PRE-FEASIBILITY REPORT

Transcription

1 PRE-FEASIBILITY REPORT FOR INSTALLATION OF 2G ETHANOL PLANT AT BATHINDA, PUNJAB BY M/S HINDUSTAN PETROLEUM CORPORATION LIMITED PREPARED BY M/s. ULTRA-TECH ENVIRONMENTAL LABORATORY AND CONSULTANCY (Gazzeted By MoEF) Unit No. 206, 224, 225 Jai Commercial Complex, Eastern Express Highway, Opp Cadbury Factory, Khopat, Thane (West) Tel: , Fax: , Website:

2 TABLE OF CONTENTS 1. EXECUTIVE SUMMARY INTRODUCTION Project Proponent Nature of Project SITE INFORMATION Environmental Setting PROJECT DESCRIPTION Process Description Manufacturing Process Land Use and Land Ownership Water Requirement Power Requirement Manpower Requirement Waste Management ENVIRONMENT CONTROL MEASURES PROJECT SCHEDULE AND COST ESTIMATES Project Schedule Project Cost Estimates LIST OF TABLES Table 3.1: Environmental Setting... 3 Table 4.1: Proposed Product List Table 4.2: Proposed Raw Materials Table 4.3: Proposed Water Requirement Table 4.4: Proposed Manpower Requirement Table 4.5: Non-Hazardous Solid Waste Table 4.5: Hazardous Waste i

3 Table 4.6: Stack Details LIST OF FIGURES Figure 3.1: Project Location... 5 Figure 3.2: Aerial Image of the Project Site... 6 Figure 3.3: Google Image of the Project Site... 7 Figure 4.1: Process Flowchart... 8 Figure 4.2: Basic Process... 9 Figure 4.3: Project Site Layout ii

4 1. EXECUTIVE SUMMARY HPCL is a Government of India Enterprise with a Navratna Status, and a Forbes 2000 and Global Fortune 500 company. It had originally been incorporated as a company under the Indian Companies Act It is listed on the Bombay Stock exchange (BSE) and National Stock Exchange (NSE), India. HPCL owns & operates 2 major refineries producing a wide variety of petroleum fuels & specialties, one in Mumbai (West Coast) of 6.5 Million Metric Tonnes Per Annum (MMTPA) capacity and the other in Visakhapatnam, (East Coast) with a capacity of 8.3 MMTPA. HPCL also owns and operates the largest Lube Refinery in the country producing Lube Base Oils of international standards, with a capacity of 428 TMT. This Lube Refinery accounts for over 40% of the India's total Lube Base Oil production. Presently HPCL produces over 300+ grades of Lubes, Specialities and Greases. The company appointed M/s. Ultra Tech Environmental Consultancy & Laboratory (MoEFCC recognized and NABL approved), Thane to carry out study of the impacts of the project on local environment and for obtaining Environmental Clearance. Ultra-Tech is an established Consultancy in the field of Environmental Services. Company is giving services in this field for past 29 years. The Notification No. S. O promulgated on 14 th September 2006 has covered this type of industries under its schedule 5(g) A. Hence, HPCL intends to approach MoEF&CC for environment clearance for proposed Distillery. The prefeasibility report is prepared for forming a frame work for EIA study, scoping and finalizing terms of reference as may be required. Form I, as is prescribed by the said notification is duly filled up and submitted. The Prefeasibility Report is an accompaniment to the same and prepared as per MoEF guideline dated 27/02/2012. HPCL proposes to Installation of 2G Ethanol plant at Bathinda, Punjab. HPCL has acquired 15.1 ha (37.28 Acres) from Government of Punjab on a long term lease in the Village Nasibpura, District Bathinda. The Khasra No are 1136(39-3), 1137/1(12-10), 1138(29-10), 1139/1(13-10), 1139/2(11-10), 1140(25-0), 1141/1/1(8-5), 1141/1/2(3-2), 1143(25-0), 1144/1(13-0), 1144/2(11-0), 1144/3(9-6), 1144/4(1-14), 1145/2(3-18), 1145/3(21-2), 1146/1(16-13), 1146/2(24-13), 1151/1(12-10), 1151/2(7-0), 1151/3(2-10), 1151/4(2-10), 1152(25-0). Agricultural land has now been converted to industrial land use. The copy of Change in Land Use (CLU) has been provided as Annexure III. The estimated production capacity of the project is 2G Ethanol 100 KLD and other By-products. The commercial operation date (COD) is envisaged in 18 months reckoned from the effective zero date. The total project cost for the Proposed Installation of 2G Ethanol Plant is around Rs. 600 crores. This includes the cost of land and land development, on lease from Govt. of Punjab as per lease rentals/terms & conditions. 1

