Siddapur Distilleries Limited

SIDDAPUR DISTILLERIES LIMITED

Post: Siddapur, Taluk: Jamkhandi, Dist: Bagalkot State: Karnataka PIN: 587 302

PROJECT REPORT FOR CAPACITY ENHANCEMENT FROM 60 KLPD TO 70 KLPD BY KEEPING THE EFFLUENT GENERATION CONSTANT.

June, 2016

M/s. SIDDAPUR DISTILLERIES LIMITED Post: Siddapur, Tal: Jamkhandi, Dist.BagalkotState: Karnataka CONTENTS

Chapter Chapter Name Page No. No. Board of Directors 1

Project Profile 2

I Introduction 3

II Project Concept and Justification 6

III Demand for Alcohol 9

IV Molasses Based Fermentation Technologies 28

Manufacture of Alcohol by Multi-Pressure Vacuum V 35 Distillation.

VI Distillery Specifications – 42

Basis of Project 42

Fermentation 44

Distillation – Rectified Spirit & Extra Neutral 45 Alcohol

VII Environmental Management Plan 53

BOARD OF DIRECTORS

Sr.No. Name Designation 1 ShriJagadeesh S.Gudagunti Chairman & Managing Director

2 ShriChandrashekharaiah G.Mathad Director

3 ShriMaharudrayya I.Ghanakumarmath Director

MANAGEMENT

Sr.No. Name Designation 1 ShriSudheer S.Gudagunti Vice President

2 ShriChandrashekar D.Haragapure Director (Operations)

3 ShriM.G. Alalalmath Distillery Manager

4 Shri K.I.Korti Sr.Manager (F&A)

5 Shri Jyothi K.M. Manager (Environment)

6 Shri D.I.Muchandi Civil Engineer

Project Profile for Enhancement of 60 KLPD Distillery to 70 KLPD Distillery Plant Based on FED-Batch Fermentation & Multi-Pressure Vacuum Distillation to Produce Rectified Spirit &Ethanol or Extra Neutral Alcohol& Ethanol.

1 Name and Address SIDDAPUR DISTILLERIES LTD. Siddapur Village, Tal:Jamkhandi Dist.Bagalkot (Karnataka State) Ph.No.08353-238073, 238183 Fax No.08353-238063

2 Constitution and Type Public Limited Company

3 Project Concept

a) Products 1.Alcohol Conforming to I.S.I. Grade – I, 323 (1959) 2. Extra Neutral Alcohol I.S.I. Grade-I, 6613 (1972) 3. Head Spirit Conforming to I.S.I. Grade – II, 323 (1959) 4. Bio-gas 5. Bio-Compost

b) Working days/Annum 270 c) Molasses required, 70,000 MT of Molasses/Annum 4 a) Alcohol production/Annum 94.50 Lac Ltrs. Rectified Spirit & Ethanol or 94.50 Lac Ltrs. Extra Neutral Alcohol & Ethanol

b) Steam requirement MT/day Max. 216 MT

c) Electricity requirement, (Distillery plant, ENA, Boiler, Max. 19200 KWH/day Biomethanation, Bio-compost and plant yard lightning etc.)

d) Water requirement, M³/day 870

130Nos. for Distillery, Biogas and Bio- 5 Staff and Labours composting unit.

CHAPTER – I

INTRODUCTION

Siddapur Distilleries Limited is a Public Limited Company registered under the Company’s Act 1956 in the year 2003 bearing Registration No.08/32213 dated 07/07/2003 having its Registered Office at 2nd Block, 1st Floor, “Sukrut” Building, Opp:K.C.Park Main Gate, P.B. Road, Dharwad and plant site at Siddapur Village, JamkhandiTaluk, Bagalkot District. Siddapur Distilleries Limited has installed 60 KLPD Distillery Plant in the year 2004-05. Distillery plant is based on continuous fermentation and multi-pressure vacuum distillation technology to produce good quality potable grade Rectified Spirit, Extra Neutral Alcohol and Fuel Alcohol to meet the requirements of Potable Alcohol Consumers, Pharmaceuticals Industries and Oil Companies for blending with petrol. Distillery Plant was supplied by Mojj Engineering System Ltd., Pune and started its trial and Commercial production on 11th November, 2004. The last 5 years performance of the distillery is given in the Table 1.1.

