PRODUCT, BY-PRODUCT, RAW MATERIAL

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1 PRODUCT, BY-PRODUCT, RAW MATERIAL Sr. No. Name of Product Existing Quantity (30 KLPD) Expansion Quantity (30 KLPD) Total (60 KLPD) 1. Ethanol 8100 KL/Annum 8100 KL/Annum KL/Annum 2. Rectified Spirit 8100 KL/ Annum 8100 KL/ Annum KL/ Annum 3. Extra Neutral Alcohol 3000 KL/ Annum 3000 KL/ Annum 6000 KL/ Annum Sr. No. Name of By - Product Quantity Quantity Quantity 1. Fusel Oil 17 KL/Annum 17 KL/Annum 34 KL/Annum 2. CO 2 Gas 690 MT/M 690 MT/M 1380 MT/M 3. Compost (from Spentwash treatment) 14,820 MT / Season 14,820 MT / Season MT / Season Sr. No. Name of Raw Material Quantity Quantity Quantity 1. Molasses 3600 MT / Month 3600 MT / Month 7200 MT / Month 2. Yeast Test Tube Culture Test Tube Culture Test Tube Culture 3. DAP 1200 Kg / Month 1200 Kg / Month 2400 Kg / Month 4. Antifoaming compound 3500 Kg / Month 3500 Kg / Month 7000 Kg / Month 5. Urea 1200 Kg / Month 1200 Kg / Month 2400 Kg / Month 6. Formaline 100 ltrs 100 ltrs 200 ltrs 7. Bleaching Powder 60 Kg / Month 60 Kg / Month 120 Kg / Month 8. Sulphuric Acid 3000 Kg / Month 3000 Kg / Month 6000 Kg / Month 9. Caustic Soda 200 Kg / Month 200 Kg / Month 400 Kg / Month

2 Manufacturing Process The proposed distillery plant will operate on molasses as feed stock during season and on saved/ purchased molasses as feed stock during off-season. With 45 % fermentable sugar in molasses one ton of molasses will yield 256 lit of total ethanol molasses required per days is worked out in the following table. THE PROCESS Section-A: Yeast Propagation and Fermentation GIACL have planned to install the proposed 30 KLPD plant expansion of MOJJ Engineering Systems Ltd., Pune. MOJJ is the leading supplier of distillery plants in India, South Asia, Africa and South Central America, and have continuously developed process technologies and engineering for distilleries. Over the last fifteen years, MOJJ has supplied several fermentation and distillation plants, which are essentially designed to suit international norms of spirit quality and fermentation efficiency. The fermentation plant designs include cascade fermentation with cell recycle, cascade fermentation with yeast recycle and cascade fermentation with granulating yeast and gravity settling. The distillation plants are customized for quality, consumption and operational ease. There shall be state art specially designed equipments enabling efficient separation of impurities with reduced scaling and down time. MÖJJ, for the first time introduced the concept of integrated evaporator for substantial reduction of spent wash volume at no extra steam. As a latest development in the fermentation technology, MOJJ fermentation process has evolved. The technology is designed to specially handle the changing composition of molasses without having the problem of sludge recycle and build up, contamination and resulting low fermentation efficiencies. The technology uses special type of yeast with self-granulating property. This is Saccharomyces cerevesiae yeast with high specific growth rate and productivity. Due to the self-granulating property, the yeast can be separated by gravity settling and treated to wash away contamination. The treated yeast passes through activation step and is recycled back to fermentation. The MOJJ fermentation process thus gives high fermentation efficiency based on molasses composition and can be flexibly adapted for modernization of existing batch fermentation plants as well as for expansion or for new projects. The sections comprise yeast propagation section, fermentation section with four fermenters, yeast separation & treatment section and yeast activation section. While starting up the plant yeast propagation is done in propagation system. The grown yeast is used to fill up first fermenter and in a similar manner all the other fermenters are filled. When the fermenters are ready for distillation, the fermented wash is subjected to gravity settling for yeast separation. Sufficient residence time is used for completing fermentation. The residence time is dependent on molasses composition. The reactivated and grown yeast is sent to fermentation. All fermenters are sparged with Air / CO 2 generated during fermentation. This helps in maximum recovery of pure CO 2 from fermentation. Similarly, it helps in minimum generation of by-products. The CO 2 generated in fermentation is scrubbed through the CO 2

