PRE – FEASIBILITY REPORT

For

ETHANOL PLANT

M/s Kesar Enterprises Limited Distillery Division Baheri, , 243201, has proposed the expansion of existing molasses based distillery from 45 KLD to 125 KLD (RS/ENA/Ethanol) along with installation of 4 MW Power Plant.

at Baheri, Bareilly, 243201, Uttar Pradesh

by

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TABLE OF CONTENT Sr No. Content Page No. 1.0 Executive Summary 3 2.0 Location with coordinate 5 3.0 Details of alternative site considered and basis of 5 selecting the Proposed site 4.0 Brief Description of the project 9 5.0 Need of project and its importance to the country and region. 5.1 Demand-Supply Gap 11 5.2 Advantages of Fuel Ethanol 12 5.3 Environmental Benefits 13 6.0 Technology and Process Description 15 7.0 Water Requirement 21 8.0 Waste Water Treatment 24 Figure 1.1 Toposheet showing location of proposed project 6 1.2 Google Map of the proposed Project Location 7 1.3 Maps of the Project Location 8

1.4 Flow diagram of Molasses based distillery 20 operation 1.5 Water Balance: 125 KLD Molasses Based Distillery 22 1.6 Sections of Condensate Polishing Unit 23 1.7 Waste water treatment strategy 24 Tables 1.1 Environmental sensitivity within 15 km radius of 3 the proposed project 1.2 Latitude and longitude of the project site 5 1.3 Project Highlights 9 1.4 Demand and Supply of Ethanol 12

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PRE - FEASIBILITY REPORT

1.0 Executive Summary (I) Introduction M/s Kesar Enterprises Limited Distillery Division Baheri, Bareilly, 243201, Uttar Pradesh has proposed the expansion of existing molasses based distillery from 45 KLD to 125 KLD (AA/ENA/Ethanol) along with installation of 4 MW Power Plant.at Baheri, Bareilly, 243201, Uttar Pradesh. For proposed Expansion of distillery project Molasses and Bagasse will be sourced from existing own sugar mill and from nearby sugar mills on necessity. As per EIA Notification dated 14th Sept, 2006 and as amended from time to time; the project falls in Category „A‟, Project or Activity: 5(g).

TABLE 1.1 ENVIRONMENTAL SENSITIVITY

WITHIN 15 KM RADIUS OF THE PROPOSED PROJECT

Sr. No. Particulars Details 1 Location Kesar Enterprises Limited Village Baheri District Bareilly State Uttar Pradesh Latitude 28°46'50.08"N Longitude 79°30'20.26"E 2 Elevation 195 M 4 Highway SH-37 Adjacent to the factory

5 Nearest Railway Station Baheri Railway Station is located 0.62 Km in South West Direction from the project site 6 Nearest Airport Pantnagar Airport: 27.92 km In North Direction from the project site. 7 Tourist Places Nil(within 15 kms of study area ) 8 Archaeological important places Nil(within 15 kms of study area )

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9 Area which are important or sensitive NIL(within 15 kms of study area ) for ecological reasons- Wetlands, watercourses or other water bodies, coastal zone, biospheres, mountains, forests.

10 Reserved Forest Nil (within 15 kms of study area ) 11 District headquarter Headquarter is located 36.40 Km from the project site in South direction 12 Village within 2 km Radius Baheri Town: Adjacent to factory in the surrounding the project west direction Shakras village : 1.15 Km in East 13 Nearest River Kichha Canal: 0.63 Km in South East direction. Dhora Nadi: 3.49 Km in the East direction. Deoranlon Nadi: 5.77 Km in South East direction. Bara Canal: 7.75 km in south East direction. Bahgul Nadi: 10.60 km in the East direction. Bahadurpur Minor: 12.40 in the East direction. Kichha Nadi:2.15 Km in West direction Baheri Distributary:1.33 km in north west direction. Daulatpur Distributary:4.45 km in the West direction. Kalwa nadi: 6.70 km in the West direction. Baraur Nadi: 8.30 km in the North West direction. Dhori Nadi: 11.76 km in the North West direction. Kahlaiya Nadi: 13.81 in West direction. 14 Nearest Hill Range Nil 15 Soil Type Tarai, Khader & Bangar 16 Seismic Zone Earthquake High Damage Risk Zone (MSK IV)