LAST FIVE YEARS PERFORMANCE OF 60 KLPD DISTILLERY

Table 1.1

Spirit production Average Total Molasses (Lac BL) Alcohol Sl. Spirit Year Consumption Recovery No Production Rectified Impure (Ltrs./MT of (MT) ENA Ethanol (Lac BL) Spirit Spirit Molasses) 1 2011-12 41826 19.99 73.17 4.23 23.28 120.67 288.55 2 2012-13 43740 51.12 55.92 5.12 16.14 128.30 293.35 3 2013-14 35176 20.19 60.16 5.18 9.63 95.16 270.59 4 2014-15 48710 24.07 83.15 4.76 20.80 132.78 272.65 5 2015-16 46238 9.19 84.92 4.14 30.34 128.59 278.13

Siddapur Distilleries Limited is a sister concern of Shri Prabhulingeshwar Sugars & Chemicals Limited,having 12000 TCD Sugar Plant at Siddapur Village, Tq.Jamkhandi, Dist.Bagalkot having its Registered Office at 1st Floor, “Sukrut” Building, Opp.K.C.Park Main Gate, P.B.Road, Dharwad.

Shri Prabhulingeshwar Sugars & Chemicals Limited is a Public Limited Company consisting about 14000 members holding Equity &Preference shares. The Company owns about 200 acres of land near Siddapur village, Tq.Jamkhandi, Dist.Bagalkot. The Company has established its factory in the said area with all the infrastructure facilities like Staff Quarters, Guest House, Workers Quarters, Canteen, School, Medical and Bus facility etc. The initial crushing capacity was 2500 TCD. The capacity was expanded from 2500 TCD to 8000 TCD during the year 2000-2010, 8000 to 10000 TCD during the year 2010-11 and finally to 12000 TCD in the year 2015-2016 with a view to crush all the available sugarcane in the area of operation.

In addition to industrial growth in the area, the factory is also involved in several socio-economic developmental activities to help members, farmers and workers of factory.

1. Staff Quarters: The Company has provided quarters to the Head of the Departments, Chemists, Manufacturing Assistants and Engineers in the factory premises. There are about 20 “B” type quarters, 12 “C” type quarters and 40 “E” type quarters. Apart from this, about 100 residential quarters have been constructed for the Fitters, Helpers and others. These quarters are provided with free water, dish antenna for entertainment and electricity for their use. A telephone facility is also provided to “E” type quarters along with a Security facility.

2. The Company has constructed a temple in the office premises. This allows the staff, workers and their families to gather in the temple yard on festivals and other days.

3. The factory has a hospital facility consisting of a Doctor for treatment of the patients. Apart from this the Company has also provided a mobile hospital van with all the necessary equipments to attend emergency cases. This mobile Van is being used for the workers, labours as well as by the farmers who are supplying cane to the factory. To look after health of these people, Mobile Hospital Van is sent to all the villages turn by turn and free medical assistance is provided to the needy patients.

4. To assist the general public of around the villages of the factory, the Company organizes every year a “Free Health Camp” with the assistance from Walness Mission Hospital, Miraj. About 2500 to 3000 villagers, farmers, workers and others are taking advantage of this camp. Free health checkup, free distribution of medicines and free food was also served to all the people who came to the camp. Apart from this, the Doctors of the Walness Mission Hospital assisted some of the serious patients by inviting them to their Miraj Hospital for providing further necessary treatments at concessional charges.

5. Education Facilities:In the area of operation education facilities from primary to graduation level are available, which take care of educational need of farmers and employees.

6. The Company has provided a separate land of 3 acres named “Kailash” for construction of various temples to create holy atmosphere in the factory premises. There is a plan to plant 2000 Ayurvedic medicinal plants which will help for preparing Ayurvedic medicines.

7. The Company is providing concessional rate bus/tempo fare to the workers who are travelling from nearby places like Jamkhandi, Mudhol, etc., The Company has also arranged transportation for children to go to Jamkhandi for attending the school.

8. For recreational purpose, 3 playgrounds are provided in the factory premises; for playing Volleyball, Kabaddi,Football, Cricket and other games which are named as “Nehru Maidan” and “Gandhi Maidan”. Further for children a separate playground is provided. The Company has conducted competitions in volley ball and other games. Players from nearby villages have participated in these competitions.

9. The Company has also developed greenery by planting various flower plants, trees, etc., and has also developed lawns near the factory and residential premises. The lush greenery has given a very pleasant look and soothing effect to the mind of everyone. A rose garden has also been developed.

10. The Company has taken up and developed certain roads connecting the factory from nearby villages as well as to Siddapur, etc., This has greatly helped in smooth transportation of cane to factory.

11. The Company has contributed by providing free of cost sugar to some social organizations who conducted mass marriages etc., likewise free of cost sugar was also given to various temples and special organizations for assisting the social activities of the public in nearby villages. The Company has also donated liberally for assisting the educational institutions by contributing towards construction cost of school buildings.

