Amendment required in the existing EC

Transcription

1 Amendment required in the existing EC Change/Addition in Phase I; 250 KLPD Grain based Distillery with 20 MW Co-gen Power Plant / Molasses 160 KLPD based distillery with 12 MW Co-gen Power Plant in Environmental Clearance (EC letter no. J-11011/228/2015-IA II (I) dated 15th January, 2018) issued for Expansion of Grain based Distillery from 100 KLPD to 600 KLPD & Cogeneration Power Plant of 40 MW at Village Mansoorwal, Tehsil Zira, District Ferozepur (Punjab) Unit Details as per the EC Letter To be Revised / Read as Distillery (Ethanol/ ENA/ RS/ Industrial Alcohol Plant) 500 KLPD Grain based distillery (2X 250 KLPD) 500 KLPD Grain/ Molasses based distillery (Phase I ; 160 KLPD Molasses / 250 KLPD Grain based and Phase II ; 250 KLPD Grain based) Co -generation power plant 40 MW (2X 20 MW) 32 MW (12 MW & 20 MW) CO2 Plant 225 TPD (2X TPD) 225 TPD (2 X TPD) DDGS/ Cattle feed/ Poultry feed 300 TPD (2X150 TPD) 300 TPD - During 500 KLPD grain based operation 150 TPD - During 250 KLPD grain based operation The point wise amendments desired in the existing EC are as mentioned below: - 1. Para 2 - Unit with Capacity Details as per the EC Letter for Grain Based operation 250 KLPD x 2 Phase Distillery KLPD Grain based (2 x 250 KLPD) Co-generation Power Plant - 40 MW (2 x 20 MW) Distillery KLPD Grain/ Molasses based Phase ; i; 250 KLPD Grain / 160 KLPD Molasses & Phase ii; 250KLPD Grain based Distillery) Co-generation Power Plant 32 MW (12 MW & 20 MW) Justification / Reason The proposed amendment is sought keeping in mind due to - The ample availability of Molasses in the state of Punjab and as a whole in the country due to bumper crop of sugarcane. The current policy of Govt. of India permits the supply of Ethanol for Blending with fuel, only if it is produced from molasses. The cost economics of production also supports the proposal for manufacturing of ethanol from molasses.

2 2. Para 4 - Raw material Details as per the EC granted by MoEFCC on dated 15 th January, 2018 The raw material for the production shall be grains (damaged grain feed stock, nakku, kinki, sorghum, maize, bajra, barley, TPD), which shall be obtained from nearby areas. The raw material for the production shall be grains (damaged grain feed stock, nakku, kinki, sorghum, maize, bajra, barley) & molasses which shall be obtained from nearby areas. Ample availability of Molasses in the state of Punjab and as a whole in the country due to bumper crop of sugarcane. 3. Para 5 - Fresh Water requirement - The fresh water requirement will remain the same after amendment as there is no additional water requirement. Details as per the EC granted by MoEFCC on dated 15 th January, 2018 The total water requirement is estimated to be cum/ day. The treated effluent of 6848 cum/day is proposed to be recycled/ reused for different industrial operations, leaving the fresh water requirement for the proposed expansion limited to 4410 cum/day which is proposed to be met through Sirhind Canal Water. Necessary permission to draw 2.5 cusecs (6000 cum/day) of water has been obtained from the concerned authority i.e. Sirhind Canal Circle, Ludhiana. The total water requirement is estimated to be cum/ day. The treated effluent of 7402 cum/day is proposed to be recycled/ reused for different industrial operations, leaving the fresh water requirement for the proposed expansion limited to 3512 cum/day which is proposed to be met through Sirhind Canal Water. Necessary permission to draw 2.5 cusecs (6000 cum/day) of water has been obtained from the concerned authority i.e. Sirhind Canal Circle, Ludhiana. Water table and balance are given below The fresh water requirement will be decreased by 598 KLPD due to 160 KLPD molasses operation. Inplace of total fresh water consumption 4110 KLPD for 500 KLPD grain based operation, will be reduced to 3512 KLPD during phase -I: 160 KLPD molasses and phase II: 250 KLPD grain based operation.

