 10 Crores Recurring Cost/annum: Rs. 1.0 Crores/annum 9.0 ANALYSIS OF PROPOSAL (i) Financial and social benefits with special emphasis on the benefit to the local people including tribal population, if any, in the area. The proposed project is expected to bring significant socio-economic and environmental benefits both at local level as listed below: SOCIAL INFRASTRUCTURE: Social awareness programmes will be improved by the local authority such as sanitation and hygiene, HIV Prevention Program. Adult education and female education programme is planned for illiterate adults and backward females of the villages in the project surrounding area. EMPLOYMENT POTENTIAL: The project will create some employment. Due to this project activity, some persons in the project area will be recruited as skilled and semi skilled workers by the company as per its policy. Therefore, some employment and income are likely to be generated for the local people. So, the project will contribute in a positive manner towards direct employment in the project area. Some employment potential benefits are given below: Long term employment of up to 60 people in the operation phase. Moreover, indirect employment will be generated substantially. BENEFITS TO THE REGION The company will supply its product to the domestic market which is likely to improve the regional economy. PERIPHERAL DEVELOPMENTS: The Company intends to take up developmental work in the periphery area. The activities that have been considered include the following: Supporting existing schools for development of education in the area. Help in imparting vocational training to local eligible youth. M/s. Shri Gang Industries & Allied Products Limited 28

29 Provide health facilities by way of medical check up, by holding medical camps etc. in the neighbourhood. Thus, the proposed project shall usher in the social and economic up-liftment of the persons living in the vicinity of the Project i.e. of society at large. M/s. Shri Gang Industries & Allied Products Limited 29