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2.0 Location with coordinate: For EIA Study 15kms radial study area will be covered and the same is shown on SOI Topo sheets 53P/5, 53P/6, 53P/9& 53P/10 in the map below Fig: 1.1. Latitude and Longitude of the site at the centre given below in Table 1.2 Table; 1.2: Latitude and longitude of the project site Coordinates Direction Coordinate 1: North Latitude: 28°46'51.86"N Longitude: 79°30'44.9"E Coordinate 2: East Latitude: 28°46'45"N Longitude: 79°30'39.82"E Coordinate 3: South Latitude: 28°46'41.51"N Longitude: 79°30'29.60"E Coordinate 4: West Latitude: 28°46'52.86"N Longitude: 79°30'15.97"E Coordinate 5: Centre Latitude: 28°46'50.08"N Longitude: 79°30'20.26"E

3.0 Details of alternative site considered and basis of selecting the proposed site: Alternative sites for the proposed project are not considered, because of following reasons – I. The project proponent is having land which is adequate for the proposed units as well as ancillary units thereof such as storage, treatment, disposal units, etc. II. The present site meets the guidelines for sitting of an industry prescribed by MoEF & CC, III. Proposed expansion will be done within existing distillery unit and it is adjacent to the existing sugar unit. Proposed site is adequate for raw material availability and fuel. IV. No rehabilitation or restoration issues involved with the proposed site, V. Infrastructure and resources such as road, water, electricity, manpower, etc is already available.

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TOPOSHEET MAP SHOWING 10 KMS RADIUS AROUND PROJECT SITE TOPO SHEET NO. 53P/5, 53P/6, 53P/9& 53P/10 (GEOLOGICAL SURVEY OF )

Legend:

- Site

PROJECT NAME: Kesar Enterprises Limited Distillery Division Baheri, Bareilly, 243201, Uttar Pradesh Project Area: 20.831 Hectare

Project Location Coordinates: Latitude: 28°46'50.08"N Longitude: 79°30'20.26"E SCALE: 1:50000

fig 1.1: Toposheet showing location of proposed project

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Figure1.2: Google Map of the proposed Project Location

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Figure1.3: Maps of the Project Location

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4.0 Brief description of the project Proposed site meets the guidelines as prescribed by Ministry of Environment, Forest and Climate Change for expansion project. Table 1.3, Project Highlights

Sr No. Item Details

1. Name of the Project M/s Kesar Enterprises Limited Distillery Division, Baheri, Bareilly, 243201, Uttar Pradesh. 2. Earlier Unit was established in year 1951; at that time there was no Environmental provision for environmental clearance, unit is getting regular Clearance consent (Air and Water) from UPPCB. 3. Total Project Area Existing land as per Land for expansion earlier20.831 HectareEC 20.831 Hectare (No additional land required) 4. Capacity Expansion from 45 KLPD to 125 KLPD of Distillery (Rectified Spirit/Extra Neutral Alcohol / Ethanol) 5. Power Generation 4.0 MW Co- Generation of Power. 6. Category Category “A” and Schedule - 5 (g)

Project Summary:

For Proposed 125 KLD Sl no. Attributes (45 KLD+80 KLD new) capacity

1. Green belt area Unit will now develop 35% of total area as green belt 2. No. of working days 360 days 3. Total Project Cost 98.50 Crore Quantity of Molasses 562.5 KLD 4. required (@ 4.5 KL/ KL of product)

5. CO2 55 TPD 6. Steam Requirement 32 TPH New 2 no.s of Slop fired Boiler Capacity 27 TPH, 7. Slop fired boiler 12 TPH respectively shall be installed. Bagasse = 100 TPD 8. Fuel type & Quantity + Slop =270 m3/day Air Pollution Control 9. ESP (proposed) Device

