Pre Feasibility Report For Molasses Based Fuel Ethanol Plant of 60 KLD Along with 25 TPH Incineration Boiler At Village – Pondar, Post - Salichouka Tehsil- Gadarwada Distt – Narsinghpur (MP) Proposed By M/S Narmada Sugar Pvt Limited Village- Vill.- Thaini , Post – Bankhedi, Dist .- Hoshangabad, MP- 461990
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Pre Feasibility Report
For
Molasses Based Fuel Ethanol Plant
of 60 KLD
Along with 25 TPH
Incineration Boiler
At
Village – Pondar, Post - Salichouka
Tehsil- Gadarwada
Distt – Narsinghpur (MP)
Proposed By
M/S Narmada Sugar Pvt Limited Village- Vill.- Thaini , Post – Bankhedi,
Dist .- Hoshangabad, MP- 461990
1. Identification of project and project proponent
M/s Narmada Sugar Pvt Limited (NSPL) is as partnership firm registered
with State Govt and located at Village- Pondar Tehsil- Gadarwada Dist
Narsinghpur (MP)
M/s. Narmada Sugar Private Limited (NSPL) is one of the pioneering sugar
factories of Madhya Pradesh and is in its 10th year of operation. NSPL
received its memorandum for manufacturing of vacuum pan sugar and
molasses along with other sugarcane by products from the Ministry of
Commerce & Industry in April 2005. The factory started its crushing
operations in the year of 2006-07. The licensed crushing capacity of the
plant is 4500 tonnes per day.
Brief Description of Nature of the Project
The present proposal is for setting up a 60 KLD fuel ethanol plant (Molasses
based) with 25 TPH Incineration Boiler at Village- Pondar Tehsil- Gadarwada
Dist Narsinghpur (MP) in the State of Madhya Pradesh at an estimated cost
Rs. 6358 Lacs. The proposed project will be set up within in premises of
existing sugar unit (4500 TCD & 30 MW power plant) of M/s NSPL.
Most of the infrastructure facility is already available with the industry as
present sugar manufacturing operation is being continued from several
years.
The Company proposes to set up an integrated pollution free (Zero
discharge) fuel ethanol plant in the State with an installed capacity of 60
KLD in the State of Madhya Pradesh. The proposed Industrial Complex shall
process molasses as its raw material to produce RS & Dehydration:
Silent feature of the project
• Provided with most efficient Fed batch Fermentation technology
Distillation operating on Multi-Pressure Technology -a efficiently heat
integrated system, operating on fully automated PLC control system
On line cleaning system is provided for distillation equipment's to
minimize plant shut down period.
Process equipment's are designed as per TEMA/ ASME standards
Closed water recycles system and plant process is designed to minimize
fresh water requirement by recycling various effluents.
Zero Effluent Discharge norms is applied while designing the plant
Sr. No. Particulate Description
1. Name of the proponent M/s Narmada Sugar Pvt. Limited (NSPL)
2. Project capacity 60 KLPD Molasses Based Fuel Ethanol Plant with
25 TPH Incineration Boiler 3. Khasara No. & Location of the
From the above table it can be concluded that actual production of ethanol in India has not kept pace with the demand. Also with robust growth for chemical and potable industries it will mean greater shortage of ethanol in the coming years ahead. The Government of India has set an indicative target of 20% blending of ethanol with petrol and also for diesel with biodiesel across the country by 2017.
5. Imports Vs. Indigenous Production
No import is proposed as demand in domestic market is enough to
consume the product.
World Alcohol Production and Consumption (Billion Litres)
World Regions Years
2010 2011 2012 2013 2014
Americas 23.23 27.81 30.02 33.35 37.30
Asia 6.02 6.54 6.44 6.61 7.15
European Union 2.54 2.50 2.50 2.71 3.13
Rest of Europe 1.45 1.48 1.47 1.46 1.36 Africa 0.51 0.54 0.57 0.59 0.62
Oceania 0.18 0.16 0.15 0.15 0.17
World Total 33.93 39.03 41.15 44.87 49.73
India 1.80 1.90 1.65 1.70 2.0
* Projected
Source: F. O. Lichfs World Ethanol and Biofuels Report, Vol.4, No.17,
09/05/2006. Ethyl alcohol is basically used for three purposes i.e. 1) Industrial
alcohol for production of downstream chemicals, 2) Pptable Alcohol for
mamifacture of alcoholic beverages (Country Liquor and IMFL) and 3) Fuel
ethanol or Anhydrous alcohol, which can be blended with petrol or diesel.
