S. NO. CONTENTS PAGE NO. 1.0 EXECUTIVE SUMMARY INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION PROJECT DESCRIPTION

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2 INDEX S. NO. CONTENTS PAGE NO. 1.0 EXECUTIVE SUMMARY INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION PROJECT DESCRIPTION SITE ANALYSIS PLANNING BRIEF PROPOSED INFRASTRUCTURE REHABILITATION AND RESETTLEMENT (R & R) PLAN PROJECT SCHEDULE & COST ESTIMATES ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) 35 i

3 PRE - FEASIBILITY REPORT 1.0 EXECUTIVE SUMMARY (i) Introduction M/s. Oasis Ethanol Industries Pvt. Ltd. is proposing 320 KLPD Molasses/Grain Based Distillery, 6 KLPD Malt Spirits Plant & 15 MW Co-generation Power Plant at Village Jatwar, Block Shahzadpur, Tehsil Naraingarh, District Ambala (Haryana) Molasses will be used as a raw material in molasses based operation which is available from nearby sugar mills. Grains such as damaged grain feed stock, broken rice, maize, bajra & sorghum, starchy materials etc will be used as raw material for Grain based operation, which are easily available from the local market. As per EIA Notification dated 14 th September, 2006 and as amended from time to time, the project falls under Category A, Project or Activity 5(g) Distillery project & Category B, Project or Activity 1 (d) 15 MW Co-generation Power Plant (Biomass based). TABLE 1 Salient Features of the Project S. No. Particulars Details A. Nature of Project Proposed Project B. Size of the Project Units Proposed Capacity Molasses / Grain based Distillery 320 KLPD Malt Spirits Plant 6 KLPD Co- generation Power Plant 15 MW C. Location Details Village Jatwar Block Shahzadpur Tehsil Naraingarh District Ambala State Haryana Latitude 30 25'33.70"N to 30 25'54.79"N Longitude 76 55'17.65"E to 76 55'27.33"E Toposheet No. H43K15, H43K14 & H43L3 D. Area Details, Total Project Area 25 Acres ( ha) Greenbelt & Plantation Area 3.33 ha (8.25 Acres) i.e. 33% of the plant area will be developed under greenbelt & plantation. E. Environmental Setting Details (with approximate aerial distance & direction from plant site) 1. Nearest Village Chhajju Majra (~ 0.70 km in SSE direction) 2. Nearest Town & City Ambala City (~ km in SW direction) M/s. Oasis Ethanol Industries Pvt. Ltd. 1

4 3. Nearest National Highway / NH 72 (~ 0.30 km in South direction) State Highway 4. Nearest Railway station Ambala Cantt. Railway Station (~ km in SW direction) 5. Nearest Airport Ambala Air force station (~ km in SW direction) Chandigarh Airport (~ 30.0 km in NNW direction) 6. Defence installations Ambala Cantt. (~ 10.5 km in SW direction) Ambala Air force station (~ km in SW direction) 7. State boundaries Interstate Boundary (Punjab - Haryana) (~ 0.60 km in SW direction) 8. National Parks, Wildlife No National Parks, Wildlife Sanctuaries, Biosphere Reserves, Sanctuaries, Biosphere Tiger/ Elephant Reserves, Wildlife Corridors, Reserved Forest Reserves, Tiger/ Elephant (RF)/ Protected forest (PF) etc. lies within 10 km radius of the Reserves, Wildlife Corridors, plant site. Reserved Forest (RF)/ Protected forest (PF) etc. within 10 km radius 9. Water Body (within 10 km Dangri Nadi (~ 0.50 km in West direction) radius) Baliali Nadi (~ 0.80 km in SE direction) Dhanana River (~ 3.5 km in SE direction) Amri Nadi (~ 5.0 km in SSE direction) Choa Nala (~ 5.2 km in WNW direction) 10. Seismic Zone Seismic Zone - IV (High Damage Risk Zone) as per IS: 1893 (Part-I): A. Cost Details Total cost of the project Rs Crores Cost for Environment Capital Cost: Rs Crores Management Plan Recurring Cost: Rs. 8.0 Crores/annum B. Basic Requirements for the project Water Requirement (KLD) Fresh Water requirement Operation Mode Distillery Cogeneration Power Plant Malt Plant Total Water Power Requirement (kwh) Man Power Requirement Molasses based operation Grain based operation 3190 KLPD 210 KLPD 94 KLPD or KLPD 94 KLPD KLPD Source - Ground water 3494 KLPD 3100 KLPD Total power required will be 11.0 MW. Source: 15 MW Co-Generation Power Plant Total manpower required will be 150 persons Source: Unskilled / Semi-Skilled - local area; Skilled Local & outside areas M/s. Oasis Ethanol Industries Pvt. Ltd. 2

