Based Distillery and Co-generation Power Plant (MW)

Transcription

1 Proposed Expansion of Existing Grain based Distillery from 50 to 250 KLPD (Ethanol/ENA/RS) along with installation of 5.0 MW Co-Generation Power Plant PRE - FEASIBILITY REPORT 1.0 EXECUTIVE SUMMARY (I) Introduction Oasis Distilleries Limited is one of the largest grain based manufacturers of Extra Neutral Alcohol in the country with a captive production of more than 26 crores litres per annum. Oasis Distilleries Limited has five Grain Based Distilleries located in North India and are presently supplying grain based ENA to Seagrams (Pernord Richard) UB Spirits, Allied Blenders and bottlers (Officers Choice Whisky) and number of other leading houses in the country. Besides this, the company is one of the largest exporters of grain based ENA outside India with an average of containers per month. M/s. Oasis Distilleries Limited has an existing 50 KLPD grain based distillery and 20 KLPD molasses based distillery. Currently, the company is running only 50 KLPD grain based distillery. The company has the permission to run either on 50 KLPD grain based or on 20 KLPD molasses based distillery. But the company can run molasses based only after installation of incinerator boiler. The company is now proposing expansion of Grain based Distillery from 50 KLPD to 250 KLPD along with installation of Co-generation power plant of 5.0 MW within their existing plant premises at Village Boralli, Tehsil-Badnawar, District- Dhar, Madhya Pradesh. 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) [Non-Molasses based Distilleries 60 KLPD]. TABLE - 1 Salient Features of the Project S. NO. PARTICULARS DETAILS A. Nature & Size of the Project Units Existing Capacity Proposed Expansion Capacity Total Capacity after Proposed expansion Grain Based 50 KLPD 200 KLPD 250 KLPD Distillery or Molasses 20 KLPD - 20 KLPD Based Distillery and Co-generation Power Plant (MW) - 5 MW 5 MW B. Category of the Project As per EIA Notification dated 14 th Sept., 2006 & as amended from time to time; this project falls under Category A, Project or M/s. Oasis Distilleries Limited 1

2 Proposed Expansion of Existing Grain based Distillery from 50 to 250 KLPD (Ethanol/ENA/RS) along with installation of 5.0 MW Co-Generation Power Plant C. Location Details Village Tehsil District State Latitude Longitude D. Area Details Total Plant Area Activity - 5(g) (i) [Non-Molasses based Distilleries 60 KLPD] Boralli Badnawar Dhar Madhya Pradesh 22 56'19.41"N to 22 56'42.99"N 75 15'11.66"E to 75 15'45.72"E o Existing plant area: 35 ha or acres o No additional land is required for the proposed expansion & installation, as the same will be done within the existing plant premises ha i.e. ~33 % of the total plant area has already been developed under greenbelt / plantation. Greenbelt / Plantation Area (ha) E. Environmental Setting Details (with approximate aerial distance & direction from plant site) 1. Nearest Village Boralli (adjacent to Plant Site in West direction) 2. Nearest Town/City Badnawar (~9 km in NNW direction) 3. Nearest National Highway / o NH-79 (adjacent to plant site in North direction) State Highway o SH 18 (~9 km in North direction) 4. Nearest Railway station o Ratlam Railway Station (~49 Km in NNW direction) o Indore Railway Station (~68 Km in SW direction) 5. Nearest Airport Devi Ahilya Bai Holkar Airport, Indore (~62 km in SW direction) 6. National Parks, Wild Life No National Park, Wild Life Sanctuary, Biosphere Reserve, Tiger / Sanctuaries, Biosphere Elephant Reserve, Wildlife Corridors etc. falls within 10 km radius Reserves, Tiger/ Elephant of the plant site. Reserves, Wildlife Corridors etc. within 10 km radius 7. Reserved Forests (RF) / No Reserve Forests (RF)/Protected Forests (PF) etc. Falls within Protected Forests (PF) etc. 10 km radius from the plant site. within 10 km radius 8. River / Water Body (within o Chamla River (~6.2 Km in SE direction) 10 km radius) o Bagedi River (~7 km in NW direction) F. Cost Details Total Cost of the Proposed Rs. 140 Crores Expansion Project Cost for Environment o Capital Cost - Rs Crores Management Plan o Recurring Cost - Rs. 1.5 Crores / annum. G. Basic Requirements for the project Existing Additional for proposed Capacity Total after proposed Capacity Expansion Expansion Water Requirement (KLD) Source: Ground Water Power Requirement (MW) Source: Co-Generation Power Plant & D.G set -1X750 KVA & 2X500 KVA D. G. Sets will be used after the proposed expansion for the power back up. Man Power Requirement Source: Unskilled / Semi-Skilled - Local Area; Skilled - Outside M.P H. Product Rectified Spirit, Extra Neutral Alcohol & Ethanol I. Working Days 350 Days per Annum M/s. Oasis Distilleries Limited 2