Sr. No. Ethanol Consumption for (%)
1 Industrial 21
2 Potable 11 3 Fuel 68
Industrial Alcohol: -
Ethyl Alcohol is an Important feedstock for the manufacture of
chemicals.
World ethyl alcohol consumption for the production of chemicals is
around 1%. These chemicals are primarily the basic carbon based
products like Acetic acid, Butanol, Butadiene, Acetic Anhydride, Vinyl
Acetate, PVC etc. The existing plants such as synthetic rubber
requiring large quantities of alcohol will certainly grow to a large
capacity. Acetic acid & Butanol, which are needed in pharmaceuticals,
paints & in many other areas are important industries as they are value
added products. Ethylene, Ethylene oxide & Mono-ethylene glycol are
also produced from petrochemical route. However latest technological
development & taking into account the increasing cost of petrochemical
raw material, it is now possible toproduce Ethylene oxide, Mono-ethylene
glycol etc. starting from ethanol.
During the last 5-6 years, a number of alcohol-based industries have come
up& the existing has marginally expanded. The raw material needs
of the alcohol based chemical industry have to be niet to facilitate
maximum capacity utilization of these units in order to meet the
domestic demands for the end products. These units are starving for
want of raw materials. The shortage is wide spread & it has hit a most of
chemical drug & other industries. The drug industry is also bedeviled by
scarcity of industrial alcohol. Producers of insulin, antibiotics, tonics &
several other essential bulk drugs & finished formulations are unable to
obtain their quota of industrial alcohol, which is a vital raw
material for them. Thus, even in Maharashtra, which should be a
State with surplus production of alcohol, drug & chemical units are in
the group of acute shortage of industrial alcohol. It follows that the
supply of industrial alcohol to chemical and drugs units in the country
will remain below normal for some more time. In order to maintain
proper rate of growth of industries, production of alcohol must
increase.
6 Export Possibility
The company is setting up fuel ethanol plant, to supply the finish goods in
the country, at present is no export possibility at this capacity is envisaged.
7 Domestic/Export Markets
As above
8 Employment generation (direct and indirect) due to the project
Existing employment at sugar & co gen unit : 100+ 60 no.
Proposed Employment : 90 Nos. ( skilled and Direct )
Apart from that indirect employment generation is envisaged from the
project.
Total manpower requirement Sr. No Staff Nos.
1. Distillery manager 1
2. Production manager 1
3. ETP in-charge 1
4. Lab chemist 4
5. Operators 8
6. Project Engineer / Shift Engineer 8
7. Electrician 4
8. Mechanical fitters 4
9. Office Peon 3
10. Office assistant 3
11. Excise officer 1
12. Waterman/ Pump man 4
13. Other Contractual staff 48
14. Total 90
9 Project Description
i. Type of the project including interlinked and interdependent project, if any
As submitted, the Ethanol Plant is proposed with the existing sugar unit of 4500
TCD. Incineration Boiler of 25 TPH is also proposed for implementation of zero
discharge concept. CO2 will also generated as by product from the fermentation
process which is turn can be utilized after further treatment at CO2plant in
industrial or food grade application. It is also proposed Evaporation plant of
effluent to provide better environment conservation and pollution control
arrangement in the unit as well as for the surrounding area.
ii. Location (map showing general location, specific location, and project
boundary & project site layout) with Coordinates:
The unit is spreaded over 23.5+11.7968=35.2968 acres of land in village
Pondar Tehsil, Gardarwada Dist. – Narsinghpur of MP. The latitude and
longitude of the site is as below :
1. 22°51'12.60"N- 78°39'2.67"E
2. 22°51'16.24"N- 78°38'58.12"E
3. 22°51'22.80"N- 78°39'5.94"E
4. 22°51'18.52"N- 78°39'12.07"E
Satellite Image of the Project area
Topographical Base Map
iii. Details of Alternate Site:
The site is proposed on the piece of land where sugar unit ( 4500 TCD) with
cogen plant of 30 MW is already in operation. The entire land is about 35.298
acres and out of that proposed unit will require 4.25 of land. Most of the
infrastructure is already available. Therefore proposed site suitable for the
project configuration.
iv. Size or magnitude of Operation:
It is proposed to produce 60 KLD of fuel ethanol from molasses based operation
along with 25 TPH Incineration Boiler. The unit shall adopt zero discharge
technology for the effluent disposal. .
v. Project Description With Process Details: The overall process is shown on the attached Block Flow Diagram, and Process
Flow Diagrams. The following describes the production of ENA and co-products
from grain. The process envisages use of own molasses, as well as procured
molasses from nearby sugar factories, for manufacture of ethanol during sugar
mill season and during off- season days.