12. The Company is also distributing the bio-compost to villagers and cane growers at concessional rates, which is used as manure to achieve “Zero Discharge” of spentwash as per CREP norms.Factory has already installed bio-methanation plant as primary effluent system, followed by secondary bio-composting as effluent treatment system. The annual requirement of filler material like press mud cake (70,000 – 78,000 MT), boiler ash etc., is available with factory which will be also sufficient for expanded capacity of Distillery.In short, the performance of factory is quite impressive. To exploit more benefit from this industrial complex, the management of the factory has decided to enhancement capacity of existing 60 KLPD distillery unit to 70 KLPD based on Fed-Batch fermentation and MPR distillation to produce industrial, potable rectified spirit and potable extra neutral alcohol from molasses. 7

CHAPTER – II

PROJECT CONCEPT AND JUSTIFICATION

India is the largest producer of sugarcane as well as sugar in the world. The sugar industry occupies a pride of place in rural economy. Most of the sugar industries are located in rural areas providing employment to rural masses.

The molasses is used mainly for production of ethyl alcohol. There are more than 350 distilleries in the country with annual installed capacity 4.295 billion litres of alcohol production and licensed capacity 4.527 billion litres. The alcohol production in the year 2007 was 2.3 billion litres. At present the state of Karnataka is having 35 distilleries.

Molasses is considered as one of the valuable by-products of sugar industry. The total molasses availability in the country was around 85.49 lac MT in 2005-06 and increased upto 131.11 Lac MT in 2006-07 and to 113.11 Lac MT in 2007-08. However, molasses produced in the country in the year 2008-09 was 65.42 Lac MT. In the ensuing crushing season, the crushing of cane and molasses will be highest and the required quantity will be available to all the distilleries in the state.

CAPACITY OF DISTILLERY:

Normally distilleries are expected to work for 270 days in a year and most of the distilleries in India have adopted seasonal working of their distilleries in view of the fact that they can receive surplus steam and power from their sugar factories. It is an important consideration to keep the cost of production low. Some factories have installed independent boiler and turbo-alternator to run the Distillery unit during off season. This will help the distilleries to use all available molasses.

Following few suggestions shall be useful for proper designing of the distillery:

1) Management should take efforts to supply molasses in adequate quantity to the distillery.

2) Both distilleries and sugar factories should have adequate molasses storage tanks of mild steel.

3) As per the latest norms of CPCB, all distilleries are required to achieve “Zero Discharge” of spentwash. Therefore, necessary measures should be taken by the management to achieve Zero Discharge and prevent any kind of pollution in surrounding area. 8

LOCATIONAL CONSIDERATIONS:

The important factors for expansion of distillery unit are, a) Nearness to raw material. b) Availability of utilities such as steam, electricity and water. c) Adequate land for distillery and effluent treatment plant. d) Avoiding likely odour nuisance to the residential colony and the public in general. e) Availability of technical assistance in case of necessity. f) Ease of control over both sugar factory as well as distillery by one management and sharing common facilities like workshop etc.

MOLASSES STORAGE:

The total molasses requirement will be 70,000MT/annumfor 70 KLPD capacity. The production of molasses is assumed to be 60,000-65,000 MT based on the cane crushing during the years 2013-14 and 2014-15. Procurement of about 10000 to 15000MT of molasses will be procured from nearby sugar factories. At present the distillery is having of one UCR Masonry tank of 1100 MT and three MS tanks for molasses storage and capacity of each tank is 6000 MT.

Proper care should be taken by the sugar factory to cool down molasses before it goes to molasses storage tank. The molasses storage tank should have a suitable pump for recirculation of molasses. A two months stored molasses is ideal for fermentation. The molasses can be pumped through pipeline, which can be laid down from the storage tank to the distillery molasses tank.

WATER REQUIREMENT:

For Fed-batch fermentation based 70 KLPD distillery with integrated multi-product system the maximum water requirement is about 870 KL/day. The factory is drawing water from Krishna River, which is about 20 km. away from factory. Water storage facility is available with the factory. The factory has constructed 2 Nos. water reservoirs having total storage capacity of 54500M3. Thus, sufficient quantity of water can be made available to the distillery from the factory water reservoir. To achieve better efficiency and to maintain the plant and machinery in good condition, it is necessary to have proper water treatment system. Process water will be treated with chemicals and will be reusedfor the process or for the cooling tower.

STEAM REQUIREMENT & POWER GENERATION:

Steam Requirement:

The steam requirement of the proposed 70 KLPD distillery plant is 9 – 10 MT/hr. (for Multi-pressure option). The sugar factory is having total three boilers, two boilers having steam generation capacity of 60 MT/hr. at 66 Kg/cm2 pressure. The factory has already installed a cogeneration unit of 36 MW, which was expanded upto 52 MW capacity. Therefore, required steam at 3.5 Kg/cm2 pressure can be made available from factory to distillery for 270 days/annum.