3 Proposed Expansion of Existing Grain based Distillery from 50 to 250 KLPD (Ethanol/ENA/RS) along with installation of 5.0 MW Co-Generation Power Plant 1.1 ENVIRONMENTAL MANAGEMENT PLAN Particulars Air Quality Management Emissions Monitoring Water Management Management Monitoring DETAILS Stacks of 31 m height equipped with MDC & cyclone have already been installed with the boiler of capacity of 10 TPH & 6 TPH to control the particulate and gaseous emissions due to combustion of fuel. Bag-filter/ESP will be installed with the proposed Boiler of capacity 65 TPH to keep the emissions below permissible level after proposed expansion & installation. CO 2 generated during the fermentation process is being/will be collected by utilizing CO2 Scrubbers and sold to authorized vendor. Grain is being/will be stored in silos. All the roads are concreted to control the fugitive dust emissions. Proper servicing & maintenance of vehicles is being/will be carried out. Greenbelt has already been developed all around the plant boundary and the same will be maintained. Ambient air quality and stack emission is being / will be regularly monitored to ensure that ambient air quality standards are being met all the time. Multi pressure distillation plant with integrated evaporator and dryer is being used thus, the project is based on Zero Effluent Discharge. Grain Slops (Spent Wash) is being/will be taken through Centrifuge Decanters for separation of Suspended Solids separated as Wet Cake and which goes as cattle feed as it contains high protein. (Also known as DWG Distillers Wet Grains) Thin Slops from the Decanter Centrifuge is being/will be 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 is being passed through steam tube bundle drier for drying into cake with 10-12% moisture (max.) to give higher shelf life. Solid dry cakes are being obtained finally. The Process condensate is being / 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. Domestic waste water generated from the plant is being/will be disposed off in soak pits via septic tanks. Effluent Treatment Plant has been installed and treated water from ETP is recycled back to the process and remaining is used for green belt development. Rain Water harvesting is being/will be done within the existing plant premises. Regular monitoring of water quality is being / will be carried out. M/s. Oasis Distilleries Limited 3

4 Proposed Expansion of Existing Grain based Distillery from 50 to 250 KLPD (Ethanol/ENA/RS) along with installation of 5.0 MW Co-Generation Power Plant Noise Management Management Monitoring Solid Waste Management Management Odour Management Management Green belt Development/ Plantation Management Personal Protective Equipment like earplugs and earmuffs is being / will be provided to the workers exposed to high noise level. D.G sets are being /will be provided with acoustic to control the noise level within the prescribed limit. Proper maintenance, oiling and greasing of machines at regular intervals is being / will be done to reduce generation of noise. Green Belt of appropriate width inside the plant premises and at the plant boundary has been developed. Regular monitoring of noise level is being / will be carried out and corrective measures in concerned machinery are being/will be adapted accordingly to the possible extent. Solid waste from the Grain based operations generally comprises of Fibres and proteins in the form of DDGS, which are being / will be ideally used as Cattle Feed. Ash from the Boiler is being / will be sold to Brick manufacturers. Yeast sludge is being / 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 as hazardous waste are being / will be sold out to the CPCB authorized recycle. The remedial measures are being/will be taken such as better house-keeping by regular steaming of all fermentation equipments and same will be followed in future. Temperature is being/will be kept under control during fermentation to avoid in-activation/killing of yeast and staling of fermented wash will be avoided. Green belt development in and around the plant site helps to attenuate the pollution level. Out of the total plant area approx. 33% land has already been developed as green belt/plantation. Green belt has been developed as per Central Pollution Control Board (CPCB) guidelines. Native species have been planted in consultation with the local DFO. 2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION (i) Identification of Project and Project Proponent Applicant : M/s Oasis Distilleries Limited Registered Address : H 102, B2 Metro Towers, First floor, Vijay Nagar, Indore-10, Madhya Pradesh The Oasis Group has Hotels of star category at Mussoorie and Delhi under the world known management group Carlson and brand name Country Inn & Suites by Carlson M/s. Oasis Distilleries Limited 4

5 Proposed Expansion of Existing Grain based Distillery from 50 to 250 KLPD (Ethanol/ENA/RS) along with installation of 5.0 MW Co-Generation Power Plant The group is also in luxury goods business under the brand name of Dillano Luxurious Jewels which caters to the niche business class and participates in elite jewellery exhibitions such as Wedding Asia etc. Oasis Group, India Based Group are well known and highly reputed in the Luxury/hospitality 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 owned five running Distilleries, two bottling Units and expanding and diversifying into different business at fast pace. 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 15 years, the Malhotra Group has grown into a diversified business and industrial house with a high growth rate and a total commitment to persistent growth. The group was founded by Shri Om Prakash Malhotra. It is his foresight and vision that has promoted the organization to take its present shape. Its present Chairman and Director, Mr. Deep Malhotra, a second-generation entrepreneur, carries with him rich experience coupled with sharp commercial acumen. The Group has a team highly qualified, experienced, trusted persons with a right mix of technocrats, Finance Experts and management professionals. Group Companies:- 1. Country Inn & Suites By Carlson (A Unit of Diamond Resorts Pvt. Ltd.), Mussoorie 2. Oasis Resorts Pvt. Ltd., Delhi 3. Dillano Luxurious Jewels Ltd., Delhi 4. Oasis Commercial Pvt. Ltd., Haryana 5. Oasis Overseas Pvt. Ltd., Haryana 6. Malbros International Pvt. Ltd, Punjab 7. Oasis Distilleries Ltd, Indore 8. Gauravh Wines Pvt. Ltd., Punjab 9. Om Sons Marketing Pvt. Ltd, Punjab 10. Malbros Enterprises Pvt. Ltd, Delhi 11. Calx Paper Pvt. Ltd, Delhi 12. Gee Emm Bros. Distributors Pvt. Ltd., Delhi 13. Vijeta Beverages Pvt. Ltd., Rajasthan 14. Gautam Wines Pvt. Ltd., Punjab M/s. Oasis Distilleries Limited 5