63 meter stack shall be installed with 27 TPH Boiler 10. Nos. of Stack 45 meter stack shall be installed with 12 TPH Boiler

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750 [email protected] KL/KL of Alcohol for industrial use, and 11. Water Requirement 20.0 KLD for domestic purposes. Total water requirement:770 KLD. 12. Spent wash generation 750.0 [email protected] KL/KL of product For Spent Wash Treatment: MEE + Incineration (Slop fired Boiler) For Other Effluent (Condensate, Leese , Floor washing , Blow downs) Secondary 13. Waste Water Treatment Treatment Plant shall be installed up-to tertiary level to achieve the Zero Discharge. Note: Initially waste water treatment strategy was based on bio composting and anaerobic treatment unit, now unit shall completely close the bio composting. Total Ash Generated : 42.0 TPD Solid Waste Generation Fermenter sludge: 10.0 TPD 14. Ash from Boiler

Use: Use: Total Ash & sludge shall be used as manure. Cost towards Environmental 15. Rs. 18 Crores protection measures ( Capital cost) Recurring cost towards 16. Environmental control Rs.2 Crores /Annum measures.

2% of total annual Profit as per the CSR Act Corporate Social 17. (By Ministry of corporate affairs) Notification GSR 129 Responsibility (E).

1% of additional capital investment Corporate Environment 18. (Brown Field Project) Responsibility (CER) 80 Lakhs

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5.0 Need of project and its importance to the country and region: As an agro based industry, Sugar industry in India is dependent on monsoon. Its financial viability drastically gets affected due to weather conditions as well as market. Therefore, it is forced to explore the alternative products from the available resources so as improve its financial stability. Molasses based distillery is one of such an alternative. Because raw material availability i.e. molasses is fulfilled by sugar mills situated in nearby district. Therefore, the management of the factory has planned to expand the capacity of existing distillery from 45 KL to 125 KL (molasses based distillery). In India, mainly three types of alcohol are popularly produced, i.e. rectified spirit (RS), extra neutral alcohol (ENA) and anhydrous alcohol (AA). Of these, RS is used for large number of industrial, scientific, laboratory, medical and many other applications. Thus, demand for the same is immense and it is ever increasing. ENA is used for making liquors and other alcoholic beverages. AA is a fuel alcohol; it is used for blending with petrol in the ratio of maximum 26:7.

5.1 Demand-Supply Gap Indian Government had set up an Expert Group headed by the Executive Director of the Centre for High Technology for examining various options of blending ethanol with petrol at terminals/depots. Considering the logistical and financial advantages, this Group had recommended blending of ethanol with petrol at supply locations (terminals / depots) of oil companies. In view of the above, Government vide the Gazette notification of 3rd September, 2002 No. P-45018/28/2000-C.C had mandated that with effect from 1st January 2003, 5% ethanol-doped petrol will be supplied in following nine States and four contiguous Union Territories of Andhra Pradesh, Gujarat, Haryana, Karnataka, Maharashtra, Punjab, Tamil Nadu, Uttar Pradesh, Pondicherry, Daman and Diu, Goa, Dadra and Nagar Haveli and Chandigarh. This was the beginning of ethanol implementation in 1 stphase. Government of India further announced to implement the Ethanol programme in 2 nd phase. This was intended to supply ethanol blended Gasoline across the country effective the year 2006 and in 3rd phase switching over from the existing 5% to 10% blending of ethanol in selected states.

