Pre-feasibility Report Page | 0 PRE- FEASIBILITY REPORT SUBMISSION TO MINISTRY OF ENVIRONMENT, FOREST & CLIMATE CHANGE, NEW DELHI By SHRI BAJRANG AGRO PROCESSING LIMITED (Phase – I: 1x120 KLPD Grain based & 1x60 KLPD Molasses based distillery plant to produce Ethanol/RS/ENA/ Potable alcohol/Industrial Alcohol & 6.0 MW Power plant Phase-II: 1x120 KLPD Grain based & 1x60 KLPD Molasses based distillery plant to produce Ethanol/RS/ENA/ Potable alcohol /Industrial Alcohol & 6.0 MW Power plant) Jalso Village, Tilda Tehsil, Raipur District, Chhattisgarh. PREPARED BY 6-3-652 | Flat # 7-3 | Dhruvatara Apartments | Amrutha Estates | Erramanjil | Somajiguda | Hyderabad- 82 | E mail: [email protected], [email protected]|www.pioneerenvirolabs.com | PEOPLE WHO CARE FOR ENVIRONMENT | SAVE ENVIRONMENT | Accredited by ISO 9001: 2008 Certified
49
Embed
PRE- FEASIBILITY REPORTenvironmentclearance.nic.in/writereaddata/Online/TOR/02... · 2019. 7. 2. · Pre-feasibility Report P a g e | 0 PRE- FEASIBILITY REPORT SUBMISSION TO MINISTRY
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
Pre-feasibility Report P a g e | 0
PRE- FEASIBILITY REPORT
SUBMISSION
TO
MINISTRY OF ENVIRONMENT, FOREST & CLIMATE CHANGE,
NEW DELHI
By
SHRI BAJRANG AGRO PROCESSING LIMITED (Phase – I: 1x120 KLPD Grain based & 1x60 KLPD Molasses based distillery plant to produce
11 Waste water treatment With grains as feed stock :
Spent wash will pass through decanter and then the thin slop from Decanter will be treated in Multiple Effect Evaporators (MEE) followed by Dryer and concentrated up to 90% solids w/w to get DDGS. This will be sold as Cattle feed/Poultry /fish feed etc.,It is a ZLD plant as approved by CPCB.
SHRI BAJRANG AGRO PROCESSING LIMITED DISTILLERY AND POWER PLANT
Pre-feasibility Report P a g e | 3
With Molasses as feed stock: Spent wash will be concentrated in Multiple Effect Evaporators (MEE) to 55-60% solids and then incinerated in slop fired Boilers (2x17 TPH). Spent lees & condensate will be treated in Condensate Polishing Unit (CPU). Non-process effluents like DM plant regeneration water & boiler blow down will be neutralized in neutralization tank and will be mixed with Cooling tower blow down. This treated effluent after ensuring compliance with standards stipulated by CECB for wastewater for on land for irrigation, will be utilized for internal greenbelt development, dust suppression, ash conditioning.
12 Solid / hazardous waste
management and
disposal
(a) Grain based distillery : DDGS will be used cattle /fish/prawns feed. Yeast Sludge will be used as manure. Ash generated from the boilers (2x34 TPH) will be given to
brick manufacturing units.
(b) Molasses based Distillery: Yeast Sludge will be used as manure. Ash generated from slop fired Boiler (2x17 TPH) will be
given to Fertilizer manufacturing units.
13 Green belt Greenbelt will be developed in 15 acres covering more than 33%
of the total area.
SHRI BAJRANG AGRO PROCESSING LIMITED DISTILLERY AND POWER PLANT
Pre-feasibility Report P a g e | 4
2.0 INTRODUCTION
2.0 Introduction
India, the fourth largest economy in the world, has been maintaining a GDP growth rate of
more than 7% for more than a decade. Analysts have projected that India has the potential to
almost double her present rate of growth with labour and capital productivity improvements.
Industrial development plays an essential supportive role in improving labour and capital
productivity. Investment in industrial sector is also an indicator of economic growth in all market
economies. Ethanol is the basic raw material for the utilization in the chemical industry, for
potable purposes and is now being used for blending with the petrol as fuel.
Ethanol is a clear, colorless liquid with a characteristic, agreeable odour. In dilute aqueous
solution, it has a somewhat sweet flavor, but in more concentrated solutions it has a burning
taste. Ethanol melts at -114.1°C, boils at 78.5°C, and has a typical density of 0.789 g/ml at 20°C.