6 Proposed Expansion of Existing Grain based Distillery from 50 to 250 KLPD (Ethanol/ENA/RS) along with installation of 5.0 MW Co-Generation Power Plant Oasis Distilleries Limited is one of the largest grain based manufacturers of Extra Neutral Alcohol in the country with a captive production of more than 26 crores litres per annum. Oasis Distilleries Limited have five Grain Based Distillery located in North India and are presently supplying grain based ENA to Seagrams (Pernord Richard ) UB Spirits, Allied Blenders and bottlers (Officers Choice Whisky ) and number of other leading houses in the country. Besides this, the company is one of the largest exporters of grain based ENA outside India with an average of containers per month. Oasis Distilleries Limited is having its existing Grain based Distillery of 50 KLPD capacity at Village Boralli, Tehsil Badnawar, District Dhar, Madhya Pradesh. (ii) Brief description of nature of the project M/s. Oasis Distilleries Limited has an existing grain based distillery of capacity 50 KLPD and is now proposing expansion in capacity of Grain based Distillery from 50 KLPD to 250 KLPD along with 5.0 MW Co-generation power plant within their existing plant premises at Village Boralli, Tehsil Badnawar, District Dhar, Madhya Pradesh. The Proposed expansion capacity of 250 KLPD will be Grain based alcohol using Grain as raw materials which are abundantly available in the state. The Project is based on zero effluent discharge. The distillery has put up the most modern technology for treatment of distillery spent wash which ensures Zero discharge of distillery effluents. The distillery unit will generate its own electricity by proposed Co-Generation power plant of 5.0 MW. 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) [Non-Molasses based Distilleries 60 KLPD]. (iii) Need for the project and its importance to the country and or region India has seen a sudden spurt and demand for grain extra neutral alcohol for the fast growing in IMFL Industries and for blending in Foreign Liquor outside India which has been a multi-fold surge in demand. There is still substantial deficiency in supply of grain based ENA and therefore we have identified this potentiality and have decided to go for the Plant expansion to enhance our grain based ENA production. (iv) Demand- Supply Gap The total production of ENA from molasses and grain is 148 crores litres per annum. The total requirement of ENA for IMFL in India is 120 crores litres (35% ENA from grain & 65 % from molasses). Next five year projection ENA from grain 60 % & from molasses 40 % Alcohol produced from molasses also used by oil companies crores in the year of Projection for the year crores litres by the oil companies. Post 2017 India will require 6.30 billion litres of alcohol mainly from molasses for the use in M/s. Oasis Distilleries Limited 6

7 Proposed Expansion of Existing Grain based Distillery from 50 to 250 KLPD (Ethanol/ENA/RS) along with installation of 5.0 MW Co-Generation Power Plant petrol by the oil companies. Thus the huge demand of ENA made out of grain will arise. (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 ENA production is concerned, Indian market play a vital role at both domestic & international level. So they require produce the more alcohol to meet the demand. (vi) Export Possibility Presently the company is having four other grain based distilleries other than Oasis Distilleries Ltd, Indore situated at Borali village, Dhar, M.P. Our collective grain spirit production is 22 crores litres per annum and the company on an average exports 200 to 250 containers of litres each outside India from our other units. Looking into the potentiality of further export and the proximity of Company s M.P unit to the port of Kandala, Navashiva and JNPT, the company foresaw tremendous potential in further strengthening its export which will contribute substantially to the state and national exchequer. (vii) Domestic / Export Markets Market depends on excise Department. (viii) Employment Generation (Direct and Indirect) due to the project The total manpower requirement after the proposed expansion & installation project will be PROJECT DESCRIPTION (i) Type of Project including interlinked and independent projects, if any. There are no interlinked projects related to this expansion & installation project. (ii) Location (map showing general location, specific location, and project boundary & project site layout) with coordinates M/s. Oasis Distilleries Limited 7

8 Proposed Expansion of Existing Grain based Distillery from 50 to 250 KLPD (Ethanol/ENA/RS) along with installation of 5.0 MW Co-Generation Power Plant Figure - 1: Location Map M/s. Oasis Distilleries Limited 8

9 Proposed Expansion of Existing Grain based Distillery from 50 to 250 KLPD (Ethanol/ENA/RS) along with installation of 5.0 MW Co-Generation Power Plant (iii) Key Plan Figure 2: Environmental Settings of 10 km radius area M/s. Oasis Distilleries Limited 9