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With implementation of the 5% Ethanol-Blended Petrol (EBP) programme throughout the country still a distant dream due to various complications like ethanol shortages, the variable taxation structure of state governments and regulatory restrictions, the petroleum ministry has decided to defer the proposed rollout of mandatory 10% blending of ethanol, which was expected to take place from October, 2008 onwards. Table 1.4 Demand and Supply of Ethanol Projected demand and supply of ethanol for 5% blending in Petrol Petrol Ethanol Molasses Ethanol Production Ethanol Utilization Year Dema Demand Prodn. (ML) (ML) Industr nd (ML) (MT) Molasses Cane Total Potable Balance y 2001-02 (MT)7.0 416.14 8.77 1775 0 1775 648 600 527 2006-07 10. 592.72 11.36 2300 1485 3785 765 711 2309 2011-12 12.7 756.36 11.36 2300 1485 3785 887 844 2054 07 2016-17 16. 965.30 11.36 2300 1485 3785 1028 1003 1754 85 Source: Planning Commission (2003) 4 5.2 Advantages of Fuel Ethanol Biofuels are potentially important to India because of the significant number of lives they could impact and the economic changes they could cause. India is currently the second most populous nation in the world with a growing population of over 1.147 billion people. As of August 2008, the Indian government and the World Bank both estimated that 26% of India‟s population was classified as poor despite efforts made to alleviate the problem. However, there are possibilities to ameliorate poverty through economic growth. According to the International Monetary Fund, the Indian economy is growing at over 7% a year, which means there are opportunities to invest in new industries such as biofuels that could help resolve some of India‟s economic problems. As the fifth largest energy consumer in the world, India additionally provides a good market for biofuels. 70% of its crude oil is imported from around the world and experts anticipate that over 94% of its crude oil will be purchased from abroad by 2030 if energy trends continue on their current trajectory. Biofuels offer potential opportunities to decrease the nation‟s dependence on foreign energy imports. Alcohol has assumed very important place in the country‟s economy. It is vital raw material for a number of chemicals. It has been a source of large amount of revenue by way of Excise Duty

12 | P a g e levied by State Government. Ethanol has a potentiality as fuel in the form of “power alcohol” for blending with petrol in the ratio of 10:90. This trend is continuing and will continue in view of the fact that potable liquor has larger revenue generating potential for the Governments. The demand for alcohol will always be there for industrial purposes. Further the use of alcohol in automobile fuel will enhance the demand for alcohol. Other than the above mentioned major requirement, alcohol is also being used in the production of many downstream chemicals including drugs, polymers, plastic, etc. THE USE OF ETHANOL-BLENDED GASOLINE HAS VARIOUS BENEFITS AS MENTIONED BELOW, AND HAS BEEN PROMOTED BY THE GOVERNMENT OF INDIA, UNDER ETHANOL BLENDING (WITH GASOLINE) PROGRAM. The new blend-

 is renewable  reduces dependence on Imports of foreign oil  improves market opportunity for agriculture crops  contributes to rural economic development  benefits environment  Displaces dangerous and environmental damaging component in gasoline, such as benzene.

5.3 Environmental Benefits: Ethanol is one of the best tools to fight urban air pollution from motor vehicles. As an oxygen (ethanol contains 35 oxygen by weight), fuel ethanol enhances the combustion of gasoline resulting in a more efficient burn and greatly reduced emissions. It helps reduce all pollutant including hydrocarbons, NOx, CO2, fine particulate and toxics.

 10% ethanol blends reduce carbon monoxide better than any other reformulated gasoline blend-more than 25%.

 Ethanol is a low in reactivity and high in oxygen content, making it an effective tool reducing ozone pollution.

 Ethanol is safe replacement for toxic octane enhances in gasoline such as benzene toluene and xylene.

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 ETBE lowers gasoline volatility and is particularly effective in reducing VOC emissions from automobiles.

Besides the technical and environmental benefits fuel ethanol offers, it makes tremendous economic sense in India as India's Import bill of crude petroleum is increasing every year. India is number two in the world in Sugarcane production. The number of sugar factories is 416 and 295 distilleries in the country. Large number of sugar factories co-produce ethanol.

The introduction of ethanol fuel will give big boost to Indian economy by following ways:

 The efficiency and commercial viability of sugar factories will improve.  Farmers will get higher price for sugarcane which will improve the socio-economic status of farmers.