3 Water requirement details and Breakup - Distillery Mode Total water consumption Total water 3R System Recycle / Reduce / Reuse Net water consumption EC approval for Total 500 KLPD Grain based operation Approval for Phase I ;250 KLPD Grain based operation OR phase I; Molasses 160 KLPD operation KLPD ( First Run Only) 5479 KLPD ( First Run Only) 5435 KLPD (First Run Only) 6848 KLPD 4110 KLPD 3424 KLPD 2055 KLPD 3978 KLPD 1457 KLPD For Grain 250 KLPD + Molasses 160 KLPD Water Consumption Increases / Decreases KLPD 7402 KLPD 3512 KLPD 44 KL Water Consumption decreases during 1 st run only 554 KLPD more water considered to be used under 3R s System 598 KLPD (Over all Water Saving due to Molasses running ) Water & Mass balance of 160 KLPD Molasses based Distillery are given below-

4 4. Para 6 - Spent Wash Treatment The project is being/ will be based on Zero Effluent Discharge. Details as per the EC granted by MoEFCC on dated 15 th January, 2018 Spent Wash will be taken through centrifuge decanters and thin slops from the decanter centrifuge will be partly recycled back to process (30-35 %) and partly taken to the Thin Slops Evaporation plant for concentration of remaining solids to form a syrup. This syrup will also be mixed into the wet cake coming out of centrifuge and forms part of cattle feed. Wet Cake/DWGS from decanter will be passed through steam tube bundle drier for drying into cake with 10-12% moisture (max.) to give higher shelf life. DDGS will be ideally used as cattle feed/ poultry feed/ etc. No effluent will be generated from the plant as the distillery is based on Zero Effluent Discharge. Molasses based operation Spent Wash treatment: Spent wash generated from the analyser column bottom during the operation will be concentrated in integrated & stand-alone Multi Effect Evaporator (MEE) from initial 12% solid to 55% solid and transferred for complete incineration/burning in a special boiler designed for spent wash. Called as INCINERATION BOILER. Hence, the complete spent wash will be concentrated & incinerated & no spent wash will be discharged. The Grain & Molasses based distillery is /will be based on Zero Liquid Discharge. During Molasses based operation Only 30% supporting fuel as Rice Husk/ Bagasse/Paddy/Coal will be used as to burn these spent wash quantity as to achieve ZLD concept. The water evaporated is partly taken to the process as recycle water and balance fed to ETP/STP to reuse after treatment as to achieve ZLD concept. There will be no DDGS production & total Concentrated spent wash from MEE will be fed into Incineration boiler to burn it as fuel.

5 Details as per the EC Letter Gain Operations system & Equipment s 1. Gain Storage Silo 2. Milling 3. Liquification 4. Yeast Culturing & Fermentation (6 + 1 Fementer having capacity 10 Lac each) 5. MPR Distillation 6. Integrated Evaporation 7. Decanter 8. Dryer 9. Receiver & Storage 10. Waste Water Treatment Plant (STP/ ETP) 11. Water Treatment Plant (Softener, RO System) 12. Continues Online Monitoring System for effluent, the unit shall install web camera with night vision capability & flow meters in the channel/drain carrying effluent within the premises. For 160 KLPD Molasses/250 KLPD Grain operation Molasses Operations system & Equipment s 1. Molasses Storage Tank (10,000 MT X 5 no. s) 2. Yeast Culturing & Fermentation (3 + 1 Fementer having capacity 10 Lac each) 3. MPR Distillation 4. Integrated Evaporation 5. Standard alone Evaporation 6. Incineration Boiler with ESP 7. Receiver & Storage - (Same) 8. Waste Water Treatment Plant (STP/ ETP) (Same) 9. Water Treatment Plant (Softener, RO System) - (Same) Justification / During 160 Molasses operation additional equipment s will be as; 1. Molasses Storage Tanks 2. Standard alone Evaporation to concentrate spent wash as to utilized as fuel to be fed into Incineration Boiler to achieve ZLD concept 3. Incineration Boiler; to burn total molasses spent wash concentrate as to achieve ZLD Concept.