10 Proposed Expansion of Existing Grain based Distillery from 50 to 250 KLPD (Ethanol/ENA/RS) along with installation of 5.0 MW Co-Generation Power Plant (iv) Details of alternative sites consideration and basis of selecting the proposed site, particularly the environmental considerations gone into should be highlighted. Since the proposed expansion & installation will be done within the existing plant premises and no additional land will be required; therefore, no alternative site has been considered. (v) Size or magnitude of operation Proposed expansion in capacity of existing Grain based Distillery (50 KLPD to 250 KLPD) along with installation of 5.0 MW Co-Generation Power Plant will be done within the existing plant premises at Village Boralli, Tehsil Badnawar, District Dhar, Madhya Pradesh. 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. (vi) Project Description with Process Details Project Description S. No. Units 1. Grain based Distillery 2. Molasses based Distillery 3. Co-Generation Power Plant Existing Capacity Additional Capacity for Expansion Total Capacity after proposed Expansion 50 KLPD 200 KLPD 250 KLPD 20 KLPD - 20 KLPD - 5 MW 5 MW Process Description Distillery Unit - Production from Grain: Grain storage Grain cleaning, milling and flour handling Slurry preparation & liquefaction Multi pressure distillation Alcohol (ENA& IA) daily receivers & bulk storage MEE & Dryer 1. Grain Storage : Grains are procured from various sources, such as FCI Storage godowns through agencies and are unloaded into large Storage Silos after Pre-Cleaning. Storage Silos are specially designed to keep the Grains in good condition for longer durations and also avoid its deterioration and theft, etc. It is being proposed to have days of Grain Storage facility in the Distillery. M/s. Oasis Distilleries Limited 10

11 Proposed Expansion of Existing Grain based Distillery from 50 to 250 KLPD (Ethanol/ENA/RS) along with installation of 5.0 MW Co-Generation Power Plant 2. Grain Cleaning, Milling and Flour Handling : The grain is lifted in bucket elevators, screened followed by removal of stones and iron matter. Cleaned Grains are then milled using dry milling process in Hammer Mills. The flour is fed through the bucket elevator and conveyed to the Batch Tipping Machine through a Screw Conveyor. The flour addition is metered through the Batch Tipping Machine with load cell arrangement, before transferring the flour to the Slurry Tank through another Screw Conveyor (pre-masher) for slurry preparation process. It is being proposed to have 2 x 8 TPH (+ 1 Standby option) as milling paraphernalia for this Distillery. 3. Slurry Preparation & Liquefaction : Grain flour and process water is fed at controlled rate to Initial Liquefaction tank. Mixed slurry is taken to the Initial Liquefaction Tank where additional quantity of water is added as per requirement. Viscosity reduction Enzyme and stabilizing chemicals and a portion of liquefying enzyme are also added 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. The retention vessel has 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 and is therefore susceptible to enzyme attack for liquefaction. The gelatinized mash from the Flash Tank is liquefied in the Final Liquefaction Tank where liquefying enzyme (alpha-amylase) is added. The liquefied mash is cooled in Mash Cooler and transferred to Saccharification cum fermentation section. This process initiates the formation of sugar. The gelatinized mash from the Flash Tank is liquefied in the Final Liquefaction Tank where liquefying enzyme (alpha-amylase) is added. The liquefied mash is cooled in Mash Cooler and transferred to Saccharification cum Fermentation section. 4. Hiferm-Nm Saccharification and Instantaneous 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 Fermenter. M/s. Oasis Distilleries Limited 11

12 Proposed Expansion of Existing Grain based Distillery from 50 to 250 KLPD (Ethanol/ENA/RS) along with installation of 5.0 MW Co-Generation Power Plant Saccharification & Instantaneous Fermentation: The Liquefied starch slurry comprising Dextrins is partly taken for Yeast development in Yeast Activation vessel and majorly transferred into the Fermenter. Amyloglucozydase and other nutrient Enzymes are first added to Saccharify the Starch Slurry causing formation of Sugars. Immediately, the Active Yeast is introduced in the system for simultaneous Fermentation. The process of fermentation is to convert the fermentable substrate into alcohol. To prepare the mash for fermentation, it may have to be diluted with water. The ph of the mash is adjusted by the addition of acid. Yeast is available in sufficient quantity to initiate fermentation rapidly and complete it within the cycle time. At the start of the cycle, the fermenter is charged with mash and contents of the Yeast Activation Vessel. 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 caustic solutions and sterilized for the next batch. The carbon dioxide evolved during the process is vented to atmosphere after recovery of alcohol in a scrubber. 5. Multi Pressure Distillation : This process utilizes following columns namely the Analyser, Degassifier, Pre-Rectifier Column, Stripper, Rectifier cum Exhaust, Extractive Distillation (ED) Column, Recovery Column and Simmering Column in ideal heat integration in order to reduce the energy consumption. The Analyzer & Degassifier Columns are operated under Vacuum whereas the Simmering, the Recovery Columns are operated under Atmospheric condition. The Pre-Rectifier, Rectifiercum-Exhaust Columns are operated under Pressure. The energy requirement for Analyser, Degassifier Column is met by Rectifier Column top vapours. The Rectifier Column top vapours are condensed in a thermo-siphon reboilers connected to a flash tank and then flash vapours are injected into Analyser Column. The energy requirement of the Simmering Column is met by the top vapours of Pre-Rectifier Column while that of the Recovery Column is through direct steam. The overall Technical Alcohol / Impure Spirit Cut will be maintained at 7% max. The Distillation Plant shall be designed for use of Grain starch route only. M/s. Oasis Distilleries Limited 12