5 C. Product Ethanol, ENA (Extra Neutral Alcohol)/RS, Industrial Alcohol, Malt Spirits & Power D. By-products CO2 E. Working Days 350 days/annum 1.1 ENVIRONMENT MANAGEMENT PLAN Air Quality Management: ESP with stack of adequate height will be installed with the boiler to control the particulate and gaseous emissions due to combustion of fuel. CO2 generated during the fermentation process will be recovered by CO2 Scrubbers and sold to beverage & packaging industry. DG Sets will have adequate stack height as per CPCB guidelines. All the internal roads will be asphalted. Online stack monitoring system will be installed. Greenbelt will be developed all around the plant boundary and within the plant premises. Regular monitoring will be done to ensure that ambient air quality standards are met all the time. Water Quality Management: The distillery will be based on Zero Effluent Discharge. During Molasses Based Operation: The spent wash will be concentrated in MEE and the concentrated spent wash will be mixed with auxiliary fuel and burnt in the incinerator boiler. Process Condensate will be neutralized and treated in state of art Condensate Polishing Unit (CPU) and recycled in Fermentation process and for Cooling Tower makeup. During Grain Based Operation: Grain Slops (Spent Wash) will be passed through centrifuge decanters for separation of suspended solids separated as Wet Cake (also known as DWG Distillers Wet Grains). Thin Slops from the Decanter Centrifuge will be partly recycled back to process (20% to 35%) and the balance will be fed to Thin Slop Evaporation Plant for concentration of remaining solids to form Syrup (35% TS). DWGS Drier: The Wet Cake and Syrup mixture (DWGS) will be dried in Steam Tube Bundle Dryer for producing DDGS with 8-10% moisture (max.). The DDGS will be utilized as Cattle, poultry and fish feed ingredients. The process condensate will be treated in condensate treatment plant. The treated water will be recycled back in cooling tower makeup. M/s. Oasis Ethanol Industries Pvt. Ltd. 3

6 Domestic waste water generated from the plant will be treated in STP. Rain Water harvesting will be done within the plant premises. Noise Management: Personal Protective Equipment like earplugs and earmuffs will be provided to the workers exposed to high noise level. D.G. sets will be provided with acoustic to control the noise level within the prescribed limit. Proper maintenance, oiling and greasing of machines at regular intervals will be done to reduce generation of noise. Greenbelt of appropriate width inside the plant premises and at the plant boundary will be developed. Regular monitoring of noise level will be carried out and corrective measures in concerned machinery are also being done. Solid & Hazardous Waste Management: During Molasses based operation: The concentrated spent wash from molasses based distillery will be burnt in incinerator boiler along with Biomass as fuel (15% coal will also be used as auxiliary fuel). During Grain based operation: 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. Yeast sludge will be sent to the sludge drying beds or may be added to the wet cake. Ash from the boiler will be given to brick manufacturing unit. ETP sludge will be dewatered using filter press and will be used as manure. Used oil & grease generated from plant machinery/gear boxes as hazardous waste will be sold out to the CPCB authorized recyclers. Greenbelt Development & Plantation: Out of the total plant area of 3.33 ha (8.25 Acres) i.e. ~33 % of the total plant area will be developed under greenbelt & plantation. Native plant species will be planted in consultation with local horticulturist. Greenbelt development along with the road & plant boundary attenuates noise level; arrest dusts and improve the environment in plant-surroundings. Odour Management: Adequate greenbelt all around the periphery of the plant. Efficient CO 2 scrubbing to avoid carryover of alcohol vapours & other fumes. DWGS dryer will be installed for complete drying of solids. M/s. Oasis Ethanol Industries Pvt. Ltd. 4

7 Better housekeeping, hygienic conditions will be maintained inside as well as surrounding areas of the plant. Regular use of disinfectants in the drains to avoid generation of putrefying microorganisms. 2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION: (i) Identification of Project and Project Proponent: The Company M/s Oasis Ethanol Industries Pvt. Ltd. hereinafter referred as OEIPL. Initial object of the company was to deal in Liquor and allied products, Hotel Industry etc. Presently Company is engaged manufacturing of ENA, IMFL and country liquor. Entire shares of the company are owned by Malhotra Family, their relatives and associate concerns. Oasis Group owned by Malhotra Family, Delhi Based promoters are well known and highly reputed in the liquor business. The Group has wide distribution network for both Indian and foreign made liquor in number of states. They have been engaged with this activity for more than 5 decades. At present the group owners five running State of art Grain based distilleries & three bottling units with a collective grain spirit production of more than 17 crore liters per annum. Group has Strong presence in Punjab, Haryana, Delhi, M.P., Rajasthan, Kerla, Telangana, Orrisa, J&K, Himlachal Pradesh. Group is the largest exporter of Grain Based ENA from Northern India; it is exporting ENA and IMFL to various countries in African Continent. The Oasis Group is a highly reputed conglomerate with diverse interests that include Distillery, Liquor Retailing, Hotels and Constructions. The Group s rapid growth on Indian corporate scene rests on its strong foundation of professional management and astute collective enterprises. Over the last 17 years, the Group has grown into a diversified business and industrial house with a high growth rate and a total commitment to persistent growth. The Group has a team of highly qualified, experienced, trusted persons with a right mix of technocrats, Finance Experts and management professionals. The Group is now planning to diversify in to other related area like Ethanol Production and foreseeing the potentiality of Ethanol. The Core business strength of the group is alcohol production, manufacturing and marketing of grain based Indian made foreign liquor. Oasis is one of the largest wholesalers, retailers and excise contractor of the Punjab State. They have established themselves in the field of alcohol manufacturing, Indian made foreign liquor, country liquor etc; the group is also generating their own power, harnessing carbon di-oxide (CO2) and also marketing Dried distilled grain soluble (DDGS) which has large market in the cattle field industry. M/s. Oasis Ethanol Industries Pvt. Ltd. 5