3 scrubber, for recovering alcohol in it, before realizing for recovery. This minimizes loss of alcohol. The process is designed to minimize the adverse effects of high volatile acidity and sludge in molasses. Similarly the process is designed to minimize effects of contamination. Section-B: Multi-Pressure Vacuum Distillation The fermented wash containing alcohol, non-fermentable solids and water is supplied to distillation to separate the alcohol and other impurities as a continuous flow. The distillation system is designed for premium quality Extra Neutral Alcohol. The system details are as below. The system consist of 7 columns viz. CO 2 Stripper, Stripper, Pre-Rectifier column, Extractive Distillation column, Rectification column, Refining column and Fusel Oil Concentration column. Wash is fed to CO 2 stripper column to remove CO 2 gas in wash. Alcohol is stripped off water in stripper column. The distillate from stripper column is fed to Pre-Rectifier column to remove most of fusel oils and the distillate from Pre-Rectifier column is fed to Extractive Distillation column, after dilution with soft water. In Extractive Distillation column most of high boiling impurities separated from alcohol in presence of water. The alcohol water mixture from bottom of Extractive Distillation column is pre heated by steam condensate and spent lees before being fed to rectification column. In Rectification column product Rectified Spirit is taken out from top tray and fed to refining column. In Refining column mainly methanol impurities are separated and pure Extra Neutral Alcohol from bottom of the column which is sent to storage after cooling. The impure spirit cuts from top of Pre-Rectifier column, Extractive Distillation column, Rectification column and CO 2 stripper column fed to Fusal Oil Concentration column. Final impure spirit cut is taken out from Fusal Oil Concentration column and balance alcohol is recycled back to Pre-Rectifier column. The alcohol containing fusel oil from Pre-Rectifier column and Rectification column is also fed to Fusal Oil Concentration column. The top vapors from CO 2 stripper column are partially used for heating fermented wash coming in and partially condensed in condensers. Also the vapours from Extractive Distillation column and Fusel Oil Concentration column are condensed in condensers. The Rectification column, Fusel Oil Concentration column and Pre-Rectifier column get heat from steam at 3.5 bar (g). Rectification column and Pre- Rectifier column work under positive pressure. Top vapours from Rectification column are condensed at CO 2 stripper column reboiler for giving heat to CO 2 stripper column. Most of the other columns work under vacuum or atmospheric pressure. Spent wash coming from CO 2 stripper column is partially cooled and recycled back to fermentation where it is used as diluter. Partially spent wash sent to Effluent Treatment. The special design facilities for reducing spent wash quantity from 11 ltr./lit of alcohol to finally 8 lit / lit of alcohol in CO 2 stripper column reboiler without additional steam for evaporation. Benefits of Multi pressure Distillation: 1) Operation of Analyzer column is under vacuum. This minimizes formation of by products during distillation (like Acetal). Hence, the overall quality of spirit is

4 improved. Also, chances of scaling due to invert solubility of certain precipitating inorganic salts of Calcium and Magnesium are reduced considerably in vacuum distillation. 2) Analyser column with Hyper state trays ensure high turbulence on tray, this minimizes Chances of scaling. Also, this special construction of trays and access to each tray helps in easier maintenance of column internals. 3) Pre-Rectification column ensures proper removal of Sulphur compounds / mercaptans for ensuring a good odour to alcohol. This column also reduces the load of lower boiling volatile compounds passing on to Rectifier cum Exhaust column. 4) Vacuum distillation system requires low steam consumption i.e. 1.8 kg/lit. of total alcohol of EQRS quality as against kg/lit of total alcohol of normal quality in atmospheric distillation. 5) System designed for maximum heat integration for optimum utilization of energy. 6) Minimum no of condensers. Forced circulation multi pass condensers with optimum tube side velocities. 7) Use of Term siphon re-boilers in Analyzer column helps in maintaining uniform temperature profile across the column. Also avoid excess spent wash volume generation. 8) Energy saving by recovery of Steam condensate from Thermo siphon re boiler of Analyzer column. 9) Effective separation of fusel oils from decanter. Manufacturing Process of Ethanol Rectified Spirit having 95% of alcohol taken from day receiving tank and feed it to feed pre heater through feed filter having capacity 1800 ltrs. In feed pre heater alcohol is heated up to 84 o C and feed to evaporator column. Principal of evaporator column is to evaporate Rectified Spirit to vapour state. The evaporator column is provided with re boiler for heating the spirit externally. Principally for better result of re boiler liquid level in evaporator bottom maintained as per specific norm. Spirit is feed from top of evaporator column and heat is given at bottom from re boiler. In evaporator column temperature of spirit increases up to 90 o C and converts in gaseous state from liquid state. This spirit vapours having 90 o C temperature feed to super heater where they are super-heated up to 130 o C at 0.7 kg/cm2 pressure. The super-heated vapors feed to molecular sieve beds A and B. Molecular sieves absorbs water molecules from broth of super-heated vapours and pure 99.9% alcoholic vapours carry over to regeneration pre heater followed by feed pre heater and product cooler. The cooled liquid product collected in product tank and pumped to storage section. The sieve beds are arranged in a cycle. When one is in charging state, other is in regeneration state.