Power Generation:

The Distillery hasgiven on lease a 2.50 MW TG Set to Shri Prabhulingeshwar Sugars & Chemicals Ltd. Therefore required power is available for distillery, bio- methanitation, bio-composting plant & yard lightening etc., in season & off-season.

Necessary arrangement for the pressure reducing and de-supereheating (PRDS) of steam has been made in the distillery. Based on the performance of the sugar factory in last few years, the cost of steam is assumed at Rs600/MT.

The quarters of the technical staff of the sugar factory and distillery are at factory campus & their services could be readily made available in case of necessity. The nearness of the distillery to sugar factory is also of advantage from the point of security.

CHAPTER – III DEMAND FOR ALCOHOL History of Ethanol: Human have used ethanol since prehistory as the intoxicating ingredients in alcoholic beverages. Dried residues on 9000-year-old pottery found in northern China imply the use of alcoholic beverages even among Neolithic peoples. Islamic alchemists who developed the art of distillation during the Abbasid Caliphate, the most notable of whom was A1-Razi, first achieved its isolation as a relatively pure compound. The writings attributed to Jabir IbnHayyan(Geber) (721-815) mention the flammable vapours of boiled wine. A1-Kindi (801-873) unambiguously described the distillation of wine. Distillation of ethanol from water yields a product that is at most 96% ethanol, because ethanol forms an azeotrope with water. Johann Tobias Lowitz first obtained absolute ethanol in 1796, by filtering distilled ethanol through charcoal.

Antoine Lavoisier described ethanol as a compound of carbon, hydrogen and oxygen and in 1808 Nicolas Theodore de Saussure, determined ethanol’s chemical formula. In 1858, Archibald Scott Couper published a structural formula for ethanol; this places ethanol among the first chemical compounds to have their chemical structures determined.

Ethanol was first prepared synthetically in 1826, through the independent efforts of Henry Hennel in Britain and S.G.Serullas in France. Michael Faraday prepared ethanol by the acid catalyzed hydration of ethylene in 1828.

Ethanol (Ethyl Alcohol):

The ethanol of commerce contains about five per cent water. Hence the term “Hydrous (water-containing) alcohol”. If the last traces of water are removed, “Anhydrous alcohol” (water-free or “absolute”) may be obtained. Ethanol which is used for the production of sprits is usually heavily taxed, but it is also sold in an untaxed “denatured” form, unfit for human consumption but suitable for many other purposes. Denaturing is accomplished by the addition of a few percent of foreign materials, which are not easily removed.

Non-denatured ethanol is the alcohol contained in beverages, thus the expression “potable alcohol”. It also finds wide use as an industrial solvent. Furthermore, it is the starting material for the preparation of a long list of industrial organic chemicals.

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 levied by State Government on Alcoholic liquors. It has a potentially as fuel in the form of power alcohol for blending with petrol in the ratio of maximum 26:74. The characteristics of ethanol are given in Table 3.1 on next page.

Alcohol production from various feed stocks:

Ethanol can be produced from any biological feedstock’s that contain appreciable amounts of sugar or materials such as starch or cellulose that can be converted into sugar. Sugar beets and sugarcane are examples of feedstock’s that contain sugar. Grain contains starch that can relatively easily be converted into sugar. A significant percentage of trees and grasses are made up of cellulose, which can also be converted to sugar, although with more difficulty than required to convert starch. The ethanol production process, starts by grinding up the feedstock so it is more dissolved out of the material or the starch or cellulose is converted into sugar. The sugar is then feed to microbes that use it for food, producing ethanol and carbon dioxide in the process. A final step purifies the ethanol to the desired concentration.

Fermentation alcohol may be produced from grain, molasses, fruit, wine, whey, cellulose and numerous other sources. Synthetic alcohol may be derived from crude oil or gas and coal. Both fermentation and synthetic alcohol are however, chemically identical.

On a global scale, synthetic feedstock’s play a minor role. Only six percent of overall output is accounted for by synthetic feedstock’s. Roughly 55% of world ethanol production from sugar crops, both cane and beet. Most of the remainder comes from grains, with maize playing a dominant role.

Table – 3.1 CHARACTERISTICS OF ETHANOL

Sl. Characteristics of Description Unit No. Absolute Alcohol A) General 1 Systematic Name Ethanol Ethyl alcohol, grain 2 Other Names alcohol, Hydroxyethane

