Pre Feasibility Report for Molasses Based Fuel Ethanol Plant of 45 KLD

Pre Feasibility Report For Molasses Based Fuel Ethanol Plant of 45 KLD Along with 14 TPH Incineration Boiler At Village – Mendrana Tehsil- Pansemal Distt – Badwani (MP)

Proposed By M/S Shree Durga Khandsari Sugar Mills (SDKSM) Village- Mendrana, Tehsil- Pansemal, Dist. Barwani, MP

1. Identification of project and project proponent M/s Shree Durga Khansari Sugar Mill (SDKSM) is as partnership firm registered with State Govt and located at Village- Mendrana, Tehsil- Pansemal Dist Barwani (MP) The factory was established originally as Khandsari Sugar unit of 300 TCD in 1974. Initially factory was following traditional khandsari process which was associated with number of disadvantages such as low sugar recovery, higher sugar loss in bagasse and final molasses, high fuel consumption. In year 2004, the unit upgraded the crushing capacity to 800 TCD and received permission for conversion of khandsari unit to sugar plant. Presently SDKSM is operating plant with expanded capacity of 2500 TCD. Brief Description of Nature of the Project The present proposal is for setting up a 45 KLD fuel ethanol plant (Molasses based) with 14 TPH Incineration Boiler at Village Mendrana, Tehsil- Pansemal Dist Barwani (MP) in the State of Madhya Pradesh at an estimated cost Rs. 4682 Lacs. The proposed project will be set up adjacent to the existing sugar unit (2500 TCD & 11 MW power plant) of M/s SDKSM. 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 45 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  Imported Buhler makes Mill and efficient Grain handling system is considered.  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 Shree Durga Khandsari Surgar Mills 2. Project capacity 45 KLPD Molasses Based Ethanol Plant with 14 TPH Incineration Boiler. 3. Khasara No. & Location of the Khasara No. 76/1 & 76/2, Village- Mendrana, project Tahsil Pansemal, Dist. Barwani, MP. 4. Geographic Location 21°39'24.56" N and 74°39'14.41" E 217 m MSL 5. Land requirement Total land 8.0048 acres for proposed Distillery Unit 1.989 acre built up area 2.64 acre green belt area 6. Product Product: Fuel Ethanol :45 KLPD With 14 TPH Incineration Boiler. 7. Operation days 270 days 8. Molasses required Molasses 158 TPD ( Fermentable sugar 42% w/w) 9. Total water 351 KLD (After recycling) 10. Source of water Borewell 11. Electricity Operational: 847 kWh Connected load: 1185 kWh 12. Turbine generator 1.20 MW 13. Steam 9.92 TPH 14. Fuel Concentrated spent wash: 117 TPD Bagasse – 115 TPD 15. Source Captive & Nearby Market 16. Boiler 14 TPH Incineration Boiler 17. DG Two DG sets of capacity 250 kVA 18. Effluent treatment Condensate Polishing Unit (CPU) will treat spent System lees, cooling tower blow down, boiler blow down and process condensate. Spent wash will be treated by multi effect evaporator followed by slope fired boiler. 19. Man-power 70 skilled and unskilled 20. Total project cost 4682 Lakhs 21 Land acquired 24.19 acres 22 Land required for proposed 1.989 acres plant 23 Proposed area for plantation 2.64 acres 24 Existing area of plantation 2 acres 25 Capital Cost for 1050 Lacs 100 Lacs ( May be changed during EIA Environmental measures study) (proposed ) 26 Recurring cost for environmental monitoring etc 100 Lacs ( May be changed during EIA study) (Proposed)

Existing Sugar And Cogeneration Plant Details Sr. No Description Quantity Unit

1. Crushing capacity, TPD 2500 TCD 2. Number of crushing 125 days/year 3. Boiler used 60 TPH (expected) 4. Power generation capacity 11 MW 5. Power consumption Season Offseason. MW For sugar plant and cogen 4 0.001 Other In-house consumption N A N A Power export N A N A 6. Bagasse generation 636 TPD @28.4% 7. Bagasse required for 600 TPD 8. Savedcogener baagassetion 36 TPD 9. Molasses generation 117 MT TPD 10. Fresh water requirement for Season Offseason. CuM/D Sugar and cogeneration after recycling. 465 20

11. Water storage capacity 4700 CuM/D 12. Effluent generation form Sugar manufacturing CuM/D sugar and cogeneration Process: plant 48 M3

From Cogeneration plant : 1 M3 13. Final disposal of treated 53 M3. - effluent 14. Ash generation from existing 24 TPD plant 15. Pressmud 75 TPD 16. ETP Sludge 0.001 TPD 17. Lime sludge 0.008 TPD 18. WTP Sludge 0.001 TPD 19. Final disposal of Ash Given to farmer as manure. -

20. Storage capacity of Bagasse’s 1000 MT 21. Syardtorage capacity of Molasses 3000 MT

22. Existing manpower 100 No. requirement for Sugar/Cogeneration (skilled and unskilled)

Proposed manpower 35 No. requirement for Distillery (skilled and unskilled)

23. Layout plan of existing sugar factory and cogeneration unit & proposed Distillery unit with existing green belt, parking area, storage area etc - Attached

3. Need for the project and its importance to the country and or region

Utilization of molasses for the production of ethanol in India will not only provide value addition to the by-product, it also ensures better price stability and price realization of molasses for the sugar mills. This will improve the viability of the sugar mills, which will in turn benefit to cane growers. Industry overview Molasses is one of byproducts of sugar industry which is used to produce rectified spirit/alcohol for making liquor and fuel. Traditionally, molasses has been used in India to produce rectified spirit and alcohol of higher than 95% purity for producing liquor for human consumption and for producing various chemicals. However, with technological developments in the recent past, molasses has been effectively used to produce bioethanol for blending with petrol as a fuel

Global scenario Brazil is the second largest producer of ethanol globally after U.S. While U.S. produces ethanol from corn, Brazil manufactures ethanol from sugarcane. Brazil has mandatory blending ratio of ethanol in gasoline ranging from 18% to 25%. The blend rate was as high as 25% before September 2011 and was reduced to 20% due to drop in cane output hence affecting the ethanol production. Currently, flex-fuel cars, which can use either ethanol or blended gasoline, in Brazil account for about 53% of the total car fleet and around 90% of the new vehicles sales. The proportion of the flex-fuel cars are expected to cross 80% by 2020. Currently, the Brazilian light vehicle fleet has been increasing by 6.7% y-o-y since 2003 with currently 90% of the new vehicles being flex-fuel cars. Thus, there exists an increasing demand in Brazil for ethanol which is encouraging for the sugarcane industry.