Ethanol has been made since ancient times by the fermentation of sugars. All the beverage
ethanol, and more than half of industrial ethanol, is still made by this process. Simple sugars are
the raw materials. Enzyme from yeast, changes the simple sugars into ethanol and carbon
dioxide. Starches from potatoes, corn, rice, wheat, and other grains can also be used in the
production of ethanol by fermentation. However, the starches must first be broken down into
simple sugars. The Enzymes used in Liquefaction & Scarification stages help convert the starches
into sugars, which can then be fermented using appropriate Yeast to convert into Ethyl Alcohol
(Ethanol), grades of Extra Neutral Alcohol (ENA) or Rectified Spirit (RS). This Alcohol may also be
utilized for Blending & Bottling and Potable purpose for making IMFL / IMIL / Liquors, etc.
Fuel Ethanol Market – India:
About 85% of petroleum oil need of India is being met through imports. Indian economy is
growing steadily resulting in rapid increase of vehicular population and demand for
transportation fuels. Indian Government has already mandated blending of ethanol in
gasoline by 10% to reduce the oil import. Bureau of Indian Standards is finalizing the
specification of 20% ethanol blended gasoline for use as vehicular fuel. In this context, this
review presents the current and future scenario of Indian transportation, petroleum oil and bio-
fuel sectors including global progress on utilization of ethanol as an alternative transportation
fuel in spark ignition vehicles. The data from various standard reference sources were compiled,
volume without using any steam, thus resulting in substantially energy savings over the
plant life,
Vacuum operation combined with the high turbulence tray design for Beer Stripper
column almost eliminates the scale formation, hence plant down time is substantially
reduced,
Indirect heating of Analyzer column to prevent undesired dilution of spent wash with
steam condensate
Mutli-pass design of condensers with higher tube velocities to minimize scaling inside
tubes and ensure higher heat transfer coefficients,
Highly efficient Fusel Oil Decanter with proper mixing, calming and separation zones
ensures proper separation of fusel oils,
Better quality product with effective separation of impurities,
Higher Distillation efficiency,
Fully automated plant with advanced control system eliminates chances of human error
and ensures consistent high distillation efficiencies and excellent product quality.
Integrated Evaporator:
Evaporation is a thermal operation used to remove a liquid from a solution by boiling off the
solution. The evaporation process starts with a liquid product and ends with a concentrate as the
main product from the process.
Offered Spent Wash Concentration System comprises of a Seven-effect evaporator unit thermally
integrated with the distillation plant. The integrated evaporator will use only waste heat from the
distillation plant for the concentration of thin stillage, without using any steam.
SHRI BAJRANG AGRO PROCESSING LIMITED DISTILLERY AND POWER PLANT
Pre-feasibility Report P a g e | 22
Vapors from the top of pre-concentrator and recovery columns will be used to heat the
evaporators of integrated four-effect evaporator and provide thermal energy required for
concentrating the thin stillage. The condensate from respective evaporators will be collected and
pumped back to the pre-concentrator and recovery columns as reflux.
Offered Integrated Evaporator System is a combination of falling film and forced circulation
evaporators, to optimize heat transfer requirements and electric power consumption of the
system. It is a four-effect evaporation system with three effects based on falling film concept and
one final effect based on forced circulation concept. The falling film evaporators having extremely
high thermal efficiency with low power consumption are used for the effects handling liquid with
lower solids content. For final effect, where solids content is high, forced circulation evaporator
has been used.
In forced circulation evaporator the liquid is circulated at very high flow rates through the heating
tubes. Forced circulation evaporators consume higher amount of electric energy but substantially
minimize the fouling rates and resulting down time for the Spent Wash Concentration Plant.
Salient features:
Energy efficient system running on waste heat from distillation section and requiring no
Steam for operation,
Lower fouling rates i.e. lower deposition of solids on tube surfaces results lower operating
costs with no chances of choking or system breakdown during operation.
Simplified Easy Plant Operation by full automation.
Process Condensate generated in process can be reused, minimizing the plant water
consumption.
Distillers Dry Grain & Solubles (DDGS):
After recovery of the alcohol, spent wash leaves distillation plant from the base of Beer Stripper
Column. The spent wash from grain-based distillery contains suspended and soluble grain solids
comprising of fibers, proteins, fat, etc. which remain unconverted during the fermentation
process and pass through as such, plus valuable yeast nutrients are added during the
fermentation process. The resulting product has high nutrient content and has great value as
cattle –feed.
Operation of DDGS Section can be divided broadly in three sub-sections, i.e. Decantation,
Evaporation and Drying.