3 Molecular Formula g/mol C2H6O 4 Molecular Weight 46.07 5 Appearance Colorless liquid 6 CAS Number [64 – 17 – 5] B) Properties* 1 Specific gravity at 15.6°/15.6°C Max. 0.7961 2 Phase Liquid 3 Solubility in Water Fully Miscible 4 Oxygen Content % 34.70 5 Latent vaporization heat KJ/Kg. 925 KJ/Kg. 27723 6 Lower calorific value Kcal/Kg. 6642 7 Boiling point °C 78.30 8 Melting point °C -114.3 9 Acidity PKa 15.9 (H+ from OH group. 10 Energy per unit and volume KJ/Kg 22012 11 Viscosity at 20°C Centipoise 1.192 12 Vapour pressure at 20°C Atm 0.058 13 Vapour pressure at 40°C Atm 0.177 14 Vapour pressure at 60°C Atm 0.463 15 Octane number (research) RON -- 106 16 Octane number (motor) MON -- 87 17 Stoichiometery mixture Air : Fuel 8.95:1 18 Dipole Moment 1.69 D (gas) C) Hazards 1 Material Safety Data Sheet External MSDS Flammable (F) 2 EU Classification Irritant (Xi) 3 Risk Phrases R 11 4 Safety Phrases S2, S7, S16 5 Flash Point 13°C (55.4°F *For anhydrous (Fuel) alcohol Source : - F.O. Licht’s World Ethanol and Biofuels Report, Vol8, No.16, 28/04/2010

Production of Ethanol from various feed stocks like sugarcane juice, molasses, grains and other feed stocks and by synthetic route is stated in Table No.3.2

Table – 3.2World Ethanol production by feed stock

Sr.No. Feed stock Ethanol Production (%) 1 Sugar crops 55 2 Grains 37 3 Synthetic 6 4 Others 2

Following Table: 3.3 provides the details of crop wise starch content and estimated yield of alcohol per tonne of starch content in feed stock.

Table – 3.3Alcohol yields from various renewable sources:

Alcohol Yield Fermentable Carbohydrate Crop (Lit. of alcohol (94.68% v/v/MT) at (Starch %) 90% F.E & 98.5% D.E. Potato 19-20 127.134 Tapioca 28-29 188.194 Sweet potato 30-31 201-208 Barley 50-51 335-342 Malt 58-59 389-395 Wheat 67-68 449-456 Maize 73-74 489-496 Rice 78-79 522-529 Sorghum 69-70 462-469

Ethyl alcohol is basically used for three purposes i.e. 1) Industrial alcohol for production of downstream chemicals, 2) Potable Alcohol for manufacture of alcoholic beverages (Country Liquor and IMFL) and 3) Fuel ethanol or Anhydrous alcohol, which can be blended with petrol or diesel.

Table – 3.4Uses of Alcohol

Sr.No. Alcohol Consumption for (%) 1 Potable 11 2 Industrial 21 3 Fuel 68

Table 3.5 details the name of distilleries & their installed capacities in Karnataka State Table 3.5 LIST OF DISTILLERIES IN KARNATAKA

Sr.No Name of the Distillery Installed Capacity 1 Athani Farmers Sugar Factory Ltd., Belgaum 90 KLPD 2 Bannari Amman Sugars Ltd., Mysore 60 KLPD 3 Chamundi Distilleries Pvt. Ltd., Mysore 54 KLPD Gauri Industries (Karnataka) Pvt. Ltd., RS-8100 KL 4 Chickballapur ENA – 5400 KL, CL 5 Khoday India Ltd., Bangalore 8000 KL, IMFL 6 Maruti Organics Ltd., Bidar 7200 KL, RS/ENA 10800 KL, RS/ENA/AA 7 The Mysore Sugar Co. Lltd., Mandya IMFL, CL, SFU 8 Ravindra& Co., Ltd., Bidar 4500 KL, RS/ENA &IMFL 9 Sri Chamundeshwari Sugar Ltd., Mandya 5000 KL, RS / ENA 10 Shree Doodhaganga Krishna SSK Niyamit, BGM 30 KLPD RS/ENA/AA 11 NSL Sugars Ltd., Mandya 45 KLPD RS, ENA/AA 18000 KL – RS, 9000 KL – ENA 12 Samsons Distilleries (P) Ltd., Davanagere 16500 KL – AA 13 Shri Hiranyakeshi SSK Niyamit, Belgaum 16200 KL, RS/ENA/AA 14 Siddapur Distilleries Ltd., Bagalkot 60 KLPD, RS/ENA/AA 15 Shri Malaprabha SSK Niyamit, Belgaum 9000 KL, RS, Den. SpiritSFU 16 Sri LaxmiNarsimhan Distillery Pvt Ltd., Dharwad 12775 KL, RS, 7300 KL, ENA 20000 KL RS, 15000 KL ENA 17 SomaiyaOrgano Chemicals, Bagalkot 15000 KL AA 18 Satish Sugars Ltd., Belgaum 60 KLPD15 KL AA 19 The Ugar Sugar Works Limited, Belgaum 24369 KL, RS, 15 KL ENA &Ethanol 20 United Spirits Limited, Bellary 30 KLPD RS/ENA 21 Vishwanath Sugars & Distilleries, Belgaum 30 KLPD RS 22 Wilson Distilleries Pvt. Ltd., Mandya 9000 KL, RS/ENA 23 Sri Chamundeswari Sugars Ltd., Mandya 50 KL RS 24 Shree Renuka Sugars Ltd., Manoli, Belgaum 120 KLPD, RS & 60 KLPD AA 25 Shree Renuka Sugars Ltd., Athani, Belgaum 300 KLPD Rs 26 Shree Renuka Sugars Ltd., Athani, Afzalpur 150 KLPD 27 Nirani Sugars Ltd., Bagalkot 120 KLPD RS/ENA/AA 28 GMR Industries Ltd.,Uttar Kannada 45 KLPD RS 29 Jamkhandi Sugars Ltd. – Jamkhandi 60 KLPD 30 Nandi SSK-Bijapur 60 KLPD 31 Indian Sugar Manufacturing Ltd. – Bijapur 60 KLPD 32 Shamnur Sugar – Davanageri 60 KLPD 33 Kartik Agro Industries – Bagalkot 60 KLPD 34 JP Distillery Ltd. – Tumkur 30 KLPD 35 Vijaynagar Sugars – Gadag 120 KLPD