Indian scenario India has about 330 distilleries, which produce over 4 billion liters of rectified spirit (alcohol) a year. Beyond total distilleries, about 120 distilleries have the capacity to distillate 1.8 billion liters (an additional annual ethanol production capacity of 365 million liters was built up in the last three years) of conventional ethanol per year which is sufficient to meet requirement for 5% ethanol blending with petrol.

Government policy In 2006, GOI mandated 5% ethanol blending with petrol, EBP programme to directly benefit the sugarcane farmers by assuring the sugar industry a stable and reasonable return for the molasses and then passing a significant part of the same to the farmers. But since then the programme has been struggling to take off despite the fact that the Cabinet Committee on Economic Affairs (CCEA) in November 2009 directed that a financial penalty be imposed on oil marketing companies for their failure to reach targets. In November 2012, the CCEA has made it mandatory for Oil Marketing Companies (OMCs) - Bharat Petroleum, Hindustan Petroleum and Indian Oil Corporation - to blend 5% ethanol with petrol. This is likely to reduce the fuel import bill and lower India's dependence on fossil fuel as the ethanol prices are lower than petrol. The OMCs have been blending ethanol with petrol for the past two years but the policy was partially implemented in absence of any clear directive. The committee, headed by the Prime Minister, has also approved market-based pricing of the biofuel, opening the market for ethanol producers - mostly sugar companies. This shall result in an increased demand for ethanol by OMCs. The national bio-fuel policy, approved by the Government of India, has plans for a 20% ethanol blending programme by 2017 from the current mandated 5% blending & recently increased to 10%, to reduce India’s dependence on fossil fuel imports.

4. Demand –Supply Gap

The gap between the availability of alcohol and the requirement by the industry has been widening. The existing requirement of alcohol by the industries is around 450 crore liters annually at 10% fuel ethanol blending, industrial alcohol and potable alcohol and the production is around 285 crore liters. The trend is increasing as the blending increases.

The Ministry of Petroleum recently issued gazette notification dated 11th Januray 2013 making 5% ethanol belnding with petrol mandatory across th country.

Year Ethanol production Ethanol utilization Ethanol Petrol Blending Demand Molasses Cane Total Industry Potable Balance 2001- 1775 0 1175 600 648 527 5% 448 8960 02` 10% 896 20% 1792 2006- 2300 1485 3785 711 765 2309 5% 638 12672 07 10% 1276 20% 2552 2011- 2300 1485 3785 844 887 2054 5% 814 16286 12 10% 162 20% 3257 2016- 2300 1485 3785 1003 1028 1754 5% 1039 20785 17 10% 2078 20% 4157

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 unit : 100no. Proposed Employment : 70 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 28 14. Total 70

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 2500 TCD. No interlinked and interdependent project is prpposed with the proposed Ethanol plant. Incineration Boiler of 14 TPH is also proposed for implimetation

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 24.19 acres of land in village Mendrana Tehsil, Pansemal Dist. - Barwani of MP. The latitude and longitude of the site is as below : 21°39'24.56"N - 74°39'14.41"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 ( 2500 TCD) with cogen plant of 11 MW is already in operation. The entire land is about 24.19 acres and out of that proposed unit will require 32392 sq mt 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 45 KLD of fuel ethanol from molasses based operation along with 14 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 offseason 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 270 F and 300 C and are held a 320 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 350 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 400 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 45 KLPD distillery plant nearly about 117 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 Quantity Storage Transportation material Distillery 1. Molasses 158 TPD Tank Tanker 2. Coal NA N A N A 3. Sulfuric Acid 0.25kg/KL FRP Tank Tanker

4. Anti-foam reagent 0.25 Drum Truck

Sugar unit 2500TCD Open Area Truck & Tractor 1. Sugarcane 2. Lime 658 MT/Year Bags Truck 3. Sulphur 158 MT/Year Bags Truck 4. Caustic soda (50%) 5.45MT/year Bags Truck 5. Caustic soda 5.45 MT/Year Bags Truck

SDKSM will generate about 14,688 MT of molasses from expected / sustained cane crushing of 3.125 lakh MT / year, with minimum 4.7% molasses recovery. The total requirement of molasses for the 270 days operation of the proposed distillery plant at optimum level of operation will be around 45,000 MT and the balance 28062 MT of molasses will be sourced from group units sugar factories. The fuel ethanol yield from cane molasses will be at 270 lit/ton. The per day requirement of molasses will be about 166 MT per day for 45 KLPD ethanol production per day. The total requirement of molasses for the 270 days operation of the proposed ethanol plant will be about 42,750 MT (at maximum 95% utilization level from 4th year onwards). At the projected average cane crushing of 2500 TCD for 125 days or 3.125 lakh MT per year, 14,688 MT molasses will be generated from the cane crushing. The balance quantity of 28,062 MT will be sourced from other units. In house molasses should be adequate to run the ethanol plant for at least 270 days. All four unit in-house molasses will be sufficient to run the 45 KLPD of distillery plant for 270 days at 9500 TCD combined Crushing Capacity of all four units.