8 The group enjoys very important position amongst the liquor companies in north India by virtue of owning two grain based distilleries and a bottling unit in the state of Punjab, two State of art grain based distilleries in the state of Haryana and the oldest grain based distillery unit in the state of Madhya Pradesh besides one bottling unit each in the Rajasthan and Chandigarh, thus making the group a formidable player in the North India which is further supported by a very strong presence in whole sale and retail liquor distribution in the State of Punjab. Two of the brands of the group are enlisted with the canteen stores department for supply to prestigious Indian Armed Forces. The Group has its own international exports division which is exporting grain based ENA and IMFL brands outside the country. Presently the group is exporting on an average about containers a month outside India. (ii) Brief description of nature of the project: M/s. Oasis Ethanol Industries Pvt. Ltd. is proposing 320 KLPD Molasses/Grain Based Distillery, 6 KLPD Malt Spirits Plant & 15 MW Co-generation Power Plant at Village Jatwar, Block Shahzadpur Tehsil Naraingarh, District Ambala (Haryana) Molasses will also be used as a raw material in molasses based operation which is available from nearby sugar mills. 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 September, 2006 and as amended from time to time, the project falls under Category A, Project or Activity 5(g) (i) Distillery project & Category B, Project or Activity 1 (d) 15 MW Co-generation Power Plant (Biomass based). (iii) Need for the project and its importance to the country and/ or region: Advancement in science and technology has created so many products that have enhanced the quality of human life in every passing year. The human race is largely dependent on industrialization for up gradation in quality of life. Progress of the nation is judged through its economic growth which is largely dependent on industrial productivity. In Indian economy (which is agro based) many industries are dependent over agricultural produce for production of luxury and need based commodities. Alcohol has assumed a very important place in the Country s economy. It is a vital raw material for a number of chemicals. It has been a source of revenue by way of excise duty levied by the State Government on alcohol liquors. It has a potential as fuel in the form of power alcohol for blending with petrol in the ratio of 20:80. The use of alcohol for the purpose of potable liquor is as high as its use for industrial purposes. M/s. Oasis Ethanol Industries Pvt. Ltd. 6

9 According to analysts, the Indian alcoholic beverages industry is expected to witness accelerating growth in coming years with the consumer base likely to expand amidst rising disposable income. The domestic alcoholic drinks market is estimated around $13 billion and has been growing at a compounded annual growth rate in excess of 10% in the past few years. The growth rate is higher than other major Asian markets like China and South Korea, etc. In the path of company s growth and development this project will serve as yet another milestone. (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 producing more alcohol to meet the demand. (vi) Export Possibility: There will be possibility of export of alcohol to African, European & Asian countries.. (vii) Domestic / export Markets Market depends on Excise Department. (viii) Employment Generation (Direct and Indirect) due to the project: Direct and indirect employment will be generated due to the project. The total manpower requirement for the project will be 150 persons. Unskilled / semi-skilled manpower will be sourced from the local area and skilled manpower will be sourced from outside / local. 3.0 PROJECT DESCRIPTION: (i) Type of project including interlinked and independent projects, if any. There are no interlinked projects related to this project. (ii) Location (map showing general location, specific location, and plant boundary & plant site layout) with coordinates M/s. Oasis Ethanol Industries Pvt. Ltd. 7

10 Figure - 1: Location Map M/s. Oasis Ethanol Industries Pvt. Ltd. 8

11 At Village Jatwar, Block Shahzadpur,Tehsil Naraingarh, District Ambala (Haryana) Figure - 2: Key Plan M/s. Oasis Bio Ethanol Industries Pvt. Ltd. 9

12 At Village Jatwar, Block Shahzadpur,Tehsil Naraingarh, District Ambala (Haryana) Pre - feasibility Report (iii) 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. Raw material availability & markets for both products & by-products within the state. Nearness to National Highway 72 makes it easier to transport raw materials & final product to market. (iv) Size or magnitude of operation M/s. Oasis Ethanol Industries Pvt. Ltd. is proposing 320 KLPD Molasses/Grain Based Distillery, 6 KLPD Malt Spirits Plant & 15 MW Co-generation Power Plant at Block: Shahzadpur, Village Jatwar, Tehsil Naraingarh, District Ambala (Haryana) 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 Total Proposed Capacity 1. Molasses / Grain based Distillery 320 KLPD 2. Malt SpiritS Plant 6 KLPD 3. Co-generation Power Plant 15 MW (v) Project description with process details (a schematic diagram/ flow chart showing the project layout, components of the project etc. should be given) FOR MOLASSES BASED OPERATION i) Molasses Unloading and Storage Molasses from tankers will be unloaded at unloading point and transferred in to molasses storage tank. ii) Fermentation: Yeast Activation: Yeast seed material is prepared in water-cooled Yeast Activation Vessel by inoculating sterilized mash with Active Dry Yeast. Optimum temperature is maintained by cooling water. The contents of the Yeast Activation Vessel are then transferred to Pre - Fermenter. Fermentation: The Molasses from storage tank is pumped to Dilutor installed in Fermentation section and diluted with water. The diluted Molasses called Wort is fed into Pre Fermenter for activation of Yeast. The activated yeast from the Yeast activation vessel is transferred into pre fermenter. M/s. Oasis Ethanol Industries Pvt. Ltd. 10