6 Figure:- Process flow diagram of Grain based Distillery Figure:- Process flow diagram of Molasses based Distillery

7 5. Para 7 - Power Requirement - The power requirement will remain same after desired amendment. Details as per the EC granted by MoEFCC on dated 15 th January, 2018 The total power requirement for proposed project shall be 9.0 MW proposed to be sourced from 40 MW (2X20 MW) Co- generation Power plant & 3X 1000 KVA of DG set (for back up). The total power requirement for proposed project shall be 9.0 MW proposed to be sourced from 32 MW (12 MW & 20 MW) Co- generation Power plant & 3X 1000 KVA of DG set (for back up). The total capacity of cogeneration power plant reduced from 40 MW to 32 MW only. 6. Para 8 - Boiler Details - Total Boiler capacity will remain same. Details as per the EC granted by MoEFCC on dated 15 th January, 2018 Two biomass/ rice husk/ bagasse/paddy & wheat straw fired boilers of 100 TPH capacity each shall be installed. A stack of 63 m height equipped with Electrostatic Precipitator (ESP) shall be installed to encounter the emission from boiler stack. (2x100 TPH = 200 TPH) 65 TPH Incineration boiler with fuel as concentrated Spent wash 70 % along with 30 % Biomass shall be installed for Molasses based operation. A stack of 75 m height equipped with Electrostatic Precipitator (ESP) OR Bag Filter shall be installed to encounter the emission from boiler stack. The same Boiler will be used for Phase I ; 250 KLPD Grain operation also with Fuel as biomass/ rice husk/ Bagasse/paddy & wheat straw etc as 100 %. (Phase I ; 65 TPH + Phase II ; 100 TPH = TOTAL ; 165 TPH) Total boiler capacity Reduced from 200 TPH to 165 TPH, resulting in the decrease of pollution load. ii. Chimney height increase from 63 Mtr to 75 Mtr to achieve Boiler emission within the approval level Concentrated spent wash from MEE will be fed into Incineration boiler to burn it as fuel along with biomass/ rice husk/ bagasse/ paddy & wheat straw.

8 Para of EC issued by MoEFCC Details as per the EC Letter For 160 KLPD Molasses / 250 KLPD Grain operation Boiler details Justification / Fly Ash stored in the Silo followed Boiler Ash Ash from the Boiler shall be sold to the brick manufacturers. by pneumatic Ash Handling System to complete control of dust particles emission. Total Quantity of Fly Ash will be used for Brick manufacturing by nearby Bick manufacturers. Molasses Fly Ash will be used as organic fertilizers also, due to availability of high potassium There will be no any change during Molasses Operation or Grain Operation. & all parameters of PM10 SOX, NOX & Noise level will be under approval level only. content 8 9%. PM & Emissions Particulate Matter & Gases Emission Installation of ESP with adequate Stack height Covered Storage for fuel. same will be maintained as per CPCB/HSPCB Acoustic enclosure will be provided to the DG Acoustic enclosure will be provided sets to mitigate the to the DG sets to mitigate the Generation of Noise noise pollution. The Gases emission from DG set will be noise pollution. The Gases emission from DG set will be dispersed through There will be no any change during. dispersed through adequate stack height as per guide adequate stack height lines as per guide lines

9 Details as per the EC Letter Phase I : 250 KLPD Grain Based Distillery Or 160 KLPD Molasses Based Distillery Operation Justification / Industrial/ trade effluent shall be segregated into high COD/TDS and Low COD/TDS effluent Streams, as applicable, High TDS/COD shall be passed through stripper followed by MEE and ATFD (agitated thin film drier). Low TDS effluent Stream shall be treated in ETP and then passed through RO system. Total Water Consumption for Phase- I : 250 KLPD grain based operation will be 2000 KLPD Approval of Boiler for Phase I & Phase II as per EC :(2x100 TPH = 200 TPH ) The system will be same for 250 KLPD grain based STP / ETP or 160 KLPD Molasses based operation. As per EC approval given for the treatment of waste water in STP / ETP capacity is 1900 Cum/day whereas for 160 KLPD molasses operation it will be only 1600 cum/day. But during molasses based operation net water consumption will be only 1457 KLPD, Hence there will be saving of approximately 543 KLPD Water Now Boiler will be considered for Phase I : For 250 KLPD grain operation or 160 KLPD Molasses operation will be 65 TPH only & Phase II : As per EC approval i.e total 165 TPH ( Phase I ; 65 TPH + Phase II ; 100 TPH = TOTAL ; 165 TPH) The effluent load will be decreased by 300 KLPD Hence there will be saving of approximately 543 KLPD Water Overall Boiler capacity reduced by 35 TPH during Phase I operation due to which fuel consumption, water consumption, Emission load etc. will be decreases. 7. Para 12 - Expansion Capacity - Details as per the EC granted by MoEFCC on dated 15 th January, 2018 Expansion of Grain based Distillery from 100 KLPD to 600 KLPD (by adding 2 units of 250 KLPD each in two phases as Unit II) and the expansion of Co-generation Power Plant by adding 40 MW (2X20 MW). Expansion of Grain/ Molasses based Distillery from 100 KLPD to 600 KLPD (by adding Phase I ; 250 KLPD Grain based distillery with 20 MW Co-generation Power plant or 160 KLPD Molasses Based Distillery with 12 MW Co-generation Power Plant and Phase II; 250 KLPD Grain based distillery with 20 MW Cogeneration Power Plant.