As the sugar plant is expected to crush about 3.125 lakh MT of sugarcane in future, molasses of around 14,688 MT will be produced at 4.7 % molasses generation on cane. The own molasses will be utilized by the fuel ethanol plant, leaving 28,062 MT as other unit molasses, as the total molasses requirement is 42,750 MT for optimum level of operation. The balance quantity of molasses will be sourced as procured molasses from nearby sugar factories. 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 9.92 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 351 KL per day Source : Borewells

Water Balance . Water inputs (In KLD) 1. Process water for fermentation section and CO2 scrubber 414 2. DM water for RS dilution 50 3. Water for vacuum pump, pump sealing, air blower & 6 others 4. Soft water makeup for cooling towers 340 5. Other domestic usage, laboratory uses, cleaning 5 6. Boiler 15 7. Total water input at start-up 830 Water Out Put (In KLD) 1. Spent Lees (PR & Rect.) 120 2. Process condensate 395 3. CT Evaporation & Drift Losses 272 4. Water losses from vacuum pump, pump sealing, Air blower 0.2 5. Cooling tower and boiler blow down 67 6. Total Water Output 854.2 Recycled water (In KLD) 1. Lees recycle for cooling tower make up 120 2. Process condensate fermentation 120 3. Process condensate to cooling tower, CIP, Fermentation 233 4. Pumps Sealing Water Recycle cooling tower 5 5. CO2 scrubber beer well to process water for fermentation 1

6. Total Recycling water per day 479 Daily fresh water input 351

Water requirement for existing sugar and cogeneration Sr. Particulars For sugar in For During Off No KLD Cogeneration Season in KLD 1. Total water requirement 350 150 3 M3 2. Water recovered 135 25 - 3. Total daily fresh water 215 125 - required after recycling

Wastewater generation of sugar and cogeneration Sr. Source Process KLD Treatment Final Disposal No. 1. Sugar Sugar ETP Treatment Units: Bar screen For ferti Plant manufacturi and grit chamber, oil and grease irrigation. ng Process 200 traps, reaction tank, equalization M3 tank, anaerobic tank, aeration Tank I, aeration Tank II, secondary clarifier, sludge drying bed and polishing pond. 2. Co Cooling 15 For polishing pond for For Ferti- generati Tower dilution with other effluent Irrigation on 11 Boiler Blow 5 M3 For polishing pond for For Ferti- MW down dilution with other effluent Irrigation D.M. 50 Neutralization followed F o r Ferti- Regeneration M3 bydisposal to polishing pond for Irrigation dilution with other waste water stream. 3. Total - 270 - - M3

Summary of effluent generation from proposed distillery, existing sugar and cogeneration unit Source Effluent Quantity Disposal Proposed Distiller Spent wash Raw spent wash Conc. Spent Wash generation 450 KLD Feed in Incineration concentrated spent Boiler. wash 117 KLD Sugar Molasses 117 TPD Effluent 200 KLD Co generation Blow down from the 70 KLD cooling tower &

boilers Domestic Waste Sewage generation 20 KLD water

ix. Power Requirement: Construction Phase – 30 kw

Electricity consumption bifurcation Sr. No Section Operating load Connected load (kWh) (kWh) 1. Fermentation 2. Distillation

3. MSDH 4. Integrated RSW evaporation 1185 KWH 847 KWH 5. Process condensate treatment plant 6. Alcohol storage 7. Utility (Cooling tower) 8. Instrument air compressor

9. Total 1185 KWH 847 KWH

During operation phase , the required power will be taken from cogeneration power plant. One DG set of 1010 KVA shall be kept as standby arrangement

Fuel consumption

Sr. No Fuel Quantity 1. Concentrated spent wash 117.84 TPD 2. Spent wash concentrate, GCV 1600 kcal/kg 3. Coal GCV N A 4 Bagasse 115.20 TPD 5 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) 4.82 TPH 2. Steam for Integrated Evaporation 4 TPH 3. Steam for MSDH 1.10 TPH 4. Total 9.92 TPH Steam utilization for sugar factory 5. Crushing rate 2500 TCD 6. Steam Generation 1440 MTD 7. Steam Requirement 1161 MTD 8. Steam Condensate 113 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 830 m3/day, and after recycling daily fresh water requirement will be 479 CMD. 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 Sr. Particulars For sugar During Off No Season 1. Total water requirement 350 M3 3 M3 2. Water recovered 135 M3 N A 3. Total daily fresh water 215 kld NA required after recycling

Wastewater Generation Of Sugar And Cogeneration Sr. Source Process KLD Treatment Final Disposal No. 1. Sugar Plant Sugar 200 ETP Treatment Units: Bar screen For ferti manufactur M3 and grit chamber, oil and grease irrigation. ing Process traps, reaction tank, equalization tank, anaerobic tank, aeration Tank I, aeration Tank II, secondary clarifier, sludge drying bed and polishing pond.

2 CO Gen Cooling 15 For polishing pond for For Ferti- Plant Tower dilution with other effluent Irrigation

Boiler Blow 5 For polishing pond for For Ferti- down dilution with other effluent Irrigation

D.M. 50 Neutralization followed F o r Ferti- Regeneration bydisposal to polishing pond for Irrigation dilution with other waste water stream. 2. Total - 270 - - M3

Summary of effluent generation from proposed distillery, existing sugar and cogeneration unit Source Effluent Quantity Disposal Proposed Distillery Spent wast Raw spent wash Conc. Spent Wash generation 450 KLD Feed in Incineration concentrated spent Boiler. wash 117 KLD Sugar Molasses 117 TPD ETP Effluent 200 KLD Co generation Blow down from the 70 KLD cooling tower & boilers Domestic Waste Sewage generation 20 KLD Septic tank and water soak pit

Solid And Hazardous Waste Management  Yeast sludge mixed with spent wash and incinerated in the boiler or used as manure.  Ash generated will be given to brick manufacturers.  Sludge from ETP will be used as manure.