13 At Village Jatwar, Block Shahzadpur,Tehsil Naraingarh, District Ambala (Haryana) Pre - feasibility Report Once the yeast is activated in Pre fermenters it will be transferred in to fermenters and diluted molasses is to be add. The process of fermentation is to convert the fermentable substrate into alcohol. The ph of the wort is adjusted by the addition of acid. Yeast is available in sufficient quantity to initiate fermentation rapidly and complete it within the cycle time. Significant heat release takes place during fermentation. This is removed by passing cooling water through the Fermenter PHE s to maintain an optimum temperature. The recirculating pumps also serve to empty the fermenters into Beer Well. After the fermenters are emptied, they are cleaned with water and sterilized for the next batch. The carbon dioxide evolved during the process is vented to atmosphere after recovery of alcohol in a scrubber. iii) Distillation: Fermented wash from wash holding tank / beer well is pumped by wash feed pump to the top of degassing column after preheating the same in beer heater and spent wash heat exchanger. The vapours along with non-condensable gases from the top of degassing column are rectified in Heads column, to expel the high volatiles, technically known as heads. Bottom liquid from the degasser flows into analyzer column where alcohol is stripped from the liquid. The liquid from bottom of analyzer column is completely stripped of alcohol and is pumped out by thick slop discharge pump through heat exchanger where it preheats the fermented wash before it enters degassing column. The slop from the analyser column will be feed in to MEE. The dilute alcohol vapours from near the top of analyzer column are condensed first in beer heater while exchanging heat with wash feed and then in analyzer condenser. Degasser and analyzer operate under vacuum. The condensate from beer heater and analyser condenser is collected in Rectifier Feed Tank. The vapours for stripping alcohol are generated from analyzer column bottom liquid in the analyzer column re-boiler by using the rectified column top vapours, as discussed subsequently. Vapours from the top of heads column are condensed in heads column condenser and then in head column vent condenser. Part of the condensate is returned to column as reflux while a small portion is taken out as an impure spirit cut. Liquid from bottom of heads column is also taken into Rectifier feed tank. Dilute alcohol water mixture from rectifier feed tank is pumped by rectifier feed pump through rectifier feed pre-heater in to rectifying column. Rectifier and its associated equipment work under pressure so that these vapours can supply the necessary heat for generating the vapours. M/s. Oasis Ethanol Industries Pvt. Ltd. 11

14 At Village Jatwar, Block Shahzadpur,Tehsil Naraingarh, District Ambala (Haryana) Pre - feasibility Report The condensate from analyser column reboiler is then pumped as Reflux to rectifying column. Rich alcohol vapors at a concentration of 95.5% v/v from top of rectifying column are condensed first in Analyzer reboiler and then in Reflux Vent Condenser. The liquid is then collected in Rectifier Reflux Tank. Part of the liquid from vent condenser may be drawn off as impure spirit. The impure spirit cut will be maintained as little as possible to maintain aldehyde levels to meet the required limits in Absolute Alcohol. Liquid from the rectifier reflux tank is pumped by Product Pump partly as product and partly as reflux to the top of the Rectifying Column. The necessary rectifying vapours to rectifying column are generated by boiling the bottom liquid in Rectifier Column Re-boiler by using medium pressure steam. Some side streams are drawn from rectifier column as light and heavy fractions of higher alcohols called fusel oils and cooled in fusel oil coolers. These are mixed with water and allowed to separate out in fuel oil separator. All vents from condensers are connected to Vent Gas Absorber where the vent gases are scrubbed with water to recover entrained alcohol. The scrubber water is used for washing the fuel oils in fuel oil separator to recover alcohol from the fuel oil fractions. The absorber vent is connected to vacuum pump which is used to create vacuum in the respective columns. The remaining process is same as mentioned under grain based distillation and the product ENA shall be sent for storage. iv) Alcohol Daily Receivers & Bulk Storage: Alcohol is first taken to Daily receiver storage a tank is thereafter transferred to Bulk Storage Tanks after taking the daily receiver Dip. This is transferred using flameproof pumps. Final dispatch of alcohol is again carried out using special flameproof pumps. EFFLUENT HANDLING SECTION i) Evaporation Section: The spent wash coming from Distillation section will be fed in to first calendria of the evaporator section. The multi effect evaporator (MEE) shall be designed to concentrate the dissolved solids. Suggested treatment scheme is FF + Finisher Evaporation Plant for spent wash Evaporation. The following points will elucidate the basic working principle: Shell & Tube type Evaporators with highly efficient liquid distributor working on the principle of Falling Film & Forced Evaporation have been used, with Preheaters for preheating of FEED stream which serves the purpose of energy conservation. Vapours generated in 1st effect VLS (Vapour Liquid Separator) are used as heat source in the 2 nd effect and from 2nd to third and so on. M/s. Oasis Ethanol Industries Pvt. Ltd. 12

