ADDITIONAL ATTACHMENT
LIST OF PRODUCTS AND PRODUCTION CAPACITY
SR. TOTAL NAME OF THE PRODUCTS NO. QUANTITY 1. Extra Neutral Alcohol /Rectified Spirit & Fuel Ethanol 60 KLPD 2. Co-Generation Power Plant 2.2 MWH 3. Sodium Methoxide 20 TPD 4. Sodium Ethoxide 20 TPD 5. Potassium Methoxide 20 TPD 6. Potassium Ethoxide 20 TPD BY-PRODUCT 7. Carbon Dioxide 50 TPD
MANUFACTURING PROCESS OF DISTILLERY UNIT The manufacturing process of rectified spirit/ anhydrous alcohol involves two major steps. Molasses is the basic raw material. Generally sulphuric acid is not required, nutrients like yeast, anti-foam agent etc, will be used.
Following steps are required for the Ethanol Production.
1) Fermentation Section Molasses handling: Molasses from the own sugar factory will be utilized for the proposed production. Molasses is then after weighted, sent for storage or to the process diluter tank.
Yeast Propagation: Best strain of yeast is required for the production of alcohol, yeast is bought from nearby vendor and is developed further in propagation section and maintain the viable cell population of about 300 million cells/ml by yeast recycling and continuous aeration of the fermenter.
Fermentation: When Yeast is added in container, yeast works on sugar present in molasses, break down the sugar into alcohol and carbon-dioxide, required temperature controlled to be 30-32°C (by circulating cooling water). From Fermenter CO 2 collected and directed to scrubber. Remaining content is “wash”.
2) Distillation Section The “wash” from the fermentation enters into distillation section. The hardware contains columns basically for two functions, namely Stripping and Rectification. Thus, 1) Analyser column – Operated under vacuum and 2) Rectifier cum Exhaust Column – operated under pressure. (Additional columns only for refinement).
The “wash” from fermentation is first preheated in heater and fed to analyser column. Alcohol from the wash in form of vapour from the analyser column is fed to pre-rectifier column (under vaccum). The impure spirit drawn from the top of column were collected at bottom which is fed into the rectified cum exhaust column (under pressure). Alcohol is enriched towards the top and drawn out as Rectified Spirit about 95% v/v concentrations. Fusel oil generated is drawn out to tank, washed with water, decanted, layers separated and alcohol layer returned as recovery.
3) Molecular Sieve Dehydration Molecular sieve dehydration is to produce anhydrous alcohol from rectified spirit. Water molecules are absorbed on the pore surface and the larger alcohol molecules are excluded and exit from the sieve unit. The absorption is a vapour phase process and hence, rectified spirit, vaporized and super heated in a vaporizer/column is passed through sieve unit. Generally there are two sieve units. One is under adsorption while the other is under regeneration. The cycle time for adsorption and regeneration varies from 5 to 10 minutes. Thus forms Absolute Alcohol of desired 99.8% v/v purity. There is alternate Sieve Bed 2 ready for next operation.
4) Multi-Effect Evaporation Spent wash from the process is fed into multi effect evaporator. Whole process is under vacuum and vapor generated are compressed and used as steam. Condensate water generated from evaporation will be recycled back into the process. While spent wash will be incinerated in the proposed spent wash fired boiler. MANUFACTURING PROCESS OF SYNTHETIC ORGANIC CHEMICAL
1) SODIUM METHOXIDE SOLUTION (30% TO 25%) Sodium Hydroxide flex is charged in four times Methanol and heated to reflux to get Methoxide Caustic solution which presence of one equitant molecules of water. This water is recovered with counter current dry methanol vapor in a bubble cap tray tower, the result in sodium methoxide solution is collected from the bottom of that column (25-30% W/W).
2) SODIUM ETHOXIDE SOLUTION (18 to 21%) • Take 1000 gm of ethanol in reactor. • Start Stirring at room temperature. • Then add Caustic Flex (135 gm) in the ethanol Solution. • Check the moisture content is not more than 9.0 %.