Solid Waste Details Sn Type of waste Quantity Disposal From existing sugar &- Proposed Distillery cogeneration plant Yeast Sludge N A 0.2 Kg/day Fertilizer Lime Sludge 0.008 MT/day N A Fertilizer WTP Sludge 0.001 MT/day N A Fertilizer ETP Sludge 0.001 MT/day - Fertilizer Ash Bagasse ash: Coal Ash : N A 24 MT/day Spent wash Ash ; 1.73 MT/day Domestic waste 0.01 MT/day N A Waste Oil 0.0001 Ltr/day N A

4.0 Site Analysis: i. Connectivity Location : Own land at Village Mendrana Tehsil –Pansemal, District- Barwani (MP)

Place : Tehsil –Pansemal

District : District- Barwani (MP)

S. Particulars Details No. 1 Co-ordinate 1. 21°39'24.56"N - 74°39'14.41"E

2 3 Height above mean sea 217 m MSL level 4 Nearest Town Pansemal – 4.50km 5 Nearest Railway Dondaicha – 37.25km Station/Town 6 Nearest Airport Shirpur – 48.00km 7 Nearest Highway/Road Khetia- Sendhwa Road SH 36 - 0.17 km - S 8 Hills/Valley Toramal Hill – NEE – 8.75km 9 Ecological Sensitive Zone None 10 Reserve Forest RF- NNE – 8.75km RF- ENE – 9.75km 11 Nearest Village Mendrana – E – 0.90km 12 Nearest River/ Nalla Bandbhara Buzurg nadi – N- 0.09km Gomai River – SE – 1.25km Umri Nadi – W – 3.25km 14 Surrounding Features

ii. Land Form, Land use and Land Ownership Project Proponent is having 24.19 acres of land which is possession and diverted for industrial purposes. iii. Topography Topography of the area is almost plain. Map is given in point No. 3.2 iv. Existing Land use pattern The land use of the project area is pertaining to industrial activity only. Out of project area is predominantly being used or agricultural purposes. Land use Break-Up for Existing and proposed unit Area in Sq Mt Particular Existing Sugar Unit Proposed Distillery unit Built up Area of main plant and 20245 8049 machineries Road area 2024 2024 Raw Material storage area 8098 100 Fuel Storage Area 4049 2024 Roof Area 2025 N A Parking area 2025 Common Green Belt 20245 8098 Open Land 39235 12097 Total area 97946 Sq. Mtr. (24.19 Acre) 32392

Land Bifurcation Of Proposed Distillery Unit No. Units Area (sq. m.) 1. Molasses Storage Tanks 1020 2. Fermentation Section 1040 3. Distillation Section 700 4. Evaporation Section 710 5. Product Storage & Receiver Section 1020 6. Cooling Tower for Fermentation 200 7. Cooling Tower for Disti. + Int. Evaporation 300 8. Cooling Tower for MSDH Section 200 9. PCTP Section 50 10. WTP & Raw Water Storage Tank 729 11. Weigh Bridge 30 12. Administration Office 80 13. Excise Office 20

14. Security Cabin 20 15. Time Office 20 16. Boiler House 900 17. Coal Yard N A 18. Lagoon & Settling Pit 1000 19. Fire Water Pump House 10 Total area of Plant & Machineries 8049 Sq. Meter In Acres 1.98 Acres Total area earmarked for project 8.0048 acres

v. Existing Infrastructure The required infrastructure is already in place as proposed site is in operation. State Highway is passing at 170 mtrs from the industry. vi. Soil Classification

The soils in the area are generally of sedimentary type soil .

vii. Climate data from Secondary Source:

Meteorological data month of 1st March to 31st May 2017

Relative Humidity Cloudiness Temperature OC Morning (8.00) Evening (15.00) % Octas

Wind Wind Date Wind Wind Max Min Avg. Max Min Avg. Speed Speed Mor. Eve. Dir. Dir. km/h km/h 1 35 17 26 64 14 31 E 5 SW 15 2 0 2 33 16 24 53 15 33 NW 7 WSW 18 3 2 3 32 15 23 60 12 35 NW 6 WSW 19 4 1 4 31 14 22 73 17 43 ESE 7 W 14 0 0 5 29 16 23 64 24 44 NE 10 NNW 7 0 3 6 30 16 23 68 19 36 ENE 13 SE 4 0 0 7 33 16 24 49 9 25 ESE 11 SW 13 6 3 8 31 16 23 49 15 31 WNW 14 W 20 6 10 9 31 16 23 52 14 31 WNW 14 WSW 22 7 9 10 29 16 22 53 26 40 W 21 WNW 21 8 43 11 28 15 21 77 11 33 W 21 WNW 23 10 2 12 27 9 18 47 9 26 NNE 11 N 8 0 0 13 30 14 22 42 9 25 ENE 7 W 5 2 0 14 31 13 22 42 5 24 E 12 ESE 6 0 51 15 32 16 24 35 7 18 ESE 17 SSW 9 14 1 16 34 18 26 74 9 22 SE 15 WSW 13 4 2 17 33 15 24 40 9 21 NNW 12 NW 18 0 0 18 33 18 26 49 15 28 WNW 21 WNW 23 15 10 19 33 17 25 52 16 34 ESE 10 WNW 27 7 6 20 33 17 24 60 15 34 NE 12 NE 8 1 1 21 34 19 27 52 8 28 E 9 SE 4 0 0 22 37 18 28 46 10 25 SSE 6 SW 10 0 0 23 37 19 28 38 10 23 NW 5 WSW 7 0 0

24 37 21 29 47 11 25 NNW 14 WNW 15 1 0 25 38 19 29 49 11 26 NW 10 WNW 18 0 0 26 39 18 29 53 12 29 E 5 WNW 10 0 0 27 38 23 31 47 14 27 NE 10 NNE 11 0 0 28 40 20 30 35 12 24 NW 6 NW 6 0 0 29 41 23 32 36 12 21 N 15 NW 8 0 0 30 40 22 31 28 12 19 N 15 WNW 17 0 0 31 39 23 31 39 13 26 NW 10 W 15 0 0

Table no. 3.2 (B) Meteorological data month of 1st April to 30th April

Relative Humidity Cloudiness Temperature OC Morning (8.00) Evening (17.00) % Octas