SHRI BAJRANG AGRO PROCESSING LIMITED DISTILLERY AND POWER PLANT
Pre-feasibility Report P a g e | 23
a. Decantation:
Spent wash from the distillation section will pass through horizontal high-speed Decanters, which
separates suspended solids from the spent wash and split the spent wash feed stream into two
streams, as below:
Wet Cake: it is the solids stream from decanter consisting of majority of suspended solids.
It has approximately 30% solids and 70% water.
Thin stillage: Liquid stream consisting of mainly water with all dissolved solids and
remaining suspended solids.
A part of thin stillage is recycled back to the liquefaction section, thus reducing the
requirement of process water. Balance quantity of thin stillage is pumped to Evaporators
for concentration.
b. Evaporation:
In offered system thin stillage will be concentrated to a solids content of about 30% w/w, in an
Evaporator thermally integrated with distillation section. The concentrated thin stillage syrup
from evaporator will be mixed with wet cake from spent wash decanter. The mixture is known as
DWGS (Distillers Wet Grain and Soluble). It contains all required nutrients and has high value as
very good cattle feed. But due to its higher moisture content, it can’t be stored as such for a
longer time period and needs same day disposal form the plant.
c.Drying:
The thick slop from the multiple effect evaporator system will be mixed with wet cake from the
decanter in a specially designed paddle mixer. The ratio of thick slop & wet cake will be 50% &
50% respectively.
A portion of the dried DDGS product is recycled back to paddle mixer by a suitable conveyor
system. The mixed and conditioned wet feed is then fed at a constant rate via a screw feeder.
Back mixing of the product lowers the moisture content thus improving the physical form and
handling characteristics of the feed material.
In dryer the wet mass is indirectly heated by using dry & saturated steam. The steam tubes are
arranged concentrically with tube sheet & baffles. The steam enters the tube and heats the tube
walls. A rotary joint and circulate header is used to feed steam inside the tubes with proper
distribution of steam and condensate removal arrangement.
SHRI BAJRANG AGRO PROCESSING LIMITED DISTILLERY AND POWER PLANT
Pre-feasibility Report P a g e | 24
Wet mixed material comes in contact with the hot tubes, as it moves forward in the dryer drum.
The moisture in wet, material vaporizes and it gets dried. The dried fiber product is discharged
from the dryer drum through outlet port of the discharge manifold.
The vapors generated from the drying of mixture are removed from the dryer enclosure by an ID
Fan. The fine particles escaping with the purge air are trapped and collected by a cyclone
separator and discharged continuously via rotary valve. The humid air is exhausted into
atmosphere via cyclone outlet port.
The hot and dried product is cooled in an online cooler. The product cooler system is indirect and
water cooled. Tubular cooler with fixed shell and rotating tube bundle is considered.
Control system:
A PLC based control system will be provided to ensure continuous, stable and efficient plant
operation. Electronic field instruments linked to the PLC control panel will be used for measuring
the value of various process parameters.
All measured single such as temperature, differential/absolute pressures, flows and levels will be
continuously monitored and compared with set point values in PLC system. If any deviation is
observed form set point values for any particular process parameter, a suitable control action
based on programmed algorithms will be generated by PLC system. Desired control action will be
provided through control value or viable frequency drive.
Man machine interface will be provided through SCADA (Supervisory Control and Data
Acquisition) software running on a desktop computer. The operating panel will be located in the
control room and consists of operator work station with 20th color monitor and operator
keyboard. Features such as trends, graphics, process parameter indication, etc. well be
incorporated.
Control system will store all operating data and provide historical trending and real time analysis
for evaluating the anticipated and achieved plant performance. The panels for PLC hardware
installation and motor control switch gear will be installed in a control room, to be provided by
client, in ex-free area. The process flow diagram of grain based distillery plant is shown below:
SHRI BAJRANG AGRO PROCESSING LIMITED DISTILLERY AND POWER PLANT
Pre-feasibility Report P a g e | 25
3.5.1 Process description for Molasses based plant
Molasses handling &storage:
Molasses received in tankers is unloaded in a molasses unloading pit and pumped to bulk
molasses storage tanks. As and when required, molasses is pumped from bulk storage tanks to
molasses day tank in the fermentation areas though a weighing system.
Yeast culturing:
Yeast cell mass is grown in this section. Yeast culturing system comprises of three yeast
propagation vessels of incremental sizes, which are connected in series. Diluted molasses mash is
Grain receiving, Handling & Storage
Grain Cleaning & Milling
Mashing & Cooking
Liquefaction
Saccharification & fermentation
Distillation
Decanter
DDGS Dryer
Evaporation
DDGS
ENA & TA Storage
Steam generation
Power generation
Cooling Tower
SHRI BAJRANG AGRO PROCESSING LIMITED DISTILLERY AND POWER PLANT
Pre-feasibility Report P a g e | 26
taken in 1st vessel and yeast cell mass is pitched in it under hygienic corotiors. Cell-mass grows
and is then transferred to the pre-fermenter.