13 Proposed Expansion of Existing Grain based Distillery from 50 to 250 KLPD (Ethanol/ENA/RS) along with installation of 5.0 MW Co-Generation Power Plant 6. Alcohol (ENA & TA) Daily Receivers & Bulk Storage : The Extra Neutral Alcohol & Technical Alcohol (Impure Spirit) is first taken to Daily receiver storage tanks, which is based on the State Excise laws, storage for three days considering the weekly holidays of two days. Thereafter, the alcohol is transferred to Bulk Storage Tanks after taking the daily receiver Dip. This is transferred using flameproof pumps. Final dispatch of alcohol is metered and again is carried out using special flameproof pumps. The Bulk Spirit Storage is proposed to be set up for 30 days. EFFLUENT HANDLING SECTION 1. Decantation Section: Decantation section comprises of Centrifuge Decanters, operating at high rpm which are used for separation of suspended solids from Spent Slops coming out of Distillation section. The Wet cake thus separated has 30-35% w/w solids, as removed from bottom of Decanters. This is directly loaded on the trolleys parked below. Thin slops coming out of Decanter are collected in a tank and are transferred for part recycle & further for Evaporation into thick syrup. 2. Integrated Evaporation Section: The suggested treatment scheme is a 2 FF + Finisher Evaporation Plant for Thin Slops 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 Evaporation have been used, with Plate type Preheaters for preheating of FEED stream which serves the purpose of energy conservation. Analyzer vapour is fed to the first effect evaporator shell side at the given pressure and temperature as the heating medium. The Feed from the Feed balance tank is taken to the PHCOND to make the best heat recovery. The Feed after getting heated to the predetermined temperature in preheater is fed from the first effect evaporator which is Falling Film Evaporator -1 The flow path is given below. INLET FEED - ph cond E1 E2 OUTLET PRODUCT Vapours generated in 1st effect VLS (Vapour Liquid Separator) are used as heat source in the 2nd effect. M/s. Oasis Distilleries Limited 13

14 Proposed Expansion of Existing Grain based Distillery from 50 to 250 KLPD (Ethanol/ENA/RS) along with installation of 5.0 MW Co-Generation Power Plant The product at the desired concentration of TS is obtained at the outlet of the second effect, which is a Falling Film evaporator. 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. 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. CONCLUSION The thick syrup thus obtained is mixed with the Wet Cake obtained from Decanter Centrifuges using specially designed Ribbon type mixer and this enriches the protein content in the fibrous suspended solids separated earlier in Decanter. This Protein & Fibre rich DWGS is directly sellable as Cattle / Poultry Feed. However, the DWGS By-Product has less shelf-life and needs to be consumed within 2-3 days. In order to increase the shelf life of such by-product, it is necessary to dry the product, with minimum possible moisture content. SYSTEM DESCRIPTION FOR DWGS DRYER Wet distiller s grains shall be fed into the dryer housing at controlled rate through a suitable feeding system. The Rotary Tube Bundle is enclosed in an insulated dryer housing and on its outer flights is fixed. Dry saturated steam is to be supplied to the tube bundle through rotary joint at one end & the condensate is discharged through rotary joint mounted at other end. During the course of rotation, these flights pick up the material and shower them on to the tube bundles. The heat transfer is primarily by conduction. The water vapours are exhausted through an Exhaust Blower & passed through a cyclone separator for separating fines. Dry product partially recycled back to Feed conditioner for feed conditioning through Product Screw & Recycle Conveyor. Entire operation of the Dryer is controlled through Control panel. M/s. Oasis Distilleries Limited 14

15 Proposed Expansion of Existing Grain based Distillery from 50 to 250 KLPD (Ethanol/ENA/RS) along with installation of 5.0 MW Co-Generation Power Plant SYSTEM DESCRIPTION FOR COOLING & CONVEYING DWGS below product screw is discharged into charging hopper of pneumatic conveying system. Rotary feeder feeds it into the conveying line. Ambient air is used for conveying. The material gets conveyed to product collector & discharged from rotary discharge valve. Exhaust air is vented to atmosphere. The conveying system is lean phase suction type, using centrifugal blower as prime mover. The conveying air quantity is designed considering cooling requirement & to cool the product before discharge. Figure - 4: Process flow chart For Grain Based Distillery M/s. Oasis Distilleries Limited 15

16 Proposed Expansion of Existing Grain based Distillery from 50 to 250 KLPD (Ethanol/ENA/RS) along with installation of 5.0 MW Co-Generation Power Plant B) Power Co-Generation 5.0 MW OPERATIONS The unit proposed a 5 MW Co- Generation Power Plant. After proposed expansion, 65 TPH boiler will be installed which will operate mainly to feed steam to Grain based operations and 5.0 MW power generations from turbine. Co-generation plant consists of a high pressure water tube steam boiler extraction cum condensing steam turbine. Fuel in the steam boiler will be burnt with the help of air in the boiler furnace. Water will be circulated in the boiler drum and tubes thus getting heated by the flame burning in the boiler furnace. Water comes out of the boiler drum located at the top of the boiler as steam. Flue gases rise in the boiler furnace and come in contact with the steam coming out of boiler drum. Steam after coming in contact with flue gases gets heated up further thus getting superheated. Super heated steam leaves the boiler in a pipe. Flue gases after super heating the steam pass through economizer where they pre-heat the boiler feed water before it enters the boiler drum. After economizer, flue gases pass through air pre-heaters where they heat the air which is fed to the boiler furnace for burning the fuel. After air pre heaters flue gases pass through Bag Filter 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 boilers auxiliaries etc. FIGURE 5: Process flow chart for Proposed Co-generation Power Plant M/s. Oasis Distilleries Limited 16