Cane crushing system
Fermentation system
Distillation & Fuel Ethanol
Effluent treatment system
Following is a brief description of the process:
Detail Process Description & Process Flow Charts
Fermentation
Molasses, diluted with water to the desired concentration is metered continuously
into a single tank fermenter. Additives likes urea (in the form of pellets or prills)
and defoaming oil are also introduced in the fermenter as required. There is an
automatic foam level sensing and dosing system for defoaming oil.
Every Kilogram of alcohol produced, generates about 290 Kcal of heat. This excess
heat is removed by continuous circulation of fermenting wash through an
external plate heat exchanger called the Fermenter Cooler. The fermenter
temperature is always maintained between 32 and 35 deg. C, the range optimum
for efficient fermentation.
The yeast for the fermentation is initially (i.e. during start-up of the plant)
developed in the Propagation Section described further on. Once propagated, a
viable cell population of about 500 million cells/ml is maintained by yeast
recycling and continuous aeration of the fermenter. Fluctuations in the yeast
count of +/- 20% have little effect on the overall fermenter productivity. Yeast cell
vitality which is usually above 70% may, in times of stress (such as prolonged
shut-downs) drop to 50% without affecting the fermentation.
Fermented wash passes through a series of hydro cyclones (one to three or
move in number depending on plant capacity), which remove grit, iron filings
and similar heavy particulate matter. This rejected material along with some
wash, is taken to the bottom portion of the wash column for alcohol recovery.
The overflow from the first hydro cyclone is taken a wash tank, also provided
with an arrangement to facilitate removal of heavy settable particulate matter.
Overflow from the wash tank is taken to the yeast separator, which clarifies the
wash. The hydro cyclone and the wash tank protect the separator from erosion
damage by removing grit and similar hard particles.
Wash Preparation
For the plant mash, molasses is diluted with water to give a sugar concentration
of 14 to 18% and pumped directly into the fermenter. This mash is usually not
sterilized, although in certain cases it has been pasteurised with a resultant
slight increase in efficiency. The fermenter is issued when it is one eighth to one
fourth full with a large volume of active yeast. 2 to 4% of the final volume to
allow development of the yeast during the entire filling period, which may
amount to 8 hours and to avoid growth of contaminating organisms during
this period.
Nutrients
Blackstrap molasses usually contains enough yeast nutrients to give a fast,
efficient fermentation. In some cases, however, it is desirable to add small
quantities of ammonium salts, such as ammonium sulphate, to the mash to
increase the rate and efficiency of the fermentation. In such cases, the amount
of ammonium sulphate added varies between 0.5 liters and 3 liters per 10,000
liters of mash, depending on the molasses used, the optimum amount being
determined by laboratory in a blackstrap molasses fermentation.
Fermentation Temperatures
Fermenters are usually set at a temperature between 27º F and 30º C and are
held a 32º C by the use of water sprays on the rank internal cooling coils, or by
circulation of the mash through external coolers. It is desirable to maintain the
temperature of the mash below 35º C. The amount of heat liberated during
the fermentation agrees with the theoretical value. C2H12O 2C2H5OH + 2CO2+26.0 Calories
The heat produced from a fermentation involving 100 kg of sugar is 260 cal.
If the fermenters are not cooled the temperature of the mash will rise as much as
40º C.
• Yeast Recycling:
The yeast in the fermented wash is removed as a 45 to 55 v/v slurry, and is
returned to the fermenter. This feature ensures that a high yeast cell
concentration is achieved and maintained in the fermenter. By recirculating
grown, active yeast, sugar that would have otherwise been consumed in yeast
growth, is made available for alcohol production, ensuring high process
efficiency.