5 2.1 Project Proponent 2. INTRODUCTION Hindustan Petroleum Corporation Limited (HPCL) is a Government of India Enterprise with a Navratna Status, and a Forbes 2000 and Global Fortune 500 company. HPCL has the second largest share of product pipelines in India with a pipeline network of more than 3015 kms for transportation of petroleum products and a vast marketing network consisting of 13 Zonal offices in major cities and 106 Regional Offices facilitated by a Supply & Distribution infrastructure comprising Terminals, Pipeline networks, Aviation Service Stations, LPG Bottling Plants, Inland Relay Depots & Retail Outlets, Lube and LPG Distributorships. Consistent excellent performance has been made possible by highly motivated workforce of over 11,000 employees working all over India at its various refining and marketing locations. HPCL is committed to achieve the economic, ecological & social responsibility objectives of sustainable development consistently through varied operations and activities. HPCL s focus areas are in the fields of Child Care, Education, Health Care, Skill Development & Community Development, touching lives of weaker section of society. 2.2 Nature of Project The technology is suited for both Indian and global needs and it is projected to be capable of converting all types of agricultural residues like bagasse, rice and wheat straw, bamboo, cotton stalk, corn stover, wood chips to ethanol in less than 24 hours, with optimum product yields The Bathinda Bio-refinery will be utilizing agriculture residues for production of ethanol which may be sufficient to meet the 26% of the ethanol blending requirement of the State. The proposed Bio-refinery will generate employment. The project shall also help in reducing CO 2 emissions from the paddy straw which currently is being burnt after harvesting. One of the major outputs of this Bio-refinery shall be Bio-fertilizer which shall be incorporated into the soil for improving soil fertility and overall productivity of farms in Punjab. The Bio-refinery shall also produce Bio- CNG per annum which can cater to transport and clean cooking requirements. 2

6 3. SITE INFORMATION HPCL proposes to Installation of 2G Ethanol plant at Bathinda, Punjab. HPCL has acquired 15.1 ha (37.28 Acres) from Government of Punjab on a long term lease in the Village Nasibpura, District Bathinda. 3.1 Environmental Setting The Environmental Setting in 10 km radius of project site is presented in Table 3.1 Table 3.1: Environmental Setting Sr. No. Particulars Details Plant location The Proposed project is located at Village Nashibpur Tehsil Talwandi, District Bathida Punjab Approx site Centre point Lat : Coordinates Long: Climatic conditions Maximum temperature 35 o C Minimum temperature 9 o C Annual rainfall (total) 1200mm Relative humidity Maximum- 85 Minimum- 17 Plant site elevation above MSL 686Ft Plant site topography Plain Present land use at the site Agricultural Land Nearest highway SH Km Nearest railway station Bathinda Railway Station : 31.8 Km Nearest Airport Ludhiana Airport : 180Km Nearest major water bodies River towards south 200mters Nearest village Nasibpura Archaeologically important Nil places Protected areas as per Wildlife Nil Protection Act, 1972 (Tiger reserve, Elephant reserve, Biospheres, National parks, Wildlife sanctuaries, community reserves and conservation reserves) Reserved / Protected Forests Nil Defence Installations Nil Seismicity The proposed project is located in Seismic Zone IV as per IS: 1893 and all designs will be as per IS Codes 3

7 The location map of the project site is as depicted in Figure 3.1, Connectivity Map is shown in Figure 3.2 and Google Image is as shown in Figure