17 Proposed Expansion of Existing Grain based Distillery from 50 to 250 KLPD (Ethanol/ENA/RS) along with installation of 5.0 MW Co-Generation Power Plant S. No. 1 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 The raw materials required for the Grain based distillery can be broadly categorized as follows: Grain Enzymes & Chemicals Steam Fuel Power, etc. The basic raw material for the manufacturing of ENA/RS/Ethanol will be Grain. In the present scenario, grains with different starch content are used like broken Rice, sorghum, baira, maize etc. The process requires the above grains to be milled into specific flour size. Small quantity of sulphuric acid is sometimes required. The raw material for the boiler fuel will be Coal/Rice Husk. Particular Requirement Source & Mode of Existing (TPD) Total after Transportation Additional for proposed proposed expansion (TPD) expansion (TPD) Through Grain Grain suppliers By road/rail 2. Chemicals Near-by Markets Liquefying /by road Enzymes Saccharifying Enzymes Yeast DAP and nutrients Name Raw Material of (b) Fuel Requirement Requirement Existing (TPD) Additional for Proposed Expansion (TPD) Total Quantity after Proposed Expansion (TPD) Coal Source & Mode of Transportation From Authorized Dealer / By Road M/s. Oasis Distilleries Limited 17

18 Proposed Expansion of Existing Grain based Distillery from 50 to 250 KLPD (Ethanol/ENA/RS) along with installation of 5.0 MW Co-Generation Power Plant (viii) Resources optimization/ recycling and reuse envisaged in the project, if any, should be briefly outlined. The waste water generated from the industry is being /will be properly treated through most modern technology i.e. Decantation followed by Evaporation with the Dryer; and the condensate water is being / will be recycled back in the process & also, reused for greenbelt development, which is being / will be results in Zero- Discharge. (ix) Availability of water it s source, energy /power requirement and source should be given. (a) Water Requirement and Source Existing water requirement for 50 KLPD Grain Based Distillery is 523 KLPD. Total water requirement after proposed expansion & installation will be 2961 KLPD. Source of Water: Ground Water. Water Requirement for Grain Based Operation The total water requirement for the Grain based Distillery is estimated at 2961 KLD, worked out as per details given below: TABLE - 2A WATER REQUIREMENT FOR GRAIN BASED OPERATION S. No. DESCRIPTION WATER CONSUMPTION (KLD) 1 PROCESS WATER IN LIQN & FERMENTATION DM WATER FOR RS DILUTION DM WATER FOR BOILER FEED SOFT WATER FOR VACUUM PUMP & OTHERS BLENDING BOTTLE WASHINGS 10 7 SOFT WATER MAKEUP FOR COOLING TOWER( PROCESS) OTHER DOMESTIC USAGE 10 9 SW FOR TURBINE COOLING TOWER MAKEUP 300 TOTAL WATER REQUIREMENT (A) 8344 TABLE - 2B TOTAL WATER OUTPUT S. No. DESCRIPTION WATER CONSUMPTION (KLD) 1 STEAM CONDENSATE SPENT LEES PR SPENT LEES RECTIFIER WATER IN THIN SLOPS 1214 M/s. Oasis Distilleries Limited 18

19 Proposed Expansion of Existing Grain based Distillery from 50 to 250 KLPD (Ethanol/ENA/RS) along with installation of 5.0 MW Co-Generation Power Plant 5 SOFT WATER FOR VACUUM PUMP & OTHERS WATER IN PRODUCT CT EVAPORATION & DRIFT LOSSES BOILER DRIFT AND BLOWDOWN LOSSES 40 9 CT EVAPORATION & DRIFT LOSSES ( TURBINE) DOMESTIC CONSUMPTION BOTTLE WASHING 10 TOTAL (B) 8344 TABLE - 2C RECYCLING & UTILIZATION STREAM S. No. RECYLCE & UTILIZATION STREAMS WATER CONSUMPTION (KLD) 1 RC LEES RECYCLE FOR RS DILUTION RC LEES AS COOLING WATER MAKEUP STEAM CONDENSATE RECYCLE FROM PROCESS SOFT WATER FOR VACUUM PUMP & OTHERS PROCESS CONDENSATE TO PROCESS THIN SLOPS RECYCLE PRC LEES RECYCLE TO LIQ 300 Total Recycling /Re-utilizations of water per day (C) 5383 TOTAL FRESH WATER INPUT (A-C) 2961 Hence, Fresh Water Requirement is 2961 KLD * Water requirement for first run would be 8344 KLD M/s. Oasis Distilleries Limited 19

20 Proposed Expansion of Existing Grain based Distillery from 50 to 250 KLPD (Ethanol/ENA/RS) along with installation of 5.0 MW Co-Generation Power Plant Figure - 5: Water Balance chart For Grain Based Distillery after proposed expansion M/s. Oasis Distilleries Limited 20