INDUSTRIAL ALCOHOL: Ethyl Alcohol is an important feedstock for the manufacture of chemicals. These chemicals are primarily the basic carbon based products like Acetic Acid, Butanol, Butadiene, Acetic Anhydride, Vinyl Acetate, PVC etc. The following table 3.17, 3.18, 3.19 & 3.20 indicates different important chemicals that could be made from alcohol. 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 with latest technological development and taking into account the increasing cost of petrochemical raw material, it is now possible to produce 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 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 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.

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.Denatured spirits are rectified spirit made unfit for drinking by addition of chemicals, which have strong disagreeable odour and which cannot be easily separated from spirit. The Denatured Spirits are taxed at a nominal rate so that their use in industry becomes economical.

Table 3.6 DERIVATIVE OF ETHYL ALCOHOL

Acetic Acid, Acetic Anhydride n- Butnol, Butadiene, Chloral

Acetaldehyde A Crotonaldehyde, GlyoxalPenterithritoal, Peracetic Acid Sorbic Acid

Ethyl Ethyl Acetate, Ethyl Acrylate Ethyl Amine, Ethyl Anile Alcohol Al

Ethyl Benzonate, Ethyl Bromide Ethyl Butyrate, Ethyl Caprate, Ethyl

Caproale

Ethyl Caprylate, Ethyl Cellulose Ethyl Chloracetate, Ethyl Chloride, Ethyl Cinnamate, Ethyl Cyanoacetate

Ethyl Ether, Ethyl Formate Ethyl Heptanoate, Ethyl isovalorate Ethyl Propionate

Ethyl Salicilate, Ethyl Silicate Diethyl Aniline, Diethyl Maleate, Diethyl Malonate, Diethyl Oxalate

Diethyl phthalate, DietehylSulphate,

Phenyl Ethyl Alcohol, Potassium Ethyl Xanthate, Sodium, Alginate

Ethyl Benzene, Ethylene Dichloride, Ethylene Ethyl Oxide, Polyethylene

Table 3.7

DERIVATIVE OF ETHYL ALCOHOL

Drugs & Pharma Chloroquin, Dithranon, Metronidazole, Phenacetin, Salbutanol-Sulphate, Trimethoprim

Preservatives

Direct Use Jams, Ammonium Acetate, Amyl Acetate, Anisyl KetchupsPicles, Acetate, Barium Acetate, Benyl Acetate, Syrups Butyl Acetate, Cadmium Acetate, Carbitol Textiles Acetate, Cellosolve Acetate, Cellulose Dyeing Aid Acetate, Cellulose Triacetate, Cobalt Printing Aid Acetate, Copper Acetate, Ethyl Acetate, Ferric Acetate, Ferrous Acetate, Isobutyl Acetates Acetate, Isopropyl Acetate, Lead Acetate,

Drugs & Pharma Magnesium Acetate, Manganese Acetate,

Benzidine- Methyl Acetate, Nickel Acetate, Potassium Yellow 20 Acetate, Sodium Acetate, Sodium Acetate, Diazo YellowTR Pigments Strontium Acetate, Terpinyl Acetate,

Direct Use Lake Red C Red ThalliumAceteate, Vinyl Acetate, Zinc 2, Red C Red

Acetates C12, Yellow-1 Acetate

nts

Acetamide, Acetanilide, Acetic Other Anhydride, Acetophenetidin, Acetyl Chemicals Chloride, Carboxy Methyl Cellulose, Chloro Acetic Acid, Dimethyl Acetamide, Glodin Fungicide, Glycine, Per Acetic Acid, Phenoxy Acetic Acid PTA, Strychnine, Thio Acetic Acid