3) ETHANOLIC KOH SOLUTION OR POTASSIUM ETHOXIDE SOLUTION • Take 790 kg of Ethanol in S.S. reactor • Start stirring at room temperature to 100-400 rpm. • During the addition of KOH to ethanol is a exothermic reaction. • Stare cooling water circulation to S.S. reactor and bring the temperature of Ethanol between 30-35 0C. • Start addition of 215 kg KOH (purity of KOH is 855) slowly by maintain the temperature of Ethanol should not be increased more than 35-400C. • Addition time of KOH will be 0.5 to 1.0 hrs. • After completing addition, maintain the temperature of ethanolic KOH solution at 350C for 3.0 hrs with constant stirring. • Check the moisture content. It should not be more than 9.0%. • After 3.0 hrs, transfer the ethanolic KOH in Drum/Storage tank with constant stirring. Solid un-dissolved KOH should not be settled at bottom during the transfer of ethanolic KOH solution
4) POTASSIUM METHOXIDE SOLUTION (30% to 25%) Potassium Hydroxide flex is charged in four times Methanol and heated to reflux to get Methoxide Caustic solution which presence of one equitant molecules of water. This water is recovered with counter current dry methanol vapor in a bubble cap tray tower, the result in Potassium methoxide solution is collected from the bottom of that column (25-30% W/W). PROCESS FLOW DIAGRAM OF MOLASSES BASED DISTILLERY AFTER PROPOSED
Molasses Storage and Handling
Fermentation
Rectified spirit/ Anhydrous Multi- Alcohol Pressure Distillation
Spent wash
Multi-Effect Evaporator Dried Spent wash Used as Condensate fuel in incinerator Boiler
Process/Cooling
LIST OF RAW MATERIALS
Sr. Name of the Raw Material Requirement Per Day No. 1. Molasses - F. S 43% 245 MT 2. DAP / UREA Nutrients - 46 % w/w Nitrogen 189 kg 3. Antifoam Agent 126 kg 4. Magnesium Sulphate 16 kg 5. Yeast (Active Dry Yeast/Distiller’s Yeast) Own Propagation
DETAILS OF SOLID & HAZARDOUS WASTE GENERATION DURING OPERATION
Sr. Name of the Total Method of Storage & Disposal No. Waste
1. Fly ash 18800 MT/Year Will be sold to brick manufacturers or use as manure.
Collection, Storage, transportation and disposal by selling to GPCB 2. Used Oil 0.1 KL/Year approved registered recyclers / reuse.
Discarded Collection, Storage and disposal by selling to GPCB approved 3. Container/Barrels/ 50 Nos./Year registered recyclers. Linear
EMISSIONS FROM COMBUSTION OF FOSSIL FUELS FROM STATIONARY OR MOBILE SOURCES
Sr. Stack Height Air Pollution Stack Attached To Parameter No. In Meter Control Devices Deep Fluidized Bed- Spent PM < 150 mg/nm 3 1. Wash Incinerator Boiler 45 meter ESP SO 2 < 100 ppm (20 TPH) NO 2 < 50 ppm PM < 150 mg/nm 3 D. G. Set of (1,500 KVA – 2. 11.0 meter -- SO 2 < 100 ppm Stand By) NO 2 < 50 ppm
ESSENTIAL DETAILS SOUGHT
1. Please clarify the project activities proposed under 5(f) and 5(g) are integrated. Give the justification for applying the different activity in the same plot.
Reply: 1. 5(g) Molasses based distillery : Unit is having capacity of producing 60 KLPD Extra Neutral Alcohol /Rectified Spirit & Fuel Ethanol, Molasses is used as raw material to prepare the methanol.
2. 5(f) Synthetic Organic Chemical Industry: Product like Sodium Methoxide, Sodium Ethoxide, Potassium Methoxide, Potassium Ethoxide will manufactured using methanol as major raw material.
3. Justification for applying the different activity in same plot is that from distillery methanol is utilized for manufacturing synthetic organic chemical i.e Sodium Methoxide, Sodium Ethoxide, Potassium Methoxide, Potassium Ethoxide products covered under category 5(f). to manufacture these products methanol is the key ingredient. Hence, combined project is proposed. Both activities will be carried out at different locations of the same plot with clear demarcation.
2. Layout Plan
Revised Plan layout is attached as annexure -I ANNEXURE- I