• Propagation:
The propagation section is a feeder unit to the fermenter. Yeast, either
Saccharomyees cereviseae or Schizosaccharomyees (the choice being
determined by other process parameters, mainly the downstream effluent
treatment system) is grown in 3 stages. The first two stages are designed for
aseptic growth. Propagation vessel III develops the inoculum using pasteurized
molasses solution as the medium. This vessel has a dual function. During
propagation, it serves for inoculum build-up. When the fermenter enters the
continuous production mode, Propagation Vessel III is used as an intermediate
wash tank. Propagation is carried out only to start up the process initially or
after very long shut-downs during which the fermenter is emptied.
• CO2 Scrubbing and Recovery:
The carbon-di-oxide produced during fermentation is scrubbed with water in
packed- bed scrubber, to recover alcohol. The water from the scrubber is
returned to the fermenter. About 1.0% of the total alcohol production is saved
by scrubbing the fermenter off gas. In plants where it is desired to recover
carbon-di-oxide, a part of the wash is drawn into a separate vessel and is
aerated there. This external aeration allows the recovery of CO2 uncontaminated
with air. More details of this system can be supplied on request.
• Fermentation Parameters (Typical):
The pH of the fermenter is maintained between 4.0 & 4.8 usually without addition
of any acid. The alcohol concentration is maintained between 7.0 & 7.5 % v/v,
unless a highly concentrate effluent is to be produced. To reduce the effluent
volume, the fermenter is operated at a very high dissolved solids level by
increasing the proportion of weak wash recycle. Under these conditions, alcohol
concentration is reduced to between 5.5 to 6.0% v/v.
Conversion of sugar to alcohol is instantaneous, and the residual sugar
concentration is maintained below 0.2 % w/w as glucose. This usually
corresponds to a residual reducing substances concentration of 2.0 to 2.5 %
w/w in wash.
All the nutrient elements necessary for yeast growth exist in adequate quantities
as impurities in molasses. Occasionally, Nitrogen may have to be supplemented.
Defoaming oil (DFO), say Turkey Red Oil is added to the fermenter by an
automated DFO dosing system, to control foaming. Usually no other additives are
required.
• Flexibility:
This process accords tremendous flexibility to the operator. Process conditions
and plant design can be varied to suit individual requirements of alcohol quality,
effluent concentration and characteristics. This unit can give spent wash
suitable for use in any effluent treatment process.
2. Distillation:
Clarified or de-yeasted wash flows by gravity to the propagation vessel No. III,
which during continuous production, operates as an intermediate wash tank.
From here, fermented wash is pumped to the wash preheater, which uses vapors
from the rectifying column to preheat wash. Further heating is done in an
exchange of heat with weak wash and spent wash (see flow sheet for primary
distillation). Preheated wash then enters the degasifying column of the
distillation section.
• Primary Distillation: The CO2 and the degasifying section help remove the CO2
and other non-condensable entrained in the wash. The wash column is first
column in the distillation section. It is also called the analyzer. Wash is boiled in
this column with steam either supplied as live steam from the boiler (after
pressure reduction and desuperheating) or from a reboiler which generates
steam by evaporating effluent wash.
Alcohol in wash vapourises and is carried, along with water vapor, to the top of
the wash column from where it goes to the rectification column. As wash travels
down the analyzer, it is progressively ‘stripped’ of its alcohol content. At a
point in the column, where the alcohol concentration is 0.5 to 1.0% v/v, a
portion of the wash is drawn off. This is called weak wash.
• Weak Wash Recycling :
Weak wash recycling of weak wash helps maintain the desired level of
dissolved solids in the fermenter, so that an adequately high osmotic pressure
is achieved. Osmotic pressure and the concentration of alcohol in the fermenter,
together keep off infection and minimize sugar losses. Weak wash recycling also
reduces the quantity of effluent spent wash and reduces the process water
requirement of the plant.
Spent wash is the wash from which all alcohol has been removed, this emerges
from the bottom of the wash column at about 105 deg C. Some of the heat is
recovered to preheat fermented wash entering the degasifying column.Spent wash
may also be passed through a forced circulation reboiler to generate vapors.
This concentrates the effluent and reduces the volume further.
Multi Pressure Vacuum Distillation:
After fermentation the next stage in the manufacture of alcohol is to separate
alcohol from fermented wash and to concentrate it to 95% alcohol called as
rectified spirit. For this purpose, distillation process is employed.
Distillation step consumes a considerable amount of energy and is also a
deciding factor in the quality of ENA produced. Hence, in line with the demand of
the industry, efforts have always been to minimize requirement of energy and to
improve the basic quality of alcohol produced. Ease of operation, reliability,
lower down time and flexibility of operations are other parameters considered
during the design.