Series air, necessary for yeast growth, is supplied to yeast propagator and pre-fermenter vessels.
The heat generated in pre-fermenter is removed by circulating the corterts of pre-fermenter
through pre-fermenter cooler. Finally, a part of cell-mass from pre-fermenter is transferred to the
fermentation tanks. Alternatively, dry yeast can be used for directly seeding the pre-fermenters.
Fermentation:
Offered fermentation system consists of four fermentation tanks operating tanks operating in
FED-batch mode.
Fermenters serve as bioreactor vessels in which sugar, (converted from starch in case of grain-
based operation), is converted to ethanol by the yeast (Saccharomyces cerevisiae). The
fermenters are designed for efficient heat removal and good mixing to facilitate maintenance
process. This ensures good startup with rapid fermentation and high ethanol content in the
fermenters.
Each fermenter is filled with dilute molasses and yeast cell mass the pre-fermenter is transferred
to it during the filling process. The fermentation process is exothermic, i.e. heat is generated
during the process. To maintain an optimum temperature of around 32oC in fermenters, heat
generated during fermentation process is removed by circulating fermenter contents through
external heat exchangers, cooled by cooling water. The gases generated during fermentation
process are collected and scrubbed in CO2 scrubbed, to recover ethanol being carried over with
vent gases.
After completion of fermentation process, fermented beer is transferred to the beer well and
fermenter tank is thoroughly cleaned for the next fermentation cycle. Beer well provides the
surge capacity between fermentation and distillation systems.
Efficient CIP system is provided for cleaning of fermentation tanks, heat exchangers and
associated piping to ensure sanitary conditions during fermentation. To provide proper cleaning,
each fermenter is fitted with high pressure jet type rotating tank cleaner connected to the CIP
system.
Salient features
Rugged process and ease of operation
SHRI BAJRANG AGRO PROCESSING LIMITED DISTILLERY AND POWER PLANT
Pre-feasibility Report P a g e | 27
Better sanitation and low contamination result in faster fermentation and lower residence
time.
Proper sanitary conditions maintained by effective CIP system ensure Low bacterial
activity and contamination levels in fermenters.
Consistently high-performance plant operation, as every batch is fresh and seeds
independently,
Higher alcohol concentration in fermenters leads to reduced steam consumption in
distillation and lower effluent volume.
Clean-In-Place (CLP) system:
Efficient CLP system is provided to ensure proper cleaning of process equipment with inter-
connecting piping and minimize microbial contamination in the process. The system consists of
hot water tank, a high-pressure pump with tank cleaning nozzles and associated piping. A good
quality sterilant is used during the CLP cycle to disinfect the system, as and when required.
Distillation:
Offered multi-pressure distillation system comprises of seven distillation columns operating at
different internal pressures, so that overhead vapors from the distillation columns operating
under higher pressure can be used to heat columns operating under lower pressure. This thermal
integration columns leads to system where high-grade neutral alcohol can be produced with very
low energy consumption.
Fermented beer containing alcohol is preheated and fed to the degasifying column for removal of
entrained alcohol carbon dioxide and low boiling impurities. The degassed fermented beer is then
fed to beer stripper column, where alcohol is stripped from the fermented beer.
Raw alcohol recovered in beer stripper column is fed to pre-concentrator column, which
concentrates the alcohol and provided for first stage removal of low boiling impurities and fusel
oils. The impure spirit draws are taken to recovery column for further concentration and recovery
of ethanol.
Overhead vapors from pre-concentrator column are taken to pre rectifier condensers and liquid is
pumped back to column top as reflux.
Concentrated alcohol from top of the pre-concentrator column is diluted with soft water and
recycled spent lees and then ED column where it undergoes extractive distillation under high
dilution. Extractive distillation process under high efficiency removal of all high and low boiling
SHRI BAJRANG AGRO PROCESSING LIMITED DISTILLERY AND POWER PLANT
Pre-feasibility Report P a g e | 28
impurities and ensure high efficiency removal of all high and low boiling impurities from the top
of ED column.
Purified dilute alcohol from the base of ED column is fed to rectification column where it is
concentrated to about 90% v/v ethanol content. Side draws are taken from the rectification
column to remove fusel oils/heavier impurities, while light impurities are removed from the top
of rectification column. Impure spirit draws taken to recovery column for further column for
further concentration.