15 At Village Jatwar, Block Shahzadpur,Tehsil Naraingarh, District Ambala (Haryana) Pre - feasibility Report The product at the desired concentration of TS is obtained at the outlet from the final effect, A Shell & tube type Multi-pass Surface condenser is employed for condensing the shell side vapours. The Pure and the process condensate are collected in receiving vessels. Highly efficient operating pumps will be provided for pumping the required fluid. The operation of the plant will be under vacuum. Vacuum is created with the help of a water ring vacuum pump. The plant will have high level of automation to get consistent output at required concentration. Cooling water from cooling tower is used in the surface condensers for condensing the vapours. ii) Incinerator boiler: The concentrated molasses based effluent shall be burnt in Incinerator boiler along with other biomass fuels (15% coal will also be used as auxiliary fuel) to generate high pressure steam. M/s. Oasis Ethanol Industries Pvt. Ltd. 13

16 At Village Jatwar, Tehsil Naraingarh, District Ambala (Haryana) Pre - feasibility Report Figure 3:- Process flow diagram of Molasses based Distillery M/s. Oasis Ethanol Industries Pvt. Ltd. 14

17 At Village Jatwar, Tehsil Naraingarh, District Ambala (Haryana) Pre - feasibility Report Process Description of Grain Based Distillery Operation A) Grain Storage Silos, Cleaning, Handling and Milling Section: Grain is received from various sources and is pre-cleaned off stones, husk, etc. and then stored in specially designed storage silos or in bags in storage yard. Grains are continuously lifted from the bottom of the silos, screened and followed by removal of stones in de-stoner and iron matters in magnetic separators. Cleaned Grains are then milled using dry milling process in Hammer Mills. The flour is fed through the bucket elevator and conveyed to the flour silo. B) Liquefaction Section Grain flour is mixed with recycle streams and water in Pre-masher and slurry is fed to Liquefaction tank. Required temperature is maintained by applying steam through steam sparger in liquefaction 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 liquefied mash is cooled in slurry cooler and transferred to Fermentation section. C) Fermentation Section 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 recirculation pumps also serve to empty the Fermenters into Beer Well. CO2 evolved during fermentation carries along with it some entrained alcohol. This CO2 is taken to a CO2 scrubber where it is washed with water to remove the entrained alcohol. The scrubbed CO2 can then be taken to CO2 plant or 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. D) MPR Distillation Wash to ENA: Multi-Pressure Distillation system has eight Distillation columns operating at various pressure conditions. Heat energy from columns operating under high pressure is utilized for columns operating under low pressure to optimize the operation for energy consumption. Following Columns will be under operation M/s. Oasis Ethanol Industries Pvt. Ltd. 15

18 At Village Jatwar, Tehsil Naraingarh, District Ambala (Haryana) Pre - feasibility Report Analyser Column Degasifying Column Pre-Rectifier Column cum Exhaust Column Extractive Distillation Column Rectifier cum Exhaust Column Recovery Column Simmering Column Pre-heated fermented wash is fed at the top of the Degasifying column. Analyser Column is provided with Reboiler. Top vapors of Analyser column containing all the alcohol in the wash are sent to Pre-Rectifier column. Rest of the fermented wash flows down the Analyser column and is taken out as thick slops 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 Pre rectifier column, which further is sent to Extractive Distillation column. Dilution water is fed to this column. The Extractive Column operates on the principle of inversion of relative volatility. Low boiling impurities are separated in the Extractive Distillation Column & bottom is sent to Rectifier cum Exhaust column. The Rectifier/Exhaust column concentrates the alcohol to 96% v/v. The spirit is drawn from the upper trays of the Rectification Column. Fusel oil build up is avoided in the Rectifier cum exhaust column by withdrawing side streams (fusel oils). ED condensates, fusel oil draw from R/E column are sent to Recovery column where these fusel oils are concentrated and then sent to decanter where these streams are diluted with water and fusel oil rich layer is separated. Washings are sent back to the column to recover alcohol. The 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. E) Decantation Section Excluding Decanter Centrifuges Decantation section comprises of a Centrifuge Decanters for separation of suspended solids from Thick slop coming out of Grain Distillation Plant. Wet cake is removed from bottom of Decanter. Thin slops coming out of Decanter are collected in a tank and partly recycled into the process & balance to Evaporation for further concentration. The concentrated thin slops called as Syrup is mixed with Wet cake and sold in wet form as cattle feed (DWGS) or the entire mixture can be dried in a DWGS Dryer and then sold in dry form as Cattle feed (DDGS). M/s. Oasis Ethanol Industries Pvt. Ltd. 16

19 At Village Jatwar, Tehsil Naraingarh, District Ambala (Haryana) Pre - feasibility Report F) Integrated Evaporation The suggested treatment scheme is a Multi Effect Evaporation Plant for Thin Slop Evaporation. Shell & Tube type Evaporators with highly efficient liquid distributor working on the principle of Falling Film and Forced circulation Evaporation are being used. The product at the desired concentration of 30%w/w Total Solid is obtained at the outlet of the final effect. Each effect is provided with recirculation cum transfer pumps. The condensate from surface condensers is collected in a common condensate pot. The condensate is transferred for further treatment by using centrifugal pump. The system operates under vacuum. Water-ring vacuum pumps are used to maintain a desired vacuum. Cooling water from cooling tower is used in the surface condensers for condensing the vapours. G) DWGS Dryer Section Wet distiller s grains shall be fed into the dryer housing at controlled rate through a suitable feeding system. The Rotary Bundle is enclosed in an insulated dryer housing and on its outer flights are fixed. Dry, saturated steam is to be supplied to the 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 Local Indication cum Control panel. G) Process Condensate Treatment Section The process condensate from the evaporation section is treated in this unit and this treated condensate is then recycled back to process thus reducing the fresh water consumption. M/s. Oasis Ethanol Industries Pvt. Ltd. 17