 Agriculture will get boost because of additional production of sorghum, jawar and sugarcane.  Mixing of ethanol to petrol will save foreign exchange worth Rs. 4000 crores every year.  Less dependence on imports and cheaper cost of production of ethanol will bring down the prices of fuels.  Overall it is "Eco-friendly Project".

Import vs. Indigenous production The process is straight line and the technology even for the pollution control/disposal is available indigenously.

Export possibility The finished products viz. Rectified Spirit (RS), Extra Neutral Alcohol (ENA) and Anhydrous Alcohol (AA) is having great export potential.

Employment Generation Proposed expansion project will be generating about 25 employment opportunities. Apart from this, the project is anticipated to give plenty of indirect opportunities to transporters, shopkeepers and various facility providers such as schools, medical facilities, etc.

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6.0 Technology and Process Description (a) Molasses Based Operation Technology and Process Description Alcohol production mainly involves three main Processes; A. Fermentation B. Distillation C. Dehydration The process of alcohol manufacturing involve various sections are;  Molasses Storage and Handling Section  Fermentation Section  Distillation for Production of rectified spirit and extra neutral alcohol molecular sieve for production of absolute alcohol.  RS/ENA /Ethanol receiver and Storage Section  Effluent treatment plant comprising Evaporation plant and incineration for Spent wash treatment and other effluent (Condensates, Spent lees etc) will be treated in Condensate Polishing Unit. Alcohol is produced from carbohydrates by fermentation with yeast. Yeasts are unicellular, uninucleate fungi that can reproduce by budding, fission or both. They have been used for centuries to brew alcoholic beverages and are the most commonly used micro organism in the industrial production of alcohol by fermentation. Ethanol production by fermentation comprises four steps:

 Yeast propagation from yeast slant from the laboratory.  Fermentation to produce fermented wash containing alcohol.  Recovery, enrichment and purification of alcohol from fermented wash to produce 95.5 V/V alcohol.

 Production of absolute alcohol by dehydration of 95.5% V/V alcohol to produce absolute alcohol. A proper choice of appropriate technology in each of these steps governs the efficient and viable operation of fermentation alcohol plant.

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Yeast Propagation: Yeast, for the production of alcohol is characterized by high selectivity of the yeast species, low production of by-products (side products), high ethanol yield, high fermentation rate, good tolerance towards both high ethanol concentration and high in organics in the fermenting substrate, high temperature tolerance, land high genetically stability. Although finding a strain that has all these characteristics is difficult, a proper selection and development of the best possible strain is needed. Sacharo mycete scervisiae and Sacharomycetespombe are the commonly deployed yeast strains in alcohol fermentation of sugars. The purity and sterility of yeast culture used as inoculums have great influence on the alcohol yield and longevity of yeast in fermenter. Flocculating yeasts are deployed for continuous fermentation particularly with yeast recycle system. The selectivity of yeast is also essential to maintain the required metabolic reaction pathways specific to conversion of sugars to alcohol. The side products are higher alcohols, acids, etc. which naturally reduce the alcohol yields and final quality of alcohol. It is, therefore, customary to propagate yeast from laboratory strain in increasing volumes under sterile and aerobic conditions protecting the same from other wild yeasts and moulds during their growth. This is done in 3 or four stages starting from a 1lit inoculums developed in laboratory from a well preserved yeast culture slant. Yeast will be developed in plant from fresh slant to laboratory flash culture and then in 3 stage S.S. yeast propagation vessels which operate in series but in batch mode. When enough bio mass strength is developed, it is pitched Into Fermenter. B) Fermentation The yeast propagation is only at the start and stabilization of the fermenter. When once the continuous fermentation is on, the yeast propagation is stopped and only a periodic continuous addition of small make up of fresh culture from yeast vessel is done to maintain the activity of yeast in the active yeast count in the fermenter. The yeast vessels are fitted with jacket for sterilizing and cooling the medium in situ. Sterile air is supplied to these vessels through compressor and the sterilization-system comprising a series of fine filters followed by HEPA filters. Molasses from the molasses tank in the yard are pumped to transfer pump into tipper type molasses weighing system and weighed molasses feed tank from where molasses feed pump it to yeast vessels (when necessary) or to fermenter through a static mixer type molasses diluter. Main fermenter could be one or two stages depending on the control system envisaged based on