Neutral alcohol draw from the top section of rectification column is taken to polishing column for
slow stripping and removal of any remaining light impurities, mainly methanol and diacetyl.
Purified premium quality neutral alcohol product is draw from the bottom of polishing column
and transferred to ENA receivers after cooling in the product cooler.
Impure draws from all columns consisting of heads, esters and fusel oils are taken to recovery
column for the concentration of the impurities and to recover excess ethanol. Ethanol stream
recovered from the top of recovery column is recycled back to the system. This ensure lower
overall impure cuts during the distillation process.
A highly concentrated draw of impure spirit taken from the vent condenser of recovery column
and transferred to impure spirit receiver. Fusel oil draws from the recovery column are taken to
fusel oil decanter where fusel oil is separated and transferred to fusel oil tank. The fusel oil
washings from the bottom of the decanter are taken back to the recovery column feed tank.
Salient features:
SAMPLE SISTILLATION SCHEME with optimum number of distillation column and easy
plant operations,
Energy efficient thermally integrated multi-pressure column operation leads to lower
steam consumption,
Vacuum operation combined with the high turbulence tray design for beer stripper
column almost eliminates the scale formation, hence plant down time is substantially
reduced,
Indirect heating of analyzer column to prevent undesired dilution of spent wash with
steam condensate
Multi-pass design of condensers with higher tube velocities to minimize scaling inside
tubes and ensure higher heat transfer coefficient,
SHRI BAJRANG AGRO PROCESSING LIMITED DISTILLERY AND POWER PLANT
Pre-feasibility Report P a g e | 29
Highly efficient fusel oil decanter with proper mixing, calming and separation zones
ensures proper separation of fusel oils,
Better quality product with effective separation of impurities,
Higher distillation efficiency,
Fully automated plant with advanced control system eliminates chances of human error
and ensures consistent high distillation efficiencies and excellent product quality,
Integrated Evaporator:
Evaporation is a thermal operation used to remove a liquid from a solution by boiling off the
solution. The evaporation process starts with a liquid product and ends with a concentrate as the
main product from process.
Offered integrated spent wash concentration system comprises of seven effect evaporator unit
thermally integrated with the distillation plant. The integrated evaporator will use heat from the
distillation plant (Alcohol vapours) for the concentration of RSW along with partial steam during
molasses mode whereas for the grain mode no steam shall be required and alcohol vapours shall
be sufficient to evaporate the thin slops. As part of heat source vapors from the top of pre
rectifier and recovery column will be used to heat the falling film evaporators which are on top of
these columns.
The alcohol condensate from respective evaporators will be collected and pumped back to the
respective column as reflux.
Salient features:
Energy efficient system running waste heat from distillation section and requiring
minimum steam for operation during the molasses mode
Lower fouling rates i.e. lower deposition of solids on tube surface result slower operating
costs with chances of choking or system breakdown during operation.
Simplified easy plant operation by full automation.
Process condensate generated in process can reused, minimizing the plant water
consumption.
MSDH:
Ethyl alcohol dehydration plant take advantage of a unique property of the molecular sieves. The
grade of molecular sieve chosen is such that it will selectively adsorb water molecules but will
reject ethanol molecules because they are too large under the correct operating circumstance
SHRI BAJRANG AGRO PROCESSING LIMITED DISTILLERY AND POWER PLANT
Pre-feasibility Report P a g e | 30
molecular sieve beads will absorb water from ethanol and water azeotrope. Leaving the ethanol
essentially stripped of water. The plant will be designed to operate in stand-alone mode. The
plant will produce anhydrous ethanol product with 0.20% (v/v) water content by processing a
feed of alcohol/water mixture with maximum 5.0% (v/v) water content.
Feed is preheated in feed economizer, against anhydrous ethanol product and vaporized in a
vaporizer. The hydrous ethanol vapor from the vaporizer passes down the molecular sieve bed in
one of adsorption column, where water molecules are absorbed into the pores of molecular sieve
and ethanol molecules pass through the dehydrated product alcohol leaves the adsorption
column and is condensed back. To the liquid phase and cooled to the ambient temperature in the
product cooler.
One molecular sieve column is always in the adsorption mode while the other in regeneration
mode. In regeneration mode, the adsorbed water is removed by applying deep vacuum to the
molecular sieve column under regeneration. Stream generated during the regeneration step,
which contains all of the water from saturated molecular sieve bed and some ethanol, is taken to
the recovery column. The ethanol is concentrated to the azeotropic point in the recovery column
and recycled back to the system, while the water leaves the system from the column.