Table 3.8 DERIVATIVE OF ACETIC ANHYDRIDE ACETIC ANHYDRIDE

Aromatic Chemicals Dyes & Polymers & Drugs & Compounds Pigments Intermediates Pharmacy

Acetyl Chloride Carboxy Methyl Dimethyl Cellulose Cellulose Acetamide Acetate Cellulose EDTA/NTA Meta Acetate Butyrate Amino Acetanilide Cellulose Tri Acetate Meta Nitro Aniline Vinyl Acetate Monomer

Acetophenone

Benzyl Acetate Acetyl Salicylic Acid Geranyl Acetate AminophylineAnalgin, FAST BASES Cinnamic Acid AsprinAstrapholaxine CitronellylAcetate Bordeax BisacodylCaffieneChlo

DehydroPregenolon Red B Scarlet ramplhenicol e Acetate Linalyl R Ciprofloxacin Acetate Methyl Coumarin Ibuprofen Acetate P.Cresyl REACTIC Mesterolone Acetate Phenyl Orange 4 & 16 Red Metronidazole Ethyl Acetate, Rose EP88, Red M88 Red Paracetamol Crystals VSB Supara Red Salbutamol TheophylineThiacetaz OTHERS one Vitamin E Disperse Dye

Intermediates S.D.Dyes Bordeaux GP Base

Table 3.9

DERIVATIVE OF CHLOROACETIC ACIDS

CHLORO ACETIC ACID

Drugs & Chemicals Pesticides Pharmaceuticals

Amino PhylineCaffine Carboxy Methyl Cellulose Folic Acid Chloro Acetyl Chloride Ibuprofen EDTA/NTA Ethyl Isoprotemol Chloro Acetate Glycine 2, 4, 5T 2, Naproxen Glycolic Acid 4D OxyphenButazzoneP Indigo Malonic AlachlorButachlorDi henBarbitone Acid Phenoxy Acetic methoateFormathio Phenyl Butazone Acid Polymethane Dyes nGlyhosPiroxycan Salbutamol Sulphate QuinolineDereivativeThio Quinalphos Theophylline Glycolic Acid Xylocaine

Potable Alcohol: Manufacture of alcoholic beverages from alcohol is also an attractive diversification. According to the policy of the Government and it is necessary to get license for manufacture of potable liquor. There is large demand for alcoholic beverages.

Indian Distilleries produce mostly Grade-I of alcohol. For export purpose, the quality of alcohol should be of superior standards comparable to that of major exporters to world markets like Brazil, Mexico, Spain and France. The minimum standards of alcohol prevailing in India, Brazil and Mexico are given in Table 3.21. There is need to procure alcohol of better quality. Good quality alcohol has great potentiality for export. The strength of alcohol produced should be 96% v/v. Specifications of rectified spirit as laid down by Indian Standards: 323-1959 is given in Table No.3.10.

Table 3.10 MINIMUM STANDARDS OF ALCOHOL

Characteristics India Brazil Mexico Grade-I Specific Gravity at 15.6°C 0.8171 0.8093 0.8138 Ethanol Content, % v/v (at 15.6°C 94.68 96.60 95.50 Acidity, % by wt. 0.002 0.0037 0.0037 Aldehyde Content, % by Wt. 0.006 0.006 0.006

Table 3.11

SPECIFICATION FOR RECTIFIED SPIRIT (IS : 323 – 1959)

Sl. Characteristic Requirement of Rectified *Method of Test No. Spirit for (Ref. to Grade-I Grade-II Appendix)

1. Specific Gravity at 0.8171 0.8171 B 15.6°C/15.6°C(60°/60°F) 2. Ethanol content: a) Percent by volume at 94.68 94.68 C 15.6°C(60°F) Min. b) Degrees Over-proof, Min. 66.0 66.0 C 3. Miscibility with water Miscible Miscible D 4. Alkalinity Nil Nil E

5. Acidity (as CH3 COOH) 0.002 0.01 E % by Wt. Max. 6. Residue on evaporation 0.005 0.01 F gms/100 ml. Max. 7. Aldehyde content 0.006 0.10 G (as CH3CHO) gms/100ml. Max. 8. Ester content 0.02 -- H (as CH3COOC2H5) gms/100ml. Max. 9. Copper content (as Cu) 0.0004 -- J gms/100 ml. Max. 10. Lead content (as Pb) 0.0001 -- K gms/100 ml. Max. 11. Methyl alcohol content To satisfy the requirement of L the test. 12. Fuel Oil content To satisfy the requirement of M the test. 13. Furfural content To satisfy the requirement of N the test. These refer to methods described in IS 323-1959 for Rectified Spirit.