Three basic types of plant are designed:
a) One is to produce primary quality of alcohol, usually referred to as 'Rectified
Spirit' (R.S.) from the fermented wash. Such plants are also referred to as
‘Primary distillation’ plants.
b) Second is to produce fine quality of spirit usually referred to as 'Extra Neutral
Alcohol' (ENA) starting from R.S. Such plants are also referred to as 'secondary
distillation' plants.
c) Third is to directly produce fine quality alcohol (ENA) from fermented wash.
Such plants are referred to as 'wash (mash) to ENA' plants, where the two steps
of primary and secondary distillation are combined. Such plants usually have
lower consumption of energy than two separate plants
Multi-pressure vacuum distillation system for production of Rectified Spirit
/ ENA consists of following distillation columns namely
1. Degasifying cum analyzer column – Operation under vacuum
2. Pre-rectification column – Operation under vacuum
3. Rectification cum Exhaust Column - Operated under pressure
4. Recovery column - Operated under atmospheric
5. Extractive distillation column – Operated under vacuum
6. Simmering column – Operated under atmospheric
Benefits of Pressure Vacuum Distillation: -
Following are the advantages of pressure vacuum distillation.
• Since the analyzer column operates under vacuum, the formation of byproducts
such as acetal may minimize there by improvement in quality of alcohol.
• Pre-rectification column ensure removal of sulfur compounds/mercaptans and
also reduces load of lower boiling volatile compounds passing on to Rectifier cum
exhaust column.
• The chances of scaling due to invert solubility of certain precipitating inorganic
salts are minimized in vacuum distillation.
• Vacuum distillation requires low steam consumption with re-boiler
Integrated Multi-products Concept: -
It is now possible to install a distillation system, which can produce different
products. In the proposed scheme; the production of rectified spirit have been
considered. This allows flexibility of operation and various products can be
manufactured depending on the market demand. This integrated multi-product
system involves less capital investment as compared to independent system.
In this type of system, switching over from one product to another is quite easy
and there is no chance of contamination of one product with another. The
system can work under multi-pressure principle with few columns operating
under vacuum and few under pressure/atmospheric.
3. Dehydration of Alcohol: Molecular Sieve:
The process drives the rectified feed though a bed of desiccant beds. To allow for
bed regeneration in continuous operation, twin beds are provided of which one
is in dehydration mode while the other is regenerating. Depending on feed
and product specifications, the dehydration-regeneration process releases the
adsorbed water together with contained ethanol, it is recycled back to
regeneration column for reprocessing.
The feed is pumped to regeneration column after preheating in feed
preheater. The overhead vapor of regeneration column is superheated to the
required operating temperature and circulated to sieve bed 1 assumed in the
description to be in dehydration mode. After passing though the desiccant, the
vapor is condensed, cooled and sent to storage.
A small portion of the product vapor is sent, under high vacuum, through bed
2, in regeneration mode, to prepare the desiccant for cycle changeover when bed 2
goes online. The regeneration operation forces the release of the moisture from
the desiccant, making the bed 2 ready for the next cycle. The recovered low
strength vapors are condensed and recycled back to the Regeneration column.
4. Evaporation for Spent wash Treatment
As per recent Environmental Protection Norms from Ministry of Environment
and Forests (MoEF), it is Corporates Responsibility to achieve Zero Discharge
in Inland Surface Water. For 60 KLPD distillery plant nearly about 600 M3/Day
spent wash will produced. Considering the large volume of spent and achieve Zero
liquid discharge plant operation following three stage process is proposed.
Multi pressure distillation – In this steam is utilized in direct way for heating.
Hence, spent wash quantity generated is less as compared to traditional
distillation technology. Integrated and Standalone Multi effect evaporation - The
spent wash evaporation technology is a multiple effect evaporator system in which
heat recovered from one effect is used to concentrate spent wash in second
effect evaporator with continuous recirculation of concentrated spent wash
within the system until desired concentration is obtained. This entire
concentration process is carried out under vacuum leading to less consumption
of steam and maximum concentration of spent wash with in less period of time.
This is the 3rd stage of effluent treatment wherein spent wash after integrated
evaporation is concentrated and used in incineration boiler.
5. Spent wash Incineration Technology:
After spent wash evaporation, concentrated spent wash with desired
concentration is obtained is feed to incineration type of boiler. The
concentrated spent wash generated after entire process of evaporation is then
sprayed in a furnace with auxiliary fuel such as coal and is then burnt in a
boiler.