8 Figure 3.1: Project Location 5

9 Connectivity The project site is aerially located at 6.3 Km from SH 17 Highway. The nearest Railway station is Bathinda Railway Station: 31.8 Km and The nearest airport is Ludhiana Airport: 180 Km Figure 3.2: Aerial Image of the Project Site 6

10 Figure 3.3: Google Image of the Project Site 7

11 4. PROJECT DESCRIPTION 4.1 Process Description The proposed 100 KLPD plant is based on the DBT-ICT 2G Ethanol technology developed indigenously at the DBT-ICT Centre for Energy Biosciences (CEB), Mumbai. The CEB at the Institute of Chemical Technology (ICT), Mumbai is one of India s leading multidisciplinary research facilities specializing in Bioenergy and Industrial Biotechnology. The project is designed to produce 100KL fuel grade ethanol per day, primarily from rice straw and will use approximately 400 tons of rice straw per day for the process. An additional 50 tons of straw per day will be used for supplementary fuel for steam generation. The process employed here uses rice straw as feed stock to convert into its cellulose, hemi cellulose and lignin fractions. The cellulose and hemi cellulose fractions are then converted into respective sugars through a process called saccharification.the sugars are then converted into dilute ethanol by fermentation using appropriate yeasts. The dilute impure ethanol stream is then purified and concentrated to fuel grade ethanol. The Figure 4.1 depicts the process outline. The rectangular blue blocks represent the main processing sections in the plant. Aside from these, there are ancillary sections like biomass size reduction, steam/steam /power/water supply systems, raw material and finished goods storage yards etc. Figure 4.1: Process Flowchart The plant has been designed as a zero-liquid discharge plant. The final products will be fuel grade ethanol, silica, mixed solid salts and liquid carbon dioxide. 8

12 4.2 Manufacturing Process The Figure 4.2 schematically represents the basic process outline. Biomass (rice straw/cotton stalk/napiergrass) obtained in the form of bales, is size reduced and then converted to sugars that are fermented to ethanol via two step alkali and acid treatment steps. The overall site consists of the following sections: Size reduction Fractionation to cellulose, hemicelluloses and lignin Saccharification to C6 and C5 sugars Fermentation to Ethanol Distillation and Dehydration of ethanol Purification, Compression and Bottling of CO2 Utilities(power, steam, cooling water) Figure 4.2: Basic Process 9

13 The Site layout of the proposed project is as shown in Figure 2.3. Figure 4.3: Project Site Layout 10

14 The plant is designed for the products as listed in the Table 4.1. The plant and Machinery have been designed with required specification considering volume of reaction, material of construction and are located at appropriate positions. Adequate ventilation, air conditioning and Air Filtration systems have been planned to prevent environmental hazards. The raw materials required for the proposed production is listed in Table 4.2. Table 4.1: Proposed Product List Products Rice Straw (TPD) Cotton Stalk (TPD) Napier Grass (TPD) Ethanol CO2 * Silica Fusel Oil Total Table 4.2: Proposed Raw Materials Raw Materials Rice Straw (TPD) Cotton Stalk (TPD) Napier Grass (TPD) A. BIOMASS Biomass (dry basis) Chemical characteristics Lignocelluloses (with 15% w/w moisture maximum) Physical characteristics Supplied as kg rectangular bales B. CHEMICALS Nitric Acid (60% w/w fuming liquid) Sodium Hydroxide ( w/v aqueous lye) Enzymes (liquid protein solution with stabilizers) C.FUEL Biomass Nil Nil D.OTHERS Salts Total The main features of the plant are as follows: Both C5 and C6 sugar (glucose) can be obtained separately and converted to ethanol by fermentation either independently or combined. The plant is fully automated and DCS/SCADA controlled 11