16 | P a g e the final designs. The heat of fermentation is extracted by circulating the fermenter contents through wort coolers. Temperature in the fermenter is to be maintained at 32 – 34°C. Carbon dioxide evolved during fermentation is vented out through scrubber to recover entrained alcohol vapors. Dilute molasses are fed to the fermenter continuously. The final fermented wash is transferred by wash pump to yeast separation system comprising hydrocolones and centrifuge. The sludge and dead yeast are purged into sludge tank and yeast cream is returned to the fermenter while clear fermented wash is collected in wash tank. Sludge from sludge tank is fed to the bottom of Analyzer Column in the distillation section. Part of spent wash from a selected tray in the column C-01 is returned to fermenter after cooling the same to as near to ambient temperature as possible. Anti-foam oil is added from whenever necessary when the level in the fermenter rises beyond a limit due to foaming because of runaway fermentation rate. The operations in the fermenter can be controlled closely through automation. Process water is taken into scrubber water tank from where it is fed to scrubber and overhead water tank by water pump. All process water in the fermentation section is supplied by gravity from this overhead tank. C) Rectified /ENA Spirit Distillation: Fermented wash from wash holding tank is pumped by wash feed pump to the top of degassing column after preheating the same in beer heater and spent wash heat exchanger. The vapors along with non-condensable gases from the top of degassing column are rectified in Heads column, to expel the high volatiles, technically know as heads. Bottom liquid from the degasser flows into analyzer column where alcohol is stripped from the liquid. The liquid from bottom of analyzer column is completely stripped of alcohol and is pumped out by spent wash discharge pump through heat exchanger where it preheats the fermented wash before it enters degassing column. Part of spent wash from a tray, few numbers above the bottom tray is cooled and returned to the fermenters as a measure of water saving and reduction of effluent discharge. The dilute alcohol vapors from near the top of analyzer column are condensed first in beer heater while exchanging heat with wash feed and then in analyzer condenser. Degasser and analyzer operate under vacuum. The condensate is collected in Rectifier Feed Tank. The vapors for stripping alcohol are generated from analyzer column bottom liquid in the analyzer column re-boiler by using the rectified column top vapors, as discussed subsequently. Vapors from the top of heads column are condensed in heads column condenser and then in head column vent

17 | P a g e condenser. Part of the condensate is returned to column as reflux while a small portion is taken out as an impure spirit cut. Liquid from bottom of column is also taken into Rectified feed tank. Dilute alcohol water mixture from rectifier feed tank are pumped by rectifier feed pump through rectifier feed pre-heater in to rectifying column. Rectifier and its associated equipment work under pressure so that these vapors can supply the necessary heat for generating the vapors. The condensate from Analyzer is then pumped as Reflux to rectifying column. Rich alcohol vapors at a concentration of 95.5% v/v from top of rectifying column are condensed first in Analyzer and then in Reflux Vent Condenser. The liquid from analyzer and reflux vent condenser are collected in Rectifier Reflux Tank. Part of the liquid from reflux vent condenser may be drawn off as impure spirit. The impure spirit cut will be maintained as little as possible to maintain aldehyde levels to meet the required limits in Absolute Alcohol. Liquid from the reflux tank is pumped by Product Pump partly as product and partly as reflux to the top of the Rectifying Column. The necessary rectifying vapors to Rectifying column are generated by boiling the bottom liquid in Rectifier Column Reboiler using medium pressure steam. Some side streams are drawn from rectifier column as light and heavy fractions of higher alcohols called fusel oils and cooled in fusel oil coolers and are mixed with water and allowed to separate out in fuel oil separator. All vents from High column vent condenser, analyzer condenser, rectified feed tank and reflux vent condenser are connected to Vent Gas Absorber where the vent gases are scrubbed with water to recover entrained alcohol. The scrubber water is used for washing the fusel oils in fusel oil separator to recover alcohol from the fusel oil fractions. The absorber vent is connected to vacuum pump which is used to create vacuum in the analyzer and degasser. The products Rectified Spirit and Impure Spirit, are cooled in product coolers and collected in the respective receiver tanks prior to pumping the same through respective transfer pumps into storage tanks in the excise godown. Impure spirit, is however, returned to Ethanol plant along with the rectified spirit feed, subject to maintaining, the Absolute Alcohol quality required for blending with petrol.