Wind Wind Date Wind Wind Max Min Avg. Max Min Avg Speed Speed Mor. Eve. Dir. Dir. km/h km/h 1 39 23 31 39 6 20 NW 17 W 24 0 0 2 38 22 30 38 6 16 WNW 21 W 21 0 0 3 38 18 28 34 7 20 W 18 WSW 18 0 0 4 38 19 29 60 8 29 W 19 WSW 24 0 0 5 37 20 29 48 13 32 W 17 W 21 0 0 6 38 22 30 53 7 26 W 23 WSW 24 0 0 7 36 19 28 57 5 25 WNW 19 W 22 0 0 8 36 16 26 33 4 15 NNE 12 NNW 6 0 0 9 36 20 28 31 4 13 NE 13 NNW 7 0 0 10 36 20 28 26 4 13 NE 19 NNE 13 0 0 11 38 18 28 23 4 12 SE 9 WSW 17 0 0 12 39 19 29 33 5 14 NNW 7 N 14 0 0 13 41 21 31 33 5 16 NNW 10 NNW 15 0 0 14 41 22 31 38 5 15 NNW 22 NNW 15 0 0 15 41 22 32 26 5 14 NW 23 NNW 19 0 0 16 41 22 32 29 7 15 NW 21 NNW 15 0 0 17 41 24 33 25 8 15 NNW 18 NW 14 0 0 18 41 23 32 32 8 17 NW 21 WNW 17 0 0 19 41 23 32 29 5 14 W 20 W 26 0 0 20 40 22 31 27 5 14 W 26 WNW 27 0 0 21 39 23 31 42 7 20 W 24 WSW 22 0 0 22 37 21 29 58 10 28 W 22 WSW 21 0 0 23 37 21 29 54 9 26 WNW 19 W 19 0 0 24 36 19 28 53 8 28 W 22 WSW 23 0 0 25 36 21 29 51 12 30 W 20 W 20 0 0 26 37 20 28 60 6 25 WNW 17 W 18 0 0

27 38 19 29 39 4 17 NW 12 WSW 11 0 0 28 39 21 30 27 5 14 WNW 15 WSW 24 0 0

29 39 24 31 37 10 23 W 17 W 17 0 0

30 37 21 29 41 15 28 W 18 WSW 18 0 0 Table No. 3.2 (C) Meteorological Data Month Of 1st May To 31st May 2017

Relative Humidity Cloudiness Temperature OC Morning (8.00) Evening (17.00) % Octas

Wind Wind Date Wind Wind Max Min Avg Max Min Avg Speed Speed Mor. Eve. Dir. Dir. km/h km/h 1 39 23 31 50 6 25 WNW 16 W 14 0 0 2 40 25 32 25 6 16 NE 11 SW 11 0 0 3 40 24 32 37 9 19 WNW 14 WSW 16 0 0 4 41 24 32 41 6 18 NW 14 WNW 10 0 0 5 41 25 33 35 6 18 NW 16 WSW 13 0 0 6 41 24 33 30 6 16 NW 19 WNW 15 0 0 7 40 24 32 29 9 20 WNW 8 WSW 13 0 0 8 41 25 33 51 12 30 WNW 13 W 6 0 4 9 39 24 32 51 13 29 W 15 WSW 13 0 0 10 40 23 32 45 11 27 W 14 WSW 13 0 0 11 41 23 32 43 12 24 WNW 9 WNW 10 0 2 12 42 26 33 42 13 26 NNW 13 NNW 10 0 0 13 42 27 34 34 12 20 NNW 15 NNW 10 0 0 14 42 28 35 28 13 20 NNW 14 NW 14 0 0 15 41 26 33 35 12 22 WNW 18 W 17 0 0 16 40 26 33 51 10 24 WNW 19 W 19 0 0 17 40 27 33 36 9 23 WNW 19 W 20 0 0 18 41 26 33 55 11 27 WNW 16 WNW 18 0 0 19 41 26 33 51 10 26 WNW 21 W 19 0 0 20 41 26 33 43 9 24 WNW 20 WSW 18 0 0 21 39 26 32 61 16 33 W 22 W 15 0 0 22 40 24 32 54 14 31 W 14 WNW 18 0 0 23 40 25 32 49 19 40 NW 18 WNW 12 0 0 24 42 24 33 61 18 32 NW 18 WSW 9 0 0 25 42 24 33 83 17 44 NW 15 WNW 9 0 5 26 41 23 32 65 22 44 WNW 15 W 10 0 0 27 42 27 34 66 20 40 WNW 12 W 17 0 0 28 39 26 32 70 27 44 W 20 WSW 24 0 0

29 37 25 31 65 27 47 W 18 WSW 25 0 0 30 36 22 29 78 26 55 W 16 W 13 1 5 31 40 25 32 69 26 51 WSW 12 SSW 9 0 2

viii. Social Infrastructure available Social infrastructure like community center, hospital and electricity is available in Pansemal as well as in Barwani (MP)

5.0 Planning Brief: i. Planning Concept : The grain base unit shall be installed after receiving environment clearance and consent under air and water act from the MPPCB. 14 Months has been considered for the same. ii. Population Projection: The project is small in magnitude. No influx of population is expected as labour shall be deployed from the local villages.

iii Land use planning As above

Amenities / facilities

 First aid facility has already been provided at site.  The area shall not being used at all by general public.  A rest shelter is there for workers.  Guards during day & night has already been deputed at site to prevent unauthorized entry.  In case of natural hazards such as earthquake we will take assistance from the local competent authority of Govt.

6.0 Proposed Infrastructure The major plant & machinery required for the proposed project is as given under. Outline Technical Specifications For 45 Klpd Ethanol Storage & Handling:

Sr. Equipment Technical Specification Qty. MOC No. 1 Raw Molasses Type- Screw/Gear 1+1 CI transfer pump type Capacity- 20 2 Day Molasses Tank CapacityMT/hr - 250 MT 1 MS 3 Molasses Transfer Pump Type- Screw/Gear 1+1 CI type Capacity- 20MT/hr 4 Molasses Filter Type- Basket Strainer 1+1 MS 5 Molasses Receiving Tank Type- Cyl/Vert. Shell with 1 MS Open Top & Conical Bottom, Capacity- 3 MT 6 Molasses Type- Load Cell 1 MS Weighing System Capacity 4 MT Per Trip 7 Weighed Molasses Tank Type- Cyl/Vert. Shell with 1 MS Conical Top & Sloping Bottom, Capacity- 20 MT 8 Weighed Molasses Type- Screw/Gear 1+1 CI Transfer Pump with Motor type Capacity- 15 MT/hr 9 Molasses Diluter For Type- Static Mixer 1 AISI304 Yeast Vessel