6. Process Condensate Treatment and Recycle:
The condensate polishing unit is also envisaged to take care of spent lees, cooling
tower blow down, washing and process condensate from evaporation plant. After
treatment all the stream at CPU, treated condensate can be recycled to process
for dilution and as cooling tower make up and will achieve zero liquid discharge
(ZLD) Due to recycle of process condensate back to process, fresh water demand
can be reduced at large extent.
Quantity of Raw Materials Required;
Raw Material Requirement
Sr. No. Name of raw material
Quantity Storage Transportation
Distillery
1. Molasses 220 TPD Tank Tanker
2. Sulfuric Acid 0.25kg/KL FRP Tank Tanker
3. Anti-foam reagent 0.25 kg/KL Drum Truck
Sugar Unit
1. Sugarcane 4500TCD Open Area Truck & Tractor
2. Lime 540 MT/Year Bags Truck
3. Caustic soda 20 MT/Year Bags Truck
NSPL will generate about 40851 MT of molasses from expected / sustained cane
crushing of 54 Lacs MT / year, with minimum 4.7% molasses recovery. M olasses
will be sourced from parent sugar unit and group sugar factories. The fuel ethanol
yield from cane molasses will be at 270 lit/ton. The per day requirement of
molasses will be about 220 MT per day for 60 KLPD ethanol production per
day. The total requirement of molasses for the 270 days operation of the
proposed ethanol plant will be about 59400 MT (at maximum 95% utilization
level from 4th year onwards).
vii. Resource optimization/ recycling and reuse
Multi Pressure Distillation system has lower steam consumption as it is designed
for maximum heat integration to conserve energy.
Energy efficient Multi-Pressure Distillation system with a Steam Consumption
13.20 TPH of Total Spirit (depending on mode of operation).
Vacuum operation nearly eliminates scaling problem in Analyzer Column and
ensures better separation of impurities, which results into better quality product.
Well-engineered Plants with high efficiency trays to ensure elaborate separation
and removal of impurities ensuring superior quality of Extra Neutral Alcohol.
Analyzer Column with Hyper-stat Rh-Grid 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 cleaning column internals.
Condensers are designed with multiple passes to ensure high velocity and to
minimize scaling inside tubes.
Alcohol is well known as an industrial raw material for manufacture of a variety
of organic chemicals including pharmaceuticals, cosmetics, polymers etc. A large
demand is anticipated for alcohol as a fuel. Alcohol is an eco-friendly product and
is a substitute to the imported petroleum. Indeed fuel ethanol production has
been promoted for a variety of reasons as mentioned below,
It has less severe impact on the environment than conventional gasoline and
less dangerous to health. As oxygenates are compounds such as alcohols or
ethers which contain oxygen in their molecular structure. Oxygenated fuels tend
to give a more complete combustion of its carbon to carbon dioxide (rather than
monoxide) which leads to reduced air pollution from exhaust emissions. It
reduces the dependence on oil imports.
It helps to maintain rural economy.
Factory proposes zero liquid discharge method for waste water treatment.
Maximum waste water will be recycled back into the system.
Factory proposes to install Multiple Effect evaporator followed by Incineration
boiler. Advantages are as follows
Production of steam and power generation
Reduction in air pollution as compared to coal based boiler.
Reduction in water pollution and achieve zero discharge in inland surface water.
viii.: Availability of Water its source, energy / power requirement and source:
Water requirement:
Construction Phase – 20 kld
Operational Phase – Net fresh water requirement will be 466 KL per day
Source : Borewells
Water Balance
. Water inputs (In KLD)
1. Process water for fermentation section and CO2 scrubber 552
2. DM water for RS dilution 65
3. Water for vacuum pump, pump sealing, air blower & others
8
4. Soft water makeup for cooling towers 453
5. Other domestic usage, laboratory uses, cleaning 5
6. Boiler 20
7. Total water input at start-up 1103
Water Out Put (In KLD)
1. Spent Lees (PR & Rect.) 160
2. Process condensate 525
3. CT Evaporation & Drift Losses 362
4. Water losses from vacuum pump, pump sealing, Air blower 0.2
5. Cooling tower and boiler blow down 89
6. Total Water Output 1136
Recycled water (In KLD)
1. Lees recycle for cooling tower make up 160
2. Process condensate fermentation 160
3. Process condensate to cooling tower, CIP, Fermentation 310 4. Pumps Sealing Water Recycle cooling tower 6
5. CO2 scrubber beer well to process water for fermentation 1
6. Total Recycling water per day 637
Daily fresh water input 466
Wastewater generation from sugar unit and cogeneration
Sr. No.