5 MANUFACTURING PROCESS FLOW DIAGRAM OF ETHANOL Feed Pre Heater Feed Filter Feed RS/SDS Evaporator Column Re Generation Condenser Re Generation Filter Re Generation Cooler Super Heater Feed Filter Feed Filter Sieve Bed Feed Filter Feed Filter Regeneration Pre Heater Feed Pre Heater Product Condenser Product Receiver Product Pump Product Filter Product Cooler Draw

6 Material Balance for the Spentwash Bio-composting Process at the proposed 60 KLPD Distillery Unit of Gangamai Industries and Constructions Ltd. A. Press Mud Generation Details: From the Sugar Factory- NO. DESCRIPTION QUANTITY 1. Sugar Cane Crushing 5500 MT/ Day 2. Working Days 180 Days 3. Total Crushing 9,90,000 MT/ Season 4. Pressmud Quantity (4 % of total cane crushed) 39,600 MT/ Season B. Spentwash Generation Details: From Molasses based Distillery- NO. DESCRIPTION QUANTITY 1. Quantity of Spentwash after Biomethanation and Concentration from existing and proposed Distillery unit (Total 60KLPD). 150 M 3 /Day 2. Working Days 240 Nos./ Season 3. Total Quantity of Spentwash Generated 36,000 M 3 /Season.

7 C. Material Balance for Bio-composting Process: Pressmud along with filler material available for composting= 39,600 MT/ Annum Total quantity of spentwash available for composting= 150 Cu.M/Day (Maximum) Total number of working days of distillery= 240 Days Total spentwash available for composting= 36,000 Cu.M./Season For composting purpose, 2.5 MT is consumed per MT of the filler material. Hence, from spentwash contents available i.e., from 36,000 Cu.M., the pressmud requirement would be 14,400 MT. However, the available pressmud and filler material quantity is 39,600 MT. So, it can be stated that the quantity of press mud and filler material is adequate as required for composting. Now, Press mud and filler materials contain 30% of solids whereas concentrated spentwash contain 30% of solids by weight. Therefore, Total Solids in spentwash = 10,800 MT Total Solids in pressmud = 4320 MT 1 2 Hence, Total Solids contents are = 15,120 MT Taking 20% loss of CO 2 during composting, transportation and handling etc. The Net Solids production would be = 15, (i.e. 20% of 15,120) = 12,095 Considering 35% moisture in the Compost, Net Compost produced = 12,095 MT 0.65 = 18,607 MT

8 Land Requirement for Composting The quantity of concentrated spentwash sent to Compost yard=150 Cu.M./Day Now, As per the spentwash: pressmud proportions adopted actually in practice to the tune of 2.5:1, Quantity of Pressmud needed would be = 60 MT/Day As per the plot area geometry, the length of windrow = 200 M From the Aerating Machine Design details, width of windrow = 3.0 M Therefore, The volume of single windrow = ½ X 3 X 1.5 X 200 = 450 Cu. M. Height of windrow = 1.5 M Considering the Bulk Density of Pressmud as 500 Kg/Cu.M., The weight of Pressmud in single windrow = 450 Cu.M. X 500 Kg/Cu.M. = 2,25,000 Kg = 225 MT The Composting cycle gets completed within 45 days. Therefore, The total quantity of Pressmud generated in this period = 60 MT/Day X 45 Days The quantity of Pressmud in one windrow = 225 MT = 2700 MT Therefore, the total number of windrows = 2700 MT 225 MT/Windrow =12 Nos. of windrows Now, Width required = 11 Mid-spaces X 4M + 12 Nos. X 3M + 2 Margins X 15M (Dist. In bet.windrows) (Width of windrow) (For machine movement) = 110 M Length required = 200 M + 2 Margins X 15M (Length of Windrow) = 230 M Therefore, area required = 110 M X 230M = Sq.M. = 2.52 say 2.5 Ha = 6 Acres (For machine movement)