Control system:
To provide continuous stable and efficient plant a PLC (programmable logic controller) based
plant control system with computer based SCADA (Supervisory Control and Data Acquisition)
operator interface will be provided.
All filed sensors will be electronic and the control action will be provided through pneumatically
controlled valves. All measured signals such as temperature, differential pressure, absolute
pressure, flows and levels are processed in a PLC and required control action will be decided
based on programmed algorithms in the PLC.
Man machine interface will be provided through SCADA software running on desktop computer is
located in the control room and connected to a 19” color monitor. The system will also store all
operating data for a minimum period of one month and provide historical trending and real time
analysis facilities.
The panel for motor control and the data hardware installation of the PLC and computers will be
installed in an ex free room, to be provided by client.
The process flow diagram of Molasses based distillery plant is shown below:
SHRI BAJRANG AGRO PROCESSING LIMITED DISTILLERY AND POWER PLANT
Pre-feasibility Report P a g e | 31
CO2 RECOVERY PLANT
During the biochemical reaction in fermentation section, CO2 is generated as by product along
with ethyl alcohol. This raw CO2 gas having 99% v/v purity (DB) is taken for purification followed
liquefaction.
Initially gas is taken to Foam trap to eliminate liquid particle carried over from fermentation
section. Here process water is used to rinse down the foam. Clean gas from Foam trap is then fed
to Low pressure organic removal system with the use of booster blower. Organic impurities
associated with carbon dioxide gas are scrubbed using high efficiency packing. Main impurities
like ethanol, aldehyde, ethyl acetate, are extracted in the scrubbing water through counter
current operation of the scrubber. This purified gas is then fed liquid knock out drum for removal
Molasses receiving, Handling & Storage
Fermentation
Distillation Section
Integrated Evaporation
RS/ENA/AA & By Products
Steam Generation
Power Generation
Cooling Tower
SHRI BAJRANG AGRO PROCESSING LIMITED DISTILLERY AND POWER PLANT
Pre-feasibility Report P a g e | 32
of water traces. Purified gas is compressed in two stages reciprocating non lubricated water
cooled compressor. This high pressure gas is cooled down to desired temperature in water cooled
after cooler. Additional impurity separation step is used to enhance CO2 gas purity by scrubbing
impurities present in traces by use of potable water.
Odour producing hydrocarbons and other sulphur based compounds will be removed in
adsorption tower by using activated carbon as a media. De odorized high pressure carbon dioxide
gas will be cooled down to remove significant portion of moisture using ammonia as coolant. It
will be further dried in molecular sieve dehydration unit. This step is essentially required to avoid
ice formation during liquefaction of carbon dioxide. This purified is carbon dioxide gas will be then
liquefied by using refrigeration system. Refrigeration system consists of screw compressor, pre
cooler, refrigerant condenser and accessories. Liquid CO2 still contains non condensable gases like
nitrogen, oxygen which are removed through venting. Liquid CO2 stripper is used to avoid high
vent CO2 losses which uses packed tower with reboiler and reflux condenser. Oxygenates of
nitrogen are removed through molecular sieve NOx tower. Purified liquid CO2 of desired quality
will be then sent to liquid CO2 storage tank. Liquid storage tank will be equipped with all
necessary accessories like pressure safety valves, insulation.
After the scrubber, the pressurized CO2 will be liquefied and stored in the storage container which
will be disposed through tankers to the soft drink manufacturing units. Total CO2 production will
be 165 T/day.
3.5.2 Raw Materials:
The Industry will use wide range of Agro based raw materials available in different seasons. The
Government of India and Chhattisgarh State Government is encouraging Agro based Industries in
production of Ethanol and other related products to benefit farmers, create rural employment for
agricultural labourers. The following will be the raw material requirement.
S.No
Raw Material Source Quantity
(TPD)
Method of Transport
Grain Based Distillery plant:
1 Grains (Maize, corn, Sorghum grain, broken rice and other starch based grains, etc.)
Chhattisgarh 524 Through covered trucks by
Road
Molasses Based Distillery plant:
1 Molasses From Sugar 484 Through tankers by Road
SHRI BAJRANG AGRO PROCESSING LIMITED DISTILLERY AND POWER PLANT
Pre-feasibility Report P a g e | 33
plants
(or)
Fuel (2x34 TPH Boilers & 2x17 TPH Boilers)
1. Biomass Local 380 Through covered conveyor
(or)
2. Indian coal Korba Chhattisgarh
340 Through road by covered trucks
(or)
3. Imported coal Australia/ Indonesia
250 Sea / Rail / Through covered trucks by Road
3.5.3 Resource Optimization / recycling and reuse:
Spent wash generated during the process of Fermentation, will be treated in Multiple Effective
Evaporators to concentrate the solids content up to 30% and concentrated syrup along with wet
cake will be dried in Dryer to concentrate the solids content up to 90%. This is known as DDGS.