21 Proposed Expansion of Existing Grain based Distillery from 50 to 250 KLPD (Ethanol/ENA/RS) along with installation of 5.0 MW Co-Generation Power Plant (b) Power Requirement and Source Existing power requirement is 1 MW and additional 4 MW of power will be required for proposed Expansion. Thus, the total power requirement after proposed expansion & installation project will be 5 MW. Source: Co-generation Power Plant & D.G Sets (for back-up). (c) Steam Requirement Existing steam requirement is 15 TPH which is being met by boiler of capacity (10 & 6 TPH) and after proposed expansion & installation will be 64.6 TPH of steam will be required which will be met by existing 10 & 6 TPH boiler & proposed 65 TPH boiler. TABLE 4 STEAM REQUIREMENT S. No. Purpose Requirement after Proposed Expansion (TPH) 1. Cooking & Liquefaction Multi-pressure Distillation Evaporation (Integrated) 21 & DWGS Drier (DDGS) 4. Boiler De-aeration 6 Total 64.6 Existing and proposed boiler details are mentioned in the table given below: TABLE 5 BOILER DETAILS S. No. Boiler Details Existing Proposed 1. Type of Fuel COAL COAL 2. Capacity of Boiler TPH 65 TPH 3. Stack Height metres 52 M 4. Pollution Control Equipment Measures MDC & Cyclone Bag Filters/ESP Details regarding the D.G. Sets Two D.G. sets of 500 KVA have already been installed for the power backup and after proposed expansion one D.G set of 750 KVA will be installed. Details regarding the D.G. Sets are mentioned in the table given below: TABLE 8 DETAILS REGARDING THE D.G.SETS S. No. Details Existing Proposed 1. Type of Fuel Diesel Diesel 2. Capacity 2x500 KVA 1X750 KVA 3. Stack Height (above roof level) 10 Metres As per CPCB guidelines M/s. Oasis Distilleries Limited 21

22 Proposed Expansion of Existing Grain based Distillery from 50 to 250 KLPD (Ethanol/ENA/RS) along with installation of 5.0 MW Co-Generation Power Plant (x) Quantity of waste to be generated (liquid and solid) and scheme for their management/disposal o The proposed expansion & installation project is being/will be based on ZERO EFFLUENT DISCHARGE. o Grain Slops (Spent Wash) is being/will be taken through Centrifuge Decanters for separation of Suspended Solids separated as Wet Cake. o Thin Slops from the Decanter Centrifuge are being/will be 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 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) o DWGS is being/will be taken to a dryer operating on steam and is dried to make it DDGS Distillers Dried Grain Solubles. o The process condensate is being/will be cooled and collected into a neutralization tank with sufficient residence time. After Neutralization, this process condensate is being/will be recycled into process and is used for green belt development within the complex. o Two streams of low BOD lees (White Effluent) comes out is partly used as fermenter washing and then sent for Cooling, treatment and utilized for RS dilution. The second part requires only cooling and can be used as Cooling Tower water makes up directly. o Solid waste from the Grain based operations generally comprises of Fibres and proteins in the form of DDGS, which are being / will be ideally used as Cattle Feed. o Fly Ash from the Boiler is being / will be sold to Brick manufacturers. o ETP Sludge is being/will be utilized as manure for greenbelt development. o Yeast sludge is being / will be sent to the Sludge Drying Beds or may be added to the Wet Cake. o Used oil & grease generated from plant machinery / Gear boxes & D.G. Set is being / will be partly used in oiling & greasing as lubrication of external parts of machinery & partly is being / will be sold to the CPCB authorized recycler. 4.0 SITE ANALYSIS (i) Connectivity The plant site is located about at Village Boralli, Tehsil Badnawar, District Dhar, Madhya Pradesh. The plant site is well connected to NH-79 (adjacent to the plant site in West Direction). Nearest town/city to the plant site is Badnawar (~9 km in NNW direction from M/s. Oasis Distilleries Limited 22

23 Proposed Expansion of Existing Grain based Distillery from 50 to 250 KLPD (Ethanol/ENA/RS) along with installation of 5.0 MW Co-Generation Power Plant the plant site). Nearest railway station is Ratlam Railway Station (~49 Km in NNW direction) & nearest airport is Devi Ahilya Bai Holkar Airport, Indore, which is ~ 62 km in SW direction from the plant site. The site is well connected with communication facilities like telephone, fax, wireless. (ii) Land from Land use and Land ownership Total plant area is 35 ha. Since, the proposed expansion & installation will be done within the existing plant premises, thus, no additional land is required for the same. (iii) Topography The topography of the area 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 Environmental Settings of the Area S. NO. PARTICULARS DETAILS 1. Nearest Village Boralli (adjacent to plant site in West direction) 2. Nearest City Badnawar (~9 km in NNW direction) 3. Nearest National Highway / State Highway o NH-79 (adjacent to plant site in North direction) o SH 18 (~9 km in North direction) 4. Nearest Railway station o Ratlam Railway Station (~49 Km in NNW direction) o Indore Railway Station (~68 Km in SW direction) 5. Nearest Airport Devi Ahilya Bai Holkar Airport, Indore (~62 km in SW direction) 6. National Parks, Reserved Forests (RF) / Protected Forests (PF), Wild Life Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors etc. within 10 km radius 7. River / Water Body (within 10 km radius) 8. Soil Type Black Cotton Soil No National Park, Reserved Forests (RF) / Protected Forests (PF), Wild Life Sanctuary, Biosphere Reserve, Tiger / Elephant Reserve, Wildlife Corridors etc. falls within 10 km radius of the plant site. o Chamla River (~6.2 Km in SE direction) o Bagedi River (~7 km in NW direction) 9. Seismic Zone Zone - III [as per IS 1893 (Part-I): 2002] M/s. Oasis Distilleries Limited 23