9 SPENTWASH BIO-COMPOSTING DETAILS Pressmud Generation from Sugar Factory NO. DESCRIPTION QUANTITY 1. Sugar Cane Crushing 2500 MT/ Day 2. Working Days 210 Days 3. Total Crushing 5,25,000 MT/ Season 4. Pressmud Quantity (4 % of total cane crushed) 21,000 MT/ Season 5. Other Filler Mat. [Boiler Ash & Baggasilo (57 MT/D) & Yeast Sludge (7.3 MT/D)] 13,722 MT / Season 6. Total Filler Material available for composting (4+5) 34,722 MT / Season Spentwash Generation in Distillery NO. DESCRIPTION QUANTITY 1. Quantity of Spentwash generated (Bio-methanated) 228 M 3 /Day 2. Working Days 240 Nos./ Season 3. Total Quantity of Spentwash Generated 54,720 M 3 /Season.

10 WATER BUDGET FOR EXPANSION OF 30 K.L.P.D. MOLASSES BASED DISTILLERY Daily Requirement of Water 315 K.L. (# 70 + * 245) Fermentation Dilution * 245 K.L. Plus Molasses 120 M.T. (Vol. 85 K.L.) Fermenter Cooling # 10 K.L. Condenser Cooling Replacement # 60 K.L.for R.S. Total Wash 330 K.L. (245 K.L K.L= 330 K.L.) Fermentation Cooling Blow Down 5 K.L. Distillation 330 KL 330 K.L. 240 K.L. Spent wash Steam, 54 MT (1.8 T/KL of alcohol) 60 K.L. Spent Lees CO 2 Gas to Atmosphere Condensate water 54 MT 30 K.L. Alcohols Total Effluent of 65 M 3 /Day shall be forwarded to Sugar Effluent Treatment Plant. Further, the treated effluent shall be used for gardening in own factory premises as well as for irrigation in near by farm land. 240 K.L. Final Spent wash Spent Wash from Existing Distillery 240 K.L. Bio-Methanation followed by Multiple Effect Evaporator (MEE) 480 K.L MEE Condensate 330 K.L CPU Spent Wash 150 K.L Bio-composting Used for treated water as Dilution Process Water *328 K.L Condensate Recycle for process *328 K.L (Expansion *245 + Existing *83)

11 WATER BUDGET FOR EXSISTING 30 K.L.P.D. MOLASSES BASED DISTILLERY BY Daily Requirement of Water 337 K.L (# 254+ *83) Fermentation Dilution #162 + * 83= 245K.L. PW + SW=FW Fermenter Cooling # 10 K.L. Condenser Cooling Replacement # 60 K.L.for R.S. For Boiler # 7 K.L. For Washing # 4 K.L. Laboratory # 1 K.L. Domestic #10 KL Plus Molasses 120M.T. (Vol. 85 K.L.) Total Wash 363 K.L. (245 K.L.+85 K.L= 330 K.L.) Cooling Blow Down 5 K.L. Boiler Blow Down 2K.L. Effluent Generated 3.5 K.L. Effluent Generated 0.75 K.L. Effluent Generated 6 K.L. Fermentation Distillation 330 KL Steam, 54 MT (1.8T/KL of alcohol) 330 K.L. CO 2 Gas to Atmosphere Condensate water 54 MT Total Effluent of M 3 /Day shall be forwarded to Sugar Effluent Treatment Plant. Further, the treated effluent shall be used for gardening in own factory premises as well as for irrigation in near by farm land. Domestic effluent shall be treated in septic tank followed by soak pit. 240 K.L. Spent wash 60 K.L. Spent Lees 30 K.L. Alcohols 240 K.L. Final Spent wash Bio-Methanation followed by MEE Note: # - This is the actual Quantity of Water taken from outside water supply source such as River Water. * - Water Consumption thus represented is actually utilized from the Condensation Water Quantity. i.e. The Natural Water present in Sugar Cane becoming available after crushing of the cane followed by subsequent processing, evaporation and condensation Operations as well as the Co-generation Turbine Condensate.