15 The plant is supported by an equipped QC/QA laboratory Sugars produced are fermented using specific yeast strains Enzyme and chemicals required to be procured from recommended suppliers The plant does not produce and create liquid effluent Solid byproducts generated are ash, salts (sodium nitrate) and silica that will be sold in market The following are the expected Plant Performance figures: C6 (glucose) sugar yield on biomass (dry): 80% of maximum C5 (xylose) sugar yield on biomass (dry) : 80% of maximum Ethanol yield on C6 (glucose): 0.50 L/kg Ethanol yield on C5 (xylose): 0.40 L/kg Ethanol Production per day: 0.45L/kg total sugars Overall maximum possible yield of ethanol on dry biomass: 300L/ton biomass 4.3 Land Use and Land Ownership HPCL has already signed Land agreement with Punjab Government (Village development and Panchayat Department) on Lease for a period of 33 years 4.4 Water Requirement The total water requirement for the proposed project will be 100m 3 /day; Table 4.3 shows the distribution of the water requirement Table 4.3: Proposed Water Requirement Sr. No. Water Requirement TPD 1 Process water Cooling water Boiler Drinking water 6 5 Domestic water Blow down water will be used for domestic purpose 6 Green Belt 270 (Blow down water will be used) 7 Floor Washing Blow down water will be used for floor washing 4.5 Power Requirement Total power requirement (connected load and maximum demand) and source, power exported during season and off-season will be 5 MW. Emergency power required for boiler, distillation system, cooling water circulation, membrane system and water pump for reactor flushing is 1.6 MW. Thus, the capacity of the DG set will be 2MW. 12

16 4.6 Manpower Requirement The estimated manpower requirement during operation phase will be around 120 personnels. The details of the same are provided in Table 4.4. Table 4.4: Proposed Manpower Requirement Persons for operation of plant in three 1 shifts 45 2 Persons for maintenance of the plant 45 3 Persons for lab-chemist, Microbiologist 25 4 Managers Waste Management The details of the Non Hazardous Solid Waste are as provided in Table 4.5 and Hazardous Waste is as provided in Table 4.6. Table 4.5: Non-Hazardous Solid Waste Feed stock Total Solid waste Ash + Silica (TPD) Rice Straw Cotton Stalk Napier Grass Table 4.5: Hazardous Waste Cat. Type of waste Source Qty. Method of Disposal 34.3 Sch I ETP Sludge ETP 5 MTM CHWTSDF 5.1 Sch I Used Plant & 0.5 MTM CHWTSDF Lubricants 33.3 Sch I Used Containers (Metal & Plastic) HDPE/ LDTE/ Gunny Bags Machineries Raw Material Storage Raw Material Storage 1200 (Nos.) 2000 (Nos.) Decontamination & Re-use or sell to Scrap vendors Decontamination & Re-use or sell to Scrap vendors 13

17 5. ENVIRONMENT CONTROL MEASURES During construction phase there will be fugitive emissions due to movement of equipment at site, dust emitted during the levelling, grading, earthworks, foundation works and other construction related activities. These impacts will however, be marginal and temporary in nature. The DG sets shall be acoustically insulated resulting in reduction of noise as per limits prescribed by State Pollution Control Board. The exhaust pipe from DG sets shall be taken above the building as per State Pollution Control norms All conditions & pre-requisites of water and air consents together with certificate to handle hazardous products issued by State Pollution Control Board shall be strictly adhered to. During operation phase, there shall be air pollution being generated due to the Boiler. Following stack as mentioned in Table 4.6 is as proposed. Table 4.6: Stack Details Sr. No. Stack Emission Details Details 1 Number of stacks 1 2 Number of flues per stack 2 3 Physical stack height (m) 25 4 Sack diameter (m) 30 5 Flue gas exit velocity (m/s) 4 6 Flue gas exit Temperature ( C) Flue gas density (kg/m 3 ) Emission rate per flue of SPM (kg/h) 98.0 SO2 (kg/h) 3.50 NOx (kg/h) Pollution control device and its efficiency SOx and NOx absorption (95% efficiency) and solid disposal 14

18 6. PROJECT SCHEDULE AND COST ESTIMATES 6.1 Project Schedule The commercial operation date (COD) is envisaged in 18 months reckoned from the effective zero date. 6.2 Project Cost Estimates The total project cost for the Proposed Installation of 2G Ethanol Plant is around Rs. 600 crores. This includes the cost of Land and land development, on lease from Govt. of Punjab as per lease rentals/terms & conditions 15