20 At Village Jatwar, Tehsil Naraingarh, District Ambala (Haryana) Pre - feasibility Report Figure 4:- Process flow diagram of Grain based Distillery M/s. Oasis Ethanol Industries Pvt. Ltd. 18

21 Malt Spirits Plant (6 KLPD) Malt Spirits Production process is given below: Malt handling- Malt is usually stored in silos before being milled and mashed. It has a low moisture content of between 3 and 5%. The main processes in malt handling are Intake, storage, conveying, removing unwanted materials & stones, weighing. Milling - The objective of milling is to reduce the malt to particles sizes, which will yield the most economic extract (wort) and will operate satisfactorily under brewhouse conditions and throughout the brewing process. The more extensive the malt is milled, the greater the extract production. Mashing- Mashing is the process of combining a mix of milled grain (typically malted barley with supplementary grains such as corn, sorghum, rye or wheat), known as the "grain bill", and water, known as "liquor", and heating this mixture. Mashing allows the enzymes in the malt to break down the starch in the grain into sugars, typically maltose to create malty liquid called wort. Fermentation- Fermentation is an essential stage in the brewing process. It involves adding yeasts to the cooled malt. These yeasts are fed by the amino acids in the brew and produce alcohol from the sugar that is present. These natural reactions also produce carbon dioxide. Pot Distillation- Malt Whisky is distilled twice - although a few distilleries may undertake a third distillation - in Pot Stills which resemble huge copper kettles. The spirit is driven off from the fermented liquid as a vapour and is then condensed back to a liquid. In the first distillation the fermented liquid, or wash, is put into the Wash Still which is heated either directly by fire or by steam-heated coils. At this stage the wash contains yeast, crude alcohol, some unfermentable matter and the by-products of fermentation. During the process of boiling the wash, changes take place in its constituents which are vital to the flavour and character of the whisky. As the wash boils, vapours pass up the neck of the still and then pass through a water-cooled condenser or a worm, a coiled copper pipe of decreasing diameter enclosed in a water jacket through which cold water circulates. This condenses the vapours and the resulting distillate, known as low wines, is collected for re- distilling. The liquor remaining in the Wash Still is known as pot ale or burnt ale and is usually treated and converted into distillers' solubles for animal feed. Decantation- The decantation section comprises of a Centrifuge Decanter for separation of suspended solids from Spent Wash coming out of distillation Plant. M/s. Oasis Ethanol Industries Pvt. Ltd. 19

22 Wet cake/dwgs- Spent grains also known as DWGS, has a commercial value and can be sold as by-products for livestock feed or 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. Figure 5: Process flow diagram of Malt Spirit production Power Co-Generation (15 MW) operations The unit proposes to set-up boiler and power turbine. 55 TPH X 2 Incineration boiler for molasses operation. This Boiler will operate mainly to feed steam to molasses based operations and 15.0 MW power generations from Turbine. For Grain operation 90TPH boiler (88 ata / 520 deg.c) with 15 MW Turbo Generator will be installed and based on biomass/rice Husk/ Bagasse/ Paddy & Wheat Straw along with 15% coal used a auxiliary fuel. This Boiler will operate mainly to feed steam to grain based operations and 15.0 MW power generations from Turbine. Proposed 15 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 preheat 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 M/s. Oasis Ethanol Industries Pvt. Ltd. 20

23 the fuel. After air pre heaters flue gases pass through Bag Filter where the dust particles are collected. The dust is collected from here. High pressure superheated steam from boiler is passed through a steam turbine, which is 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 is generated by the alternator. This electric power generated is consumed in house i.e. for running the distillery and utilities like boiler auxiliaries etc. Surplus power can be exported to Grid. Figure 6: Process flow chart for Proposed Co-generation Power Plant (vi) 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: The basic raw material for the manufacturing of Ethanol will be Molasses & ENA/RS will be Grain or Molasses. Molasses will also be used as a raw material in molasses based operation which is available from nearby sugar mills. 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. The raw material for the boiler fuel will be various biomasses (15% coal will also be used as auxiliary fuel) such as Rice Husk/ paddy straw/ cow dung/ poultry waste etc and concentrated spent wash for incineration when the distillery is operated on molasses. M/s. Oasis Ethanol Industries Pvt. Ltd. 21