Fermentation Section:

Sr. Equipment Technical Specification Qty. MOC No. 1 CO2 Scrubber Type: Sieve 1 AISI 304 Trays Dia: 500 2 Culture Vessel-I with Typemm - Cyl/Vert 1 AISI 304 Air Sparger Shell, Jacketed with Dished Ends. 3 Culture Vessel-II with Type - Cyl/Vert 1 AISI 304 Air Sparger Shell, Jacketed with Dished Ends. 4 Culture Vessel-III with Type - Cyl/Vert Shell, 1 AISI 304 Air Sparger Jacketed with Dished Ends. Capacity- 12 m3 5 Cell Mass Transfer Pump Type- Centrifugal with 1 with Motor Trolley Capacity- 10 m3 6 Fermenter with Agitator, Type- Cyl/Vert. Shell 4 AISI 304 SG, LG with Conical Top & Sloping Bottom, Capacity- 3 7 Molasses Broth Mixer Type300 m- Static Mixer 3 SS 304 for Fermenter

8 Fermenter Type- 4+1 CF8 Recirculatio Centrifugal n Pump with Motor Capacity- 9 Fermenter Wash Cooler Type- 3PHE 4 Plates 250m /hr AISI 10 Pre fermenter Type- Cyl/Vert. Shell with 2 AISI316 304 /Yeast Activation Conical Top & Sloping Vessel with SG,LG Bottom, Capacity- 40m3 11 Molasses Broth Mixer Type- Static Mixer 2 AISI 304 for Yeast Activation Vessel 12 Yeast Activation Type- 1+1 CF8 Vessel Transfer Centrifugal Pump with Motor Capacity- 30 m3/hr 13 Yeast Activation Type- PHE 1 Plates Vesse AISI 316 l Cooler Frame 14 Wash Holding Tank Type – Cyl/Vert. Shell 1 MSMS Epoxy with Conical Top & Sloping Bottom, Capacity – 15 Wash Transfer Pump 200Type m- 3Centrifugal Capacity- 1+1 CF8 25 m3/hr (Wetted Parts 16 Air Filter Type- HEPA 1+1 MSOnly) Frame 17 Air Blower with Motor Type- Watering Capacity- 1+1 CI 220 Am3/hr 18 Nutrient Dosing Tank Capacity- 1 m3 1 AISI 304 with Agitator 19 Nutrient Dosing Pump Type- Centrifugal 1+1 CI Capacity- 1 m3/hr 20 Acid Dosing Tank Type- Cylindrical, 1 MS Vertical Capacity- 1 m3 21 Acid Dosing Pump Type- Centrifugal 1+1 Wetted Capacity- 1 m3/hr Parts Alloy 20 22 Antifoam Dosing Tank Type- Cylindrical, 1 MS Vertical Capacity- 1 m3 23 Antifoam Dosing Pump Type: Gear Capacity- 1 m3/hr 1+1 CI 24 CIP tank Type- Cylindrical, 1 AISI304 Vertical Capacity- 25 25 CIP Pump mType3 - Centrifugal Capacity- 1+1 Wetted Parts 12 m3/hr Alloy 20

26 Piping, Valves As Per Standards Lot Instrumentati on

DISTILLATION SECTION:

Sr. No. Description MOC Tech. Specs. Qty. Analyser Column (Rh Dia: 1200 mm 1 Grid Trays) AISI 304 No. of Trays : 1 19 Degasifying Column Dia: 700mm 2 (Seive Trays) AISI 304 No. of Trays : 1 5 Pre-Rectifier Column Dia: 800 mm 3 (Bubble Cap Trays) AISI 304 No. of Trays : 1 56 Extractive Column Dia: 600 mm 4 (Bubble Cap Trays) AISI 304 No. of Trays : 1 45 Rectifier Cum 5 Exhaust Column Shell : AISI Dia: 1000 mm 1 (Bubble Cap Trays) 304 Trays No. of Trays : AISI 304 72 Recovery Column Dia: 500 mm 6 AISI 304 (Bubble Cap) No. of Trays : 1 50 7 Alcohol Scrubber AISI 304 1

Re boilers 1 Analyzer Column Reboiler Shell & Tube Type AISI 304 1 2 ED Column Reboiler Shell & Tube Type AISI 304 1 3 Rectifier Cum Exhaust Column Reboiler Shell & Tube Type AISI 304 1 4 Pre Rectifier Column Reboiler Shell & Tube Type AISI 304 1 Co ndensers & Coolers 5 DG Condenser I Shell & Tube Type AISI 304 1 6 DG Condenser II Shell & Tube Type AISI 304 1 7 Analyser Condenser I & II Shell & Tube Type AISI 304 3 8 ED Condenser I & II Shell & Tube Type AISI 304 2 9 Recovery Condenser Shell & Tube Type AISI 304 1 10 Vent Condenser for Analyzer Shell & Tube Type AISI 304 2

11 PCV Condenser Shell & Tube Type AISI 304 2 12 Product Alcohol Cooler Shell & Tube Type DOW Cu 1

13 Product (RS) Cooler Shell & Tube Type AISI 304 1 14 TA Cooler Shell & Tube Type AISI 304 1 15 FO Cooler Shell & Tube Type AISI 304 4 16 R/E Alcohol Cooler Shell & Tube Type AISI 304 1 17 ED Feed Cooler Shell & Tube Type AISI 304 1 OUTLINE TECHNICAL SPECIFICATIONS FOR 45 KLPD ETHANOL PHE's, Pumps 19 DM Water Preheater PHE SS 316 Plates /MS 1 Frame 20 Rectifier Feed Preheater PHE SS 316 Plates /MS 1 Frame 21 PR Feed Preheater PHE SS 316 Plates /MS 1 Frame 22 Analyser Bottom Centrifugal Type CF8 (Wetted Parts Only) 1+1 Transfer Pump 23 Rectifier Lees Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1 24 PR Lees Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1 25 Pre Rectifier Feed Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1 26 PR Refux Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1 27 Rectifier Reflux Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1 28 FO Washing Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1 29 ED Bottom Transfer Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1 30 Alcohol Transfer Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1 31 Recovery Feed Pump Centrifugal Type CF8 (Wetted Parts Only) 1+1 32 Steam Condensate Pump Centrifugal Type CI 1+1