D) Fuel Grade Ethanol Absolute alcohol is manufactured by dehydration of Rectified Spirit. The process adopted here is based on Pressure Swing Adsorption (PSA) system using Molecular Sieves. The flow scheme is shown in above referred flow diagram. Rectified spirit, after preheating by waste hot streams,

18 | P a g e is vaporized and superheated in analyser condenser and analyser by using medium pressure steam at 6 Kg/cm2g pressure. Hot vapors at kg/cm² g pressure and 130° C temperature pass through PSA column, where the water vapors are retained while water free alcohol is released as vapors. The vapors are condensed in high column vent condenser and Rectified column re- boiler and collected as Absolute Alcohol. When the molecular sieve bed is saturated with water the alcohol vapors are shifted to the other tower and the first tower is taken for regeneration. Regeneration is done first by pressure releasing and creating vacuum and then by elutriating with dehydrated alcohol vapors from the tower in dehydration operation. The vapors are condensed in Head column condenser and reflux vent condenser and the vent vapors are recovered through scrubber degassing column. Vacuum can be created vacuum by rectified feed pump. (Eductor may also be considered for this duty). Product is cooled in fusel oil cooler and transferred to Absolute Alcohol receiving tank and then on to storage tank.

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MOLASSES (Raw material for alcohol)

YEAST WATER

FERMENTATION PROCESS

YEAST SLUDGE WET

DISTILLATION PROCESS

Steam for Distillation of alcohol SPENT LESS ALCOHAL Wet sludge SPENT WASH

Steam for spent wash concentration EVAPORATION

BAGASSE

TURBO Steam As Fuel GENERATION BOILER CONCENTRATED SPENT WASH

Power ASH CONDENSATE (Spent Wash Evaporation & Distillery use)

Secondary Effluent Used as Treatment Plant Manure in Farm lands

Treated Water (RE-USE IN THE PROCESS, GRADENING)

Figure 1.4 Flow diagram of Molasses based distillery operation

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7.0 Water Requirement:

Fresh Water Requirement for Fresh Water Requirement Source 125 KLD Distillery (=770 KLPD) KLD Industrial 750@ 6.0 KL/KL of Ground water Purposes Product (from Tube well) Domestic 20 KLD Purposes

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Figure 1.5 Water Balance: 125 KLD MOLASSES BASED DISTILLERY

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Fig: 1.6: Sections of Condensate Polishing Unit

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8.0 Waste Water Treatment: For Spent wash: MEE + Incineration (Slop fired Boiler) will be installed. For Other Effluent: Process Condensate Polishing Plant will be installed for treatment of various other effluents (Condensate, Lees, Floor washing, Blow downs). Domestic effluent shall be disposed in Soak pit and Septic tank.

Unit will be based on zero liquid discharge.

DISTILLERY UNIT: 125 KLD

750@ 6.0 KLD/KL OF PRODUCT

SPENTWASH STORAGE TANK

MULTI EFFECT EVAPORATOR

MEE CONDENSATE CONCENTRATED SPENTWASH CIP Cleaning: (SLOP) + OTHER EFFLUENT: LEES, BOILER, CT BLOWDOWN, FLOOR WASHING INCINERATOR BOILER: etc:

STEAM FOR USE IN PROCESS CONDENSATE POLISHING UNIT

TREATED WATER FOR 100% RECYCLING IN COOLING TOWER MAKEUP, PROCESS etc.

Fig 1.7 Waste water treatment strategy

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