24 S. No. Particular TABLE - 2 Raw Material Requirement Total Requirement Source & Mode of Transportation 1 Molasses 1523 MT/day From nearby sugar mill & suppliers by tankers (road) Or Grain - Broken Rice, Sorghum, Baira, Maize etc MT/day Through Grain suppliers By road 2. Barley Malt 12 MT/Day Through Malt suppliers By road 3. Process Chemicals Near-by Markets by road Sodium Hydroxide (Caustic) Nutrients Enzymes Antifoam Agent Yeast (Active Dry Yeast/Distiller s Yeast) (b) Operation Mode Molasses based operation Grain based operation Fuel Requirement for Boilers: 1350 Kg/day 500 Kg/day 450 Kg/day 250 Kg/day 60 Kg/day During Molasses based operation - Concentrated Spent Wash and Bagasse / Rice husk / Indian coal will be used for the proposed boiler of 55 TPH X 02 NOS During Grain based operation Biomass (15% Coal to be used as auxiliary fuel) will be used for the proposed boiler of 90 TPH. Details regarding fuel requirements are given below. TABLE 3 Fuel Requirement Name of Raw Material Total Requirement Source & Mode of Transportation Concentrated Spent Wash and Biomass (15% Coal to be used as auxiliary fuel) or Biomass (15% Coal to be used as auxiliary fuel) Spent wash Slop= 569 MT/Day, Biomass =315 MT/Day & Coal = 100 MT / Day Biomass =465 MT/Day & Coal = 81 MTPD Spent wash - Own plant through pipelines biomass - From authorized dealers by road M/s. Oasis Ethanol Industries Pvt. Ltd. 22

25 (vii) Resources optimization/ recycling and reuse envisaged in the project, if any, should 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. (viii) Availability of water it s source, energy /power requirement and source should be (a) given. Water Requirement and Source Total fresh water requirement for the project (Distillery, Malt Plant & Co-gen) will be 3494 KLPD during Molasses based operation & 3100 KLPD during Grain based operation which will be sourced from Ground Water TABLE 4 Fresh Water requirement Fresh Water requirement Operation Mode Distillery Co-generation Power Plant Malt Plant Total Water Molasses based operation 3190 KLPD 210 KLPD 94 KLPD 3494 KLPD or Grain based operation 2536 KLPD 470 KLPD 94 KLPD 3100 KLPD Source - Ground water Water Requirement for proposed project during Molasses based operation The water requirement for the first run for project would be KLPD, which will be further reduced through recycling & reuse to 8841 KLPD. Hence, fresh water requirement is 3494 KLD. Details given below: Distillery (KLPD) Malt Plant (KLPD) Co-gen Power Plant Total (KLPD) (KLPD) Total Water Requirement Total Recycling Total Reuse ( after treatment ) Water Quantity Reduced Net Fresh Water Requirement M/s. Oasis Ethanol Industries Pvt. Ltd. 23

26 Figure 7: Water balance for 320 KLPD Molasses based Distillery Figure 8: Water balance for Co-generation Power Plant M/s. Oasis Ethanol Industries Pvt. Ltd. 24

27 Figure 9: Water balance for 6 KLPD Malt Spirits Plant Operation M/s. Oasis Ethanol Industries Pvt. Ltd. 25

28 Water Requirement for proposed project during Grain based operation The water requirement for the first run for project would be KLPD, which will be further reduced through recycling & reuse to 7046 KLPD. Hence, fresh water requirement is 3100 KLD. Details given below: Distillery Malt Plant Co-gen Power Plant Total Total Water Requirement Total Recycling Total Reuse ( after treatment ) Water Quantity Reduced Net Fresh Water Requirement M/s. Oasis Ethanol Industries Pvt. Ltd. 26

29 Figure 10: Water balance for 125 KLPD Grain based Distillery Operation M/s. Oasis Ethanol Industries Pvt. Ltd. 27

30 Figure 11: Water balance for 6 KLPD Malt Spirits Plant Operation M/s. Oasis Ethanol Industries Pvt. Ltd. 28

31 S. No. (b) Figure 12: Water balance for Co-generation Power Plant Power Requirement and Source The total power requirement will be 11.0 MW, which will be sourced from 15 MW Co- Generation Power Plant. Surplus power can be exported to Grid. (c) Steam Requirement Total Steam requirement will be met by boiler (55 TPH X 02 nos Incineration Boiler for Molasses Operation & 90 TPH Boiler for Grain Operation) The steam requirement for different purposes is given below: (d) TABLE 5 Steam Requirement S. No. Purpose Steam (TPH) 1 Steam for Distillery During Molasses based operation - 75 TPH Or During Grain based operation - 75 TPH 2 Steam for Malt Spirits 3.7 TPH Boiler Details: Details regarding boilers are mentioned in the table given below: Item TABLE 6 Boiler Details Boiler details 1. Boiler Capacity For Molasses based operation 55 TPH X 2 Nos 2 Type of Fuel Spent wash Slop & Biomass (15% coal will be used as auxiliary fuel) 3. Stack Height 65 Metres 65 Metres 4. Pollution Control ESP ESP Equipment Measures For Grain based operation 90 TPH Biomass (15% coal will be used as auxiliary fuel) M/s. Oasis Ethanol Industries Pvt. Ltd. 29