33 Vacuum Pump Water Ring Type CI 1+1 34 Emergency Water Supply Set Standard 1

Others

Sr. Description Tech. Specs. Qty. No. 1 FO Decanters As Per Standard 2 2 Mixing Bottle (For ED/Purifier As Per Standard 1 3 VapourColumn) Bottles As Per Standard Lot 4 Manometer Bottles As Per Standard 2 5 Seal Pot As Per Standard 1 6 Siphon For Recovery Column As Per Standard 1

7 TA Mixing Bottle As Per Standard 1 8 Pipes & Fittings, Valves and As Per Standard Lot Instrument

ABSOLUTE ALCOHOL PLANT:

Sr. Description MOC Qty. Tech. Specs. No. 1 Absorber Bed AISI 304 2 Diameter : 900 mm 2 Evaporator Column AISI 304 1 Diameter : 900 mm with Trays 3 Evaporator Column Re boiler AISI 304 1 Suitable 4 Feed Preheater AISI 304 1 Suitable

5 Regeneration Preheater AISI 304 1 Suitable 6 Product Condenser AISI 304 1 Suitable 7 Product Cooler AISI 304 1 Suitable 8 Regeneration Condenser AISI 304 1 Suitable

9 Regeneration Cooler Plates: 1 PHE SS 10 Super heater AISI316 304 1 Suitable

11 Regeneration Receiver AISI 304 1 Suitable 12 Product Receiver AISI 304 1 Suitable

13 Vacuum Educator AISI 304 1 Suitable 14 Feed Pump with Motor AISI 304 1+1 Suitable 15 Regeneration Pump with Motor AISI 304 1+1 Suitable 16 Product Pump with Motor AISI 304 1+1 Suitable

17 Filters CS 3 18 RS Feed Tank MS 1 Capacity : 50 m3 19 Instrumentation Standard Lot 20 Piping and Valves Standard Lot 21 Electricals Standard Lot

Sr. Equipment Technical MOC Qty. No. Specification 1 RS Receivers Capacity: 50 m3 MS 3 2 IS Receivers Capacity: 10 m3 MS 1

3 Ethanol Receiver Capacity: 50 m3 MS 3 4 RS Storage Tank with Vent Capacity: 900 m3 MS 2 Condenser & Flame Arrestors 5 Ethanol Storage Tank with Capacity: 900 m3 MS 1 Vent Condenser & Flame 6 ISArrestors Bulk Storage Tank with Capacity: 400m3 MS 1 Vent Condenser & Flame 7 FOArrestors Storage Capacity: 8 m3 MS 1 8 Alcohol Pumps with Centrifugal Wetted Parts Suitable Flameproof Motor CF 8 9 Issue Measures PD Flowmeters Standard 3 10 Piping & Fittings Standard Standard 1 Lot

INTEGRATED EVAPORATOR:

Sr. Description Qty. Technical data M.O.C. No. 1 Multiple effect Suitable Shell & Tube SS304 evaporator type, Falling Film 2 Vapor Separator Suitable Cylindrical SS304 3 Surface condenser 1 Sheet & Tube type SS304 4 Circulation pump Suitable Double Mech Shaft Contact Part SS 304 5 Process 1+1 Contact Part SS 304 Condensate 6 Concentratedpump Spent 1+1 Contact Part SS 304 wash transfer pump 7 Condensate Pump 1+1 Contact Part SS 304 8 Vacuum pump 1+1 Contact Part SS 304 9 Piping & Valves Lot Suitable 10 Electrical & Lot With Std. Instrumentatio Specificatio n n

INDEPENDENT EVAPORATOR:

Sr. Description Qty. Technical data M.O.C. No 1 Feed and Product Tank 2 Type:- Rectangular SS304

2 Feed Pump & Spent 1 + 1 each Type - Centrifugal type SS 316 wash pump Suitable 3 Evaporators Suitable Type : Forced circulation SS304 4 Vapor Liquid Separators Suitable Type : Gas SS304 liquid separator 5 Evaporation Pump Suitable Recirculationtype pump SS 316 6 Surface Condenser 1 Type : shell & tube; SS 304 9 Vacuum Pump 1 + 1 Type - Water ring type SS 316 10 Condensate Tank 1 Capacity – Suitable SS 304 11 Condensate Pump 1 + 1 Type - Centrifugal type SS 316 12 Piping and Valve, Electrical and Instruments

UTILITIEs: COOLING TOWER:

Sr. Equipment Description Specifications Qty. (Nos) No. 1 Cooling tower for Fermentation plant 1000 M Kcal/hr 1 2 Cooling tower for Distillation 2000 M Kcal/hr 1 3 Cooling tower for Ethanol 600 M Kcal/hr 1 4 Cooling tower for evaporation 3000 M Kcal/hr 1 5 CW Recirculation pump for Suitable. Centrifugal, 1+1 Fermentation 6 CW Recirculation pump for Distillation Suitable. Centrifugal, 1+1 7 CW Recirculation pump for evaporation Suitable. Centrifugal, 1+1 8 CW Recirculation pump for Ethanol Suitable. Centrifugal, 1+1 9 PRDS Suitable. 2 10 Instrument Air compressor & dryer Suitable capacity 1+1 11 Piping, Valves standard Lot 12 Instrumentation standard Lot

Slop Fired Incinerator Boiler & Turbine

Sr. Particulars Specification No. 1 Slop fired incinerator boiler 14 TPH, 45 Kg/Cm2 (g) Pressure with coal as supporting fuel 2 Turbine Suitable capacity of 1.2 MW back pressure with exhaust pressure of 4.5 Kg/Cm2(g)

Water Treatment Area Filtration Plant

1. Multi grade Sand Filter 1 No. Pressure vessel internally painted with black1 No.MS with epoxy coating bituminous and externally with red oxide primer :MOC Piping works with valves 1 No. Graded filtering sand specifically selected and 1 No. graded 2. Activated Carbon Filter 1 No. Pressure vessel internally painted with 1black No. MS with epoxy coating bituminous and externally with red oxide primer :MOC Piping works with valves 1 No. 3. Softener 1 No. Pressure with rubber lining from inside and 1 No. externally with red oxide primer Piping works with valves 1 set Cation Exchange resign 1 set Hardness test kit 1 set Brine saturated tank of MS construction 1 No. Brine distribution system 1 Lot 4. D.M. PLANT ( 1 No.) 1 Strong acid cation 1 No. 2 Degasser tower & pump 1 No. 3 Strong acid anion 1 No. 4 Mixed bed exchanger 1No.