This will be sold as Cattle feed/fish feed.
The condensate generated during the process of Multiple Effective Evaporators and Drying will be
reused in the Process thus decreasing the net water requirement.
3.5.4 Availability of Water:
Water requirement for the proposed project will be 2831 KLD. Water requirement for the
proposed project will be sourced from shivnath river. Prior permission from the Water Resources
Department , Govt. of Chhattisgarh will be obtained before drawing water. A water storage tank
is proposed on site to ensure adequate water supply. Efforts will be taken to minimize & conserve
water. Water harvesting measures will be taken up to augment the ground water table.
3.5.5 Power Requirement:
The power required for the proposed plant is estimated to be 12 MW. The power requirements
will be met from co-gen power plant proposed. Change over to CSPDCL connection is proposed to
facilitate start-up operations and as a backup option.
3.5.6 Quantity of wastes generated:
3.5.6.1 Waste water generation and treatment:
Grain based Distillery:
SHRI BAJRANG AGRO PROCESSING LIMITED DISTILLERY AND POWER PLANT
Pre-feasibility Report P a g e | 34
As per CPCB recommendations the spent wash quantity will be restricted to less than 6 KL/KL of
R.S. for Grain based distillery by adopting fermentation technology. The Maximum Spent wash
from the 2x120 KLPD Distillery plant will be 1440 KL/day.
Decantation of Spent Wash:
Spent wash from mash column bottom will be fed to decanter centrifuge after cooling in
fermented mash pre-heater. The decanter concentrates the solids present in the spent mash to
desired level.
The wet cake will be separated in decanter at 30% solids. This wet cake will be mixed with
concentrated Thin slop for further concentrating in Dryer.
Evaporation Process:
The objective of Evaporation is to concentrate a solution consisting of a volatile solute and a
volatile solvent. Evaporation is conducted by vaporizing a portion of the solvent to produce a
concentrated solution of thick liquor with 30% solids and 70 % moisture content. The evaporation
system consists of Evaporators connected, in series. The spent wash will be pumped from
distillation section, which will be fed to the evaporator by using feed pump. Gas Liquid separator
(5 Nos.) will be used to separate the vapor and liquid. Both Vapor & Spent wash will be fed to the
next evaporation effect so it is called as Feed Forward Effect Evaporation. The vapor from last
evaporator will be condensed in condenser and transferred to the dryer while the condensate
from the evaporators is first utilized for heat recovery. While vacuum pump maintains vacuum in
the entire system. Product final thin slop with 30% solids will be transferred to the drying system
where it is further concentrated to 90 % solids. The condensate from evaporation will be recycled.
Drying Process:
The wet cake from the Decanter and the concentrated syrup with 30% solids from the Evaporator
will be dried in a steam tube bundle dryer to produce DDGS with 10% moisture and 90% solids,
which will be sold as cattle feed. It is totally a zero discharge process, which is in accordance with
the CREP recommendations.
Zero discharge will be implemented as per CREP recommendations. Scheme for Zero Discharge
System (ETP) For Grain Based Distilleries:
SHRI BAJRANG AGRO PROCESSING LIMITED DISTILLERY AND POWER PLANT
Pre-feasibility Report P a g e | 35
Spent wash Characteristics:
S.No. Particulars Characteristics
1. pH : 4.5 to 5.0
2. Solids content : 7.0 to 10.0% w/w
3. B.O.D. : 25,000 - 30,000 ppm
4. C.O.D : 55,000 - 60,000 ppm
Molasses based Distillery:
As per CPCB recommendations the spent wash quantity will be restricted to a maximum of 8 kl/kl
of R.S. for Molasses by adopting continuous fermentation technology with yeast recycle. The
Maximum Spent wash generation from the proposed 2x60 KLPD plant with Molasses as raw
material will be 960 KL/day.
The spent wash will be concentrated to 60% solids in Multiple Effect Evaporators and then will be
incinerated in exclusive 2x17 TPH Boilers. This is a Zero Liquid discharge system approved by
Central Pollution Control Board.