12 Sr. No. I Existing Water Purpose Quantity M 3 / day Industrial Process 245 (#162 + *83) WATER CONSUMPTION Expansion Water Quantity M 3 / day Total * (#162 + *328) Fermenter Cooling # 10 # 10 # 20 Condenser Cooling # 60 # 60 # 120 Washing # # 4 Boiler Feed # # 7 Laboratory # # 1 Total 327 (#244 + *83) 315 (#70 + *245) II Domestic # #10 Grand Total Purpose Existing Effluent Quantity M 3 / day EFFLUENT GENERATION Expansion Effluent Quantity M 3 / day Total 642 (#314 + *328) Disposal Method Fermenter Cooling Condenser Cooling Boiler Blow down Washing Laboratory Total raw spent wash from existing & proposed activities shall be 480 CMD. Same shall be first subjected to Biomethanation followed by concentration in MEE. Concentrated spent wash shall be used for composting. Spent lees 60 Spent lees Domestic Note: Industrial Process Spent wash- 240 Spent wash Spent wash shall be treated in Biomethanation Plant followed by Concentration in Multiple Effect Evaporator and composting. Other Effluents viz. spent lees, fermenter cooling, condenser cooling, Boiler blow down, lab & washing shall be forwarded to sugar factory ETP. Treated in septic tanks # - Water Consumption thus represented is the quantity towards Daily Requirement of Water shown in the Water Budget Flow Chart. This is the actual Quantity of Water taken from outside water supply source such as River Water. * - Water Consumption thus represented is actually utilized from the Condensation Water Quantity. i.e. The Natural Water present in Sugar Cane becoming available after crushing of the cane followed by subsequent processing, evaporation and condensation Operations as well as the Co-generation Turbine Condensate.

16 BIOGAS PLANT SPECIFICATION Type Make Capacity CSTR MM Enviro Projects Pvt. Ltd., Nagpur (MS) 600 M 3 / Day Calorific Value 4,600 4,750 Kcal/M 3 COD Reduction 70% Gas Generation Rate 1 Kg of COD reduction gives 0.5 NM 3 Gas Gas Generation/Day NM 3 / Day Feed Rate 10 M 3 / Hr Cost Rs. 3.5 Crores During closure period, 5 Days raw spentwash tank (1500 M 3 ) will be kept full for feeding CSTR The feed to CSTR shall be 5-10 M 3 / Day depending upon microbial reaction in the CSTR. To minimize the bacterial activity further temp. of CSTR shall be controlled through PHE. Gas generated during off season shall be flared through flare stack.

17 Details of Boiler & DG Set Sr. No. Fuel Consumption Biogas Furnace # Oil HSD (a) Fuel consumption (TKD/KLD) Kg /Hr 4800 Lit /Day Nm 3 /Day (b) Calorific value ,200 Kcal/Kg Kcal/M 3 kcal/ kg (c) Ash content % % 0.1 % (d) Sulphur content % % 1 % (e) Other (specify) (A) Details of Stack (a) Stack number (s) 1 2 (b) Attached to Boiler in distillery * DG Set (c) Capacity 8 TPH 900 KVA (d) Fuel type Biogas/Furnace Oil Diesel (e) Fuel quantity 675 Nm 3 /Hr or 6 MT /Day 200 Lit / Hr. (f ) Material of construction M.S. M.S. (g) Shape (round/rectangular) Round Round (h) Height, M (from ground level) 45 M 5.5 M (i) Diameter/size, in meters 1.2 M 0.2 M (j) Control equipment preceding -- Silencers the stack (k) Nature of pollutants likely to present in the stack gases -- SO 2, NOx * D.G. Set would be used as stand by source only in case of power failure. The stack height of D.G. Sets would be 5.5 M above roof level of the building in which it would be situated. # Only when biogas from bio-methanation plant is not available then the furnace oil shall be used as fuel.

REQUIREMENTS FOR AMENDMENT IN ENVIRONMENTAL CLEARANCE JUSTIFICATION FOR MODIFICATION IN THE SCHEME FOR SPENT WASH HANDLING IN THE DISTILLERY PLANT

AMENDMENT IN ENVIRONMENTAL CLEARANCE GRANTED BY MINISTRY OF ENVONMENT AND FORESTS, NEW DELHI VIDE FILE NO. J-11011/773/2007 IA II (I) DATED 16 TH JANUARY, 2008 REQUIREMENTS FOR AMENDMENT IN ENVIRONMENTAL