Fire Fighting & Protection

Fire protection system to be offered based on site plan. The system is designed as per International rules (NFPA) & equivalent standards.

Molasses Bulk Storage Section.

Sr. Equipment Technical Qty. M.O.C. No. Specification 1 Molasses Storage Tank 4000 MT storage 2 Mild steel, capacity. Nos. painted

2 Raw molasses Transfer Gear type positive 2+2 C.S. pumps. displacement pumps Nos. 3 Interconnecting piping. Carbon steel pipes. LOT MS

ii Residential area (Non Processing area) As the local people from nearby villages shall be engaged in project activity. Therefore no housing / building is proposed.

iii Greenbelt  Approx 2 acres area has been covered with the good green belt. Further it is proposed to cover 2.64 acres in next 05 years of time.

iv Social Infrastructure Company shall evaluate the need base program under CSR and shall execute as per the given plan.

v Connectivity Site is well connected with by State Highway Khetia- Sendhwa road. .

vi Drinking water management Drinking water will be supplied through bore well with proper RO system.

vii Sewerage System The domestic waste shall be taken to soak pit and septic tank.

viii Industrial waste management As described earlier. ix Solid waste management As described earlier. x Power Requirement and supply / source As described earlier.

7.0 Rehabilitation & Resettlement Plan No R & R plan is required.

8.0 Project Schedule and Cost estimate

39 i. Likely date of start of construction and likely date of completion After obtaining environmental clearance and water / air consent the company shall start the project. Proposed date shall be July 2018 (subject to clearances) ii. Estimated project cost along with analysis in terms of economic viability of the project a. Land & Site Development (Refer Annexure – 1)

SDKSM has already earmarked 8 acres of land for the proposed fuel ethanol plant. The site development expenses is estimated at Rs. 49 lakh which include leveling, fencing, gates, internal roads, green belt development, etc Civil Works The main civil works for the fuel ethanol plant and their estimated costs are indicated in the following table. Item Cost, Rs. Lakh Main plant building, admin building, lab, Excise Office, 450.00 stores Weigh bridge, storage, distillery machinery foundations, Structural for evaporation, distillation & fermentation, Pipe Racks, Cooling tower civil works (Basin Only), Raw water tank, Treated Water storage tanks, Fire water storage tank, Raw & Concentrated Spent wash holding tank, Condensate Polishing Unit civil work, Boiler foundations & Axillaries, Turbine foundations DG set foundation, structural work for Boiler & Turbine, Ash & Fuel handlingArchitect feessystem foundations etc., staging structure and 9.00 foundationsTotal 459.00

Based on the actual civil costs incurred for similar capacity fuel ethanol plant and preliminary estimates from the project architect, the civil estimates have been worked out at Rs. 459 lakh, including Architect’s fees. The appointed architect for the project will work out detailed estimates and civil drawings (based on the inputs received by the equipment suppliers and labour / material rates at the site location). Equipment The main items of equipment for the fuel ethanol plant and their estimated erected costs are given in the following table: Item and brief specifications Estimated Erected Cost, Rs. lakh

1) 45 KLPD Capacity distillery plant, including incl. Molasses storage & handling, Fermentation, Multi-Pressure Distillation & Ethanol, Integrated & Independent Evaporation for spent wash concentration, Utility Equipment 1525.00 - Cooling Towers, Condensate Polishing Unit, Blower, Alcohol Storage & auxiliaries, interface piping, electrical & instrumentation, Air compressor, structural work, Erection & Commissioning etc.

2) 14 TPH Capacity, 45 kg/cm2 pressure slop fired 1050.00 Boiler & auxiliaries 3) 1.2 MW Capacity matching back pressure TG set & 150.00 auxiliaries 4) Balance of Plant equipment incl. PRDS, DCS, etc. 175.00 Sub-total including erection & commissioning, packing forwarding, insurance, etc. 2900.00 Avg. Taxes & Duties (18 %) 522.00 Total 3422.00

Based on the budgetary offers received from reputed machinery suppliers & possible negotiation margins, the estimated erected cost of plant and equipment for the proposed fuel ethanol plant including Boiler & Turbine has been worked out at Rs.3422.00 lakh

Item Year 1 2 3 4 5 Installed Capacity-KLPD 45 45 45 45 45 Number of shift/day 3 3 3 3 3 . No. of days 180 270 270 270 270 . No. of hrs. 24 24 24 24 24 . Annual Installed Capacity 8100 12150 12150 12150 12150 Capacity utilization, % 80 90 95 95 100 Net Production Fuel Ethanol, 6480 10935 10935 11543 12150 KL

Cost Summary Based on the capital cost break up worked out, the project cost summary for the entire integrated project is given in the following table Distillery Plant Particulars (Rs. Lakh) Land and Site Development 49

Buildings 459 Indigenous Plant and Machinery 3422 Miscellaneous Fixed Assets 248 Prelim. & Preoperative Expenses 308 Contingencies 68 Working capital margin 128 Total 4682

9.0 Analysis of Proposal (Final Recommendation)

Financial and social benefits with special emphasis on the benefit to the local people including tribal population, if any, in the area. From the foregoing analysis, it is observed that proposal is environmental compatible and will helps to people improving their financial status, performance and repayment capability. This also helps the company in venturing into production of niche specialty products which will eventually better their profits and also their ranking in the industry. CSR programme shall be executed through the group discussion and need base programme will be proposed for the area, by which people of the area will be benefitted.