EVAPORATION SYSTEM
The objective of Evaporation is to concentrate a solution consisting of a volatile solute and a
volatile solvent. Evaporation is conducted by vaporizing a portion of the solvent to produce a
concentrated solution of thick liquor with 60% solids and 40 % moisture content.
The evaporation system consists of 5 evaporators, which are connected, in series. The spent wash
will be pumped from distillation section, which will be fed to the evaporator by using feed pump.
Gas Liquid separator (5 Nos.) will be used to separate the vapor and liquid. Both Vapor & Spent
wash will be fed to the next evaporation effect so it is called as feed forward effect evaporation.
The vapor from last evaporator will be condensed in condenser and transferred to the dryer while
the condensate from the evaporators is first utilized for heat recovery. While vacuum pump
SHRI BAJRANG AGRO PROCESSING LIMITED DISTILLERY AND POWER PLANT
Pre-feasibility Report P a g e | 36
maintains vacuum in the entire system. Product final thick spent wash with 60% solids will be
used in boiler for incineration.
INCINERATION OF CONCENTRATED SPENT WASH
The final concentrate from the Evaporators (60% solids w/w) will be incinerated in the Boiler by
mixing with coal. The condensate from the Evaporation system will be reused in the plant
operation. Zero discharge will be implemented as per CREP recommendations. ETP diagram
shown in figure below.
Non-Process Effluent Treatment & Disposal:
Spent lees & condensate will be treated in Condensate Polishing Unit (CPU). Non-process effluents
like DM plant regeneration water & boiler blow down will be neutralized in neutralization tank
and will be mixed with Cooling tower blow down. This treated effluent after ensuring compliance
with standards stipulated by CECB for wastewater for on land for irrigation, will be utilized for
internal greenbelt development, dust suppression, ash conditioning after ensuring compliance
SHRI BAJRANG AGRO PROCESSING LIMITED DISTILLERY AND POWER PLANT
Pre-feasibility Report P a g e | 37
with CPCB/CECB standards. The scrubbed water from CO2 Scrubber will be consumed in the
Fermentation section.
3.5.7 Solid Waste
The following are the solid waste generation & disposal.
S. No Solid waste Quantity (TPD) Disposal
Phase-I Phase-II
1. DDGS (with 90% solids)
75 75 will be sold as Cattle /fish/prawns feed
2 Yeast Sludge 2.2 2.2 Will be used as manure
3. Boiler Ash
With 100 % biomass
34.2 34.2 Ash generated will be given to brick manufacturers when rice husk is used as fuel. Ash generated will be given to brick manufacturers / cement plant, when coal is used as fuel.
Or
With 100 % India coal
68 68
Or
With 100 % Imported
coal 30 30
SHRI BAJRANG AGRO PROCESSING LIMITED DISTILLERY AND POWER PLANT
Pre-feasibility Report P a g e | 38
4.0 SITE ANALYSIS
4.1 Connectivity:
The project Site can be approached by NH&200. The project site is at a distance of 8.1 Kms.( By
Road) from Tilda.
4.2 Land form, Land use and Land ownership:
The proposed land is private land. The present use of the land is Dry Land ( Non-Agriculture).
Total land for the project is 44.51 acres. Land diversion to industrial purpose is under process.
After diversification of land , land will be taken on long term lease
4.3 Topography:
The topography of the land is more or less flat without undulations.
4.4 Existing land use pattern:
The present use of the land is Dry Land ( Non-Agriculture).
4.5 Existing Infrastructure:
The site is well connected by NH which is at a distance of 23 Kms.( By road). Nearest railway
station is Baikunth at a distance of 3.5 Kms. from the plant
4.6 Soil classification:
The soil at the site is red soil.
4.7 Climatologically data:
The climatic conditions of the district consist of extremely hot summers and mild winters. The
period starting from April to June is the hottest. The annual rainfall in the region is about 1385
mm and is contributed to by the Southwest monsoon.
4.8 Social Infrastructure Available:
The area lacks in education. Hence will contribute to the improvement of education in the
area by improvising the existing facilities in the schools in the area.
The villages in the area are connected by road. The existing road network will be
adequate during the operation of the plant.
Medical facilities in the area needs improvement. Will contribute for improvement under
CER activities.
SHRI BAJRANG AGRO PROCESSING LIMITED DISTILLERY AND POWER PLANT
Pre-feasibility Report P a g e | 39
5.0 PLANNING BRIEF
5.1 Planning Concept:
The proposed Project is fermentation type industry in which starch containing raw materials will
be fermented for manufacturing Ethanol/RS/ENA/Potable Alcohol/ Industrial alcohol and power