24 Proposed Expansion of Existing Grain based Distillery from 50 to 250 KLPD (Ethanol/ENA/RS) along with installation of 5.0 MW Co-Generation Power Plant (v) Existing Infrastructure Total plant area is about 35 ha. Proposed expansion & installation will be done within the existing plant premises. Existing infrastructure comprises of Grain based Distillation & Fermentation unit and basic utilities such as water, power, etc. (vi) Soil classification Soil quality of District Dhar is reported to be alkaline and highly enriched with salts and it is classified as Black soil. (vii) Climatic data from secondary sources The Climate of this area is characterized by hot summer and well-distributed rainfall during the southwest monsoon season. Monsoon arrives generally in the middle of June and the weather becomes pleasant. January is generally the coolest month. Sometimes in December, the minimum temperature drops down to even as low as about 2 to 3 C. The maximum monthly rainfall takes place during the month of July. (viii) Social Infrastructure available Nearest habitation are at Boralli village. The nearest town is Badnawar, which is approx. 9 km in NNW from the plant site. At Badnawar, schools, dispensaries, small hospitals, places of worship etc are available. Electrical power supply in most of surrounding villages is available. Telephone, Medical facilities are available in the nearby towns. Almost all the villages in the buffer zone are electrified. L.T. power is being supplied for drawing water from a large number of tube wells sunk around the important village of the buffer zone, for irrigation purpose. Most of the tanks and ponds as well as the river water are being utilized for irrigation. 5.0 PLANNING BRIEF (i) Planning Concept (type of industries, facilities, transportation etc.) Town and country Planning/Development authority classification. The existing unit is Distillery industry and proposed expansion & installation will be done within the existing plant premises. Facilities required for the proposed expansion & installation project will be provided as per requirement. Transportation of raw material and final product is being / will be done by road. (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) Land use planning (breakup along with green belt etc) M/s. Oasis Distilleries Limited 24

25 Proposed Expansion of Existing Grain based Distillery from 50 to 250 KLPD (Ethanol/ENA/RS) along with installation of 5.0 MW Co-Generation Power Plant Total Plant area is 35 ha. Proposed expansion & installation project will be set up in the existing plant premises. No additional land will be required. About 33 % of the total plant area is being/will be covered under green belt & plantation in order to reduce dust & noise pollution levels & to increase aesthetic beauty of the area. (iv) Assessment of infrastructure demand (Physical & Social) Oasis Distilleries Ltd. has assessed the demand of infrastructure (Physical & Social) in nearby area of the plant site and development activities are being undertaken under corporate social responsibilities program for rural development initiatives for the upliftment of the nearby communities from time to time. (v) Amenities/Facilities Oasis Distilleries Ltd. has developed and will further develop the Amenities/Facilities in nearby area of the Plant site as per requirement of local people of the nearby area under corporate social responsibilities programs. 6.0 PROPOSED INFRASTRUCTURE (i) Industrial Area (Processing Area) For the proposed expansion of Grain based Distillery from 50 to 250 KLPD & installation of 5 MW Co-generation Power Plant, additional infrastructure will be built which includes grain storage, starch conversion, fermentation, distillation, boiler, turbine, evaporator & dryer. (ii) Residential area (Non Processing area) No residential area is envisaged. (iii) Green Belt Out of the total plant area (35 ha), 11.6 ha (~33%) has been developed under greenbelt / plantation area which will be further enhanced for proposed expansion & installation project, in order to reduce dust & noise pollution levels & to increase aesthetic beauty of the area. (iv) Social Infrastructure Proposed expansion & installation project will result in growth of the surrounding areas by ancillary development and supporting infrastructure in the region. (v) Connectivity The site is well connected with communication facilities like telephone, fax, and wireless as such no constraints are envisaged in this aspect. (vi) Drinking Water 7 m3/ day water will be required for drinking purpose after proposed expansion & installation project which will be sourced from Ground Water. M/s. Oasis Distilleries Limited 25

26 Proposed Expansion of Existing Grain based Distillery from 50 to 250 KLPD (Ethanol/ENA/RS) along with installation of 5.0 MW Co-Generation Power Plant (vii) Sewage Treatment System The waste water generated from the sanitary blocks is being/will be disposed off in soak pit via septic tank. (viii) Industrial Waste management The grain based distillery project is being / will be based on ZERO DISCHARGE. (ix) Solid Waste Management o Solid waste from the Grain based operations generally comprises of Fibres and proteins in the form of DDGS, which are being / will be ideally used as Cattle Feed. o Ash from the Boiler is being / will be sold to Cement & Brick manufacturers. o Yeast sludge is being / will be sent to the Sludge Drying Beds or may be added to the Wet Cake. (x) Power requirement and source Existing power requirement is 1.0 MW and additional 4.0 MW. Thus, the total power requirement after proposed expansion project will be 5.0 MW. Source: Co-generation Power Plant & D.G Sets (for Power Back-Up). 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). Proposed expansion & installation will be done within the existing plant premises. No additional land is required for the same and hence, Rehabilitation & Resettlement is not applicable. 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). The project will start only after obtaining Environmental Clearance and other statutory permissions. Project will be completed in 14 months after getting all the regulatory approvals. (ii) Estimated project cost along with analysis in term of economic viability of the project. Total cost of the Project: Rs. 140 Crores Cost for Environment Protection Measues: Capital Cost: Rs Crores Recurring Cost/annum: Rs. 1.5 Crores / annum. 9.0 ANALYSIS OF PROPOSAL (i) Financial and social benefits with special emphasis on the benefit to the local people M/s. Oasis Distilleries Limited 26