32 (e) Details regarding the D.G. Sets 2 nos. of D. G. Sets of capacity 1500 KVA each will be installed with the plant for emergency back-up. Details regarding the D.G. Sets are mentioned in the table given below: TABLE 7 Details Regarding the D.G. Sets S. No. Details 1. Type of Fuel HSD 2. Capacity 2 x 1500 KVA 3. Stack Height (above roof level) As per CPCB/SPCB norms 4. Pollution Control Equipment Measures Adequate stack height/ Acoustic Enclosure (ix) Quantity of Waste to be generated (liquid and solid) and Scheme for their Management/Disposal: Waste Water Generation and management: The project will be based on ZERO EFFLUENT DISCHARGE. Fresh water requirement of the project will be met by ground water. Efforts will be made to conserve as much water as possible by recycling and reusing waste water. Molasses slops (spent wash) shall be concentrated in evaporators and incinerated in boiler. Grain Slops (Spent Wash) will be taken through Decanters Centrifuge for separation of Suspended Solids separated as Wet Cake. Thin Slops from the Decanter Centrifuge will be partly (20%) recycled back to Liquefaction Process), partly (20%) used in Analyser Column Reboiler for flash steam generation under vacuum and the balance (60%) taken to Multi Effect Evaporation Plant for concentration of thin slop to form a Syrup. This Syrup as Condensed Distillery Solubles (CDS) is mixed with the Wet Cake coming out of Decanter Centrifuge and the mixture is known as Distillers Wet Grain with Solubles (DWGS). DWGS will be fed to Dryers operating on steam and is dried to make it DDGS Distillers Dried Grain with Solubles. Process condensate is cooled and collected into an equalization tank with sufficient residence time. After equalization, this process condensate will be fed for Ecophotox and after treatment it will be used for greenbelt 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 given to brick manufacturing unit. Used oil & grease generated from plant machinery / gear boxes & D.G. Set will be partly used in oiling & greasing as lubrication of external parts of machinery & partly will be sold to the CPCB authorized recycler. M/s. Oasis Ethanol Industries Pvt. Ltd. 30

33 4.0 SITE ANALYSIS (i) Connectivity Plant site is well connected to NH 72 at about ~ 0.3 km in South direction. The nearest railway station is Ambala Railway Station (~ 13.5 km in SW 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 plant site. (ii) Land from Land use and Land ownership S. No. Total plant area i.e ha (25 Acres) has already been acquired by the company. (iii) Topography Topography of the core zone of the 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 Particulars Environmental Settings of the Area Details (with approximate aerial distance and direction from project site) 1. Nearest Village Chhajju Majra (~ 0.70 km in SSE direction) 2. Nearest Town & City Ambala City (~ km in SW direction) 3. Nearest National Highway / State NH 72 (~ 0.30 km in South direction) Highway 4. Nearest Railway station Ambala Cantt. Railway Station (~ km in SW direction) 5. Nearest Airport Ambala Air force station (~ km in SW direction) Chandigarh Airport (~ 30.0 km in NNW direction 6. Defence installations Ambala Cantt. (~ 10.5 km in SW direction) Ambala Air force station (~ km in SW direction) 7. State boundaries Interstate Boundary (Punjab - Haryana) (~ 0.60 km in SW direction) 8. National Parks, Wildlife Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors, Reserved Forest (RF)/ Protected forest (PF) etc. within 10 km radius No National Parks, Wildlife Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors, Reserved Forest (RF)/ Protected forest (PF) etc. lies within 10 km radius of the plant site. 9. Water Body (within 10 km radius) Dangri Nadi (~ 0.50 km in West direction) Baliali Nadi (~ 0.80 km in SE direction) M/s. Oasis Ethanol Industries Pvt. Ltd. 31

34 Dhanana River (~ 3.5 km in SE direction) Amri Nadi (~ 5.0 km in SSE direction) Choa Nala (~ 5.2 km in WNW direction) 10. Seismic Zone Seismic Zone - IV (High Damage Risk Zone) as per IS: 1893 (Part-I): (v) Existing Infrastructure There is no existing infrastructure within the project site. (vi) Soil classification The district area is occupied by Indo-Gangetic alluvim. There are no surface features worth to mention except that the area is traversed and drained by seasonal streams namely Tangri, Beghna and Markanda. Physiographically the area is flat terrain. However a little part in the extreme north-eastern area of the district is occupied by Siwalik hills, and falls in the zone of Dissected Rolling Plain. The area slopes towards southwest with an average gradient of 1.5m/km. The general elevation in the district varies between 245 m to 300 m above MSL. The soils are non-calcareous and sandy loam on the surface, and loam to clayey loam at depth, and placed under the classification of soil as Udipsamments/Udorthents. (vii) Climatic data from secondary sources The climate of Ambala district can be classified as subtropical monsoon, mild & dry winter, hot summer and sub-humid, that is mainly dry with very hot summer and cold winter except during monsoon season when moist air of oceanic origin penetrates into the district. The hot weather season starts from mid March to last week of the June followed by the south west monsoon which lasts upto September. The transition period from September to November forms the post monsoon season. The winter season starts late in November and remains upto first week of March. Rainfall: The normal annual rainfall of the district is 1076 mm, and is unevenly distributed over the area. The average rainy days are 44. The south west monsoon sets in from last week of June and withdraws in the end of September, contributing about 81% of normal annual rainfall. July and August are the wettest months. Rest 19% rainfall is received during nonmonsoon period in the wake of western disturbances and thunderstorms. Generally rainfall in the district increases from southwest to northeast.the mean maximum temperature is 40.8 o C (May & June) and mean minimum is 6.8 o C (January) of the district. (viii) Social Infrastructure available Nearest town is Ambala (District Headquarter) ~ 15.0 km in SW direction. There are primary schools, School, dispensaries, hospitals, railway station, colleges, market places of worship in nearby area of the project site. Most of the villages are electrified. Telephone, Medical facilities and Telegraph facilities are available in the nearby towns. M/s. Oasis Ethanol Industries Pvt. Ltd. 32