Source Process KLD Treatment Final Disposal
1. Sugar Plant
Sugar manufacturing Process
266 ETP Treatment Units: Bar screen and grit chamber, oil and grease traps, reaction tank, equalization tank, anaerobic tank, aeration Tank I, aeration Tank II, secondary clarifier, sludge drying bed and polishing pond.
For ferti irrigation.
2. Co generation 11 MW
Cooling Tower
20 For polishing pond for dilution with other effluent
For Ferti-Irrigation
Boiler Blow down
6 For polishing pond for dilution with other effluent
For Ferti- Irrigation
D.M. Regeneration
66 Neutralization followed bydisposal to polishing pond for dilution with other waste water stream.
For Ferti- Irrigation
Total - 358 - -
Summary of effluent generation from proposed distillery, existing sugar and cogeneration unit
Co generation Blow down from the cooling tower & boilers
92 KLD
Domestic Waste water Sewage generation 20 KLD
ix. Power Requirement:
Construction Phase – 30 kw
Electricity consumption bifurcation
Sr. No Section Connected load (kWh)
Operating load (kWh)
1. Fermentation
1050 KWH
1360 KWH
2. Distillation
3. MSDH
4. Integrated RSW evaporation 5. Process condensate treatment plant
6. Alcohol storage
7. Utility (Cooling tower)
8. Instrument air compressor
9. Total 1050 KWH
1360 KWH
During operation phase , the required power will be taken from cogeneration
power plant. Existing DG sets of 63 KVA, 160 KVA and 400 KVA shall be
used as standby arrangement.
Fuel consumption
Sr. No Fuel Quantity
1. Concentrated spent wash 156 TPD
2. Spent wash concentrate, GCV 1600 kcal/kg
3. Bagasse 56.25 TPD
4 Bagasse GCV 2250 kcal/kg
Steam Requirement
Sr. No. Section Quantity (TPH)
Steam utilization for Distillery
1. Steam for Distillation (Wash to ENA mode) N A
Or Steam for Distillation (Wash to EQRS) 6.42 TPH
2. Steam for Integrated Evaporation 5.32 TPH
3. Steam for MSDH 1.46 TPH
4. Total 13.20 TPH
Steam utilization for sugar factory
5. Crushing rate 4500 TCD
6. Steam Generation 3300 MTD
7. Steam Requirement 1800 MTD
8. Steam Condensate 1500 MTD
Steam Requirement
S no Purpose Quantity
1 Ethanol Fuel 3.5 kg/lit
2 Evaporation 1.8 kg/lit
X. Quantity of wastes to be generated (liquid and solid) and Scheme for their
management/ disposal
For Liquid Waste
The total water requirement at the startup will be around 1103 m3/day, and after
recycling daily fresh water requirement will be 466 KL per day. Source of water
will be Bore well. Water storage facility is available with the sugar factory. Detail
water breakup is given in Table
Water Requirement For Existing Sugar Unit
Sr. No Particulars For sugar
During Off Season
1. Total water requirement 460 M3 3 M3
2. Water recovered 180 M3 N A
3. Total daily fresh water
required after recycling
280 M3 NA
Wastewater Generation Of Sugar And Cogeneration
Sr. No.
Source Process KLD Treatment Final Disposal
1. Sugar Plant Sugar manufacturing Process
266 ETP Treatment Units: Bar screen and grit chamber, oil and grease traps, reaction tank, equalization tank, anaerobic tank, aeration Tank I, aeration Tank II, secondary clarifier, sludge drying bed and polishing pond.
For ferti irrigation.
2 CO Gen Plant
Cooling Tower
20 For polishing pond for dilution with other effluent
For Ferti- Irrigation
Boiler Blow down
6 For polishing pond for dilution with other effluent
For Ferti- Irrigation
D.M. Regeneration
66 Neutralization followed bydisposal to polishing pond for dilution with other waste water stream.
For Ferti- Irrigation
Total - 358 - -
Summary Of Effluent Generation From Proposed Distillery, Existing Sugar And Cogeneration Unit