The ENA quality is judged primarily by taking P.P. Time test (Potassium permanganate reaction time test) and the organoleptic test. The spirit, which takes maximum time to fade the colour of Potassium permanganate added in the ENA at 15.6°C, is said to be good quality. For a good quality ENA, the P.P. time test should not be less than 50 minutes. The BIS specification of ENA\is given on Table No.3.23.

Table 3.12

REQUIREMENT OF NEUTRAL SPIRIT FOR ALCOHOLIC DRINKS (IS : 6613 – 1972)

Sr. Characteristic Requirement Requirement of No. Neutral Spirit Export Quality IS:6613-1972 ENA Neutral Spirit, EQENA 01 Relative density at 15/15°C 0.81245 to 0.81679 0.8118 02 Ethanol content per cent by Volume at 94 to 95 96.0 15.6°C 03 Miscibility with water Miscible Miscible 04 Alkalinity Nil Nil 05 Acidity (as CH3COOH) 2.00 1.25 Mg/100 ml. Max. 06 Residue on evaporation 2.00 2.00 Mg/100 ml. Max. 07 Esters (CH3COOC2H5) 10.00 2.00 Mg/100 Ml. Max. 08 Lead (as Pb) mg/100 ml. Max. Nil Nil 09 Methyl Alcohol Content To pass test 5 PPM 10 Furfural content To pass test To pass test 11 Aldehyde (as CH3CHO) 4.0 0.5 Mg/100 ml. Max. 12 Permanganate reaction time, minutes min. 60 60 13 Copper (as Cu), mg/100 ml. Max. 2.0 0.3 14 Fusel Oil content, mg/100 ml. To pass test 10.00

 In addition to above, the ENA shall pass specific organoleptic test required for high quality blends.

There is good market for Extra Neutral Alcohol for manufacture of good quality perfumes, homeopathic medicines, tonics and other pharmaceutical products and potable liquor. The BIS specification for perfumery grade alcohol is given on Table No.3.13.

Table 3.13 REQUIREMENT FOR ALCOHOL / PERFUMERYGRADE (IS:1049:1962

Sr. Characteristics Requirement No. 01 Specific gravity at 15.6/15.6°C Max. 0.8337 and at 15.0/15.0°C Max. 0.8348 02 Ethanol content, percent by volume, at 90 15.6°C Max. 03 Miscibility with water 1:19 by volume Miscible. 04 Acidity (as CH3COOH) percent by weight 0.0020 Max. 05 Residue on evaporation, percent by weight 0.02 Max. (The residue shall not produce any brown or red colour when treated with 1 ml. of concentrated sulphuric acid analytical reagent grade) (Sec.IS:266-1961) 06 Fusel oil and allied impurities Pass the test. 07 Aldehydes and Oxidizable impurities Pass the test. 08 Isopropyl alcohol, acetone and other Pass the test. ketones.

Fuel Alcohol:

Alcohol has a great future as renewable source of energy. The latest trend for a fuel in the world is use of alcohol as an alternative for mineral fuel oil, which is depleting as far as fuel oil is concerned. During wartime (II World War) in India alcohol in the form of power alcohol was used for blending with petrol in the proportion of 80% petrol and 20% power alcohol. This continued till 1960 when demand of alcohol for chemicals and plastics came up with establishment of alcohol based chemical industries. Because of shortage of alcohol, the scheme of blending petrol with alcohol was given up. Brazil has developed technology, which has made possible large-scale substitution of petroleum-derived fuel. Even hydrous alcohol (Rectified Spirit) can be used as exclusive fuel for automobiles. Alcohol powered vehicles has taken the first position in Brazil and now accounts for 80% of overall sales or about 5,00,000 alcohol powered units every year. Alcohol can also be blended with diesel in the proportion of 7-10%. The BIS specifications (BIS:321-1964, BIS: 15464-2004) of anhydrous alcohol (or fuel alcohol) are given in Table 3.25 and 3.26 respectively.

Table 3.14

SPECIFICATION FOR ANHYDROUS (Fuel) ALCOHOL (IS : 321 – 1964)

Sl. Characteristic Requirement of Anhydrous Alcohol Requirement for No. Special Grade-I Grade-II Grade 1. Specific Gravity at 15.6°/15.6°C Max. 0.7961 0.7961 0.7961

2. Ethanol Content: 99.60 99.60 99.60 % by volume at 15.6°C, Max. 3. Miscibility with water Miscible Miscible Miscible

4. Alkalinity NIL NIL NIL

5. Acidity (as CH3COOH) 0.006 0.006 0.006 % by weight, Max. 6. Residue on evaporation % by weight, 0.005 0.005 0.005 Max.

7. Aldehyde content (as CH3CHO) 0.10 0.006 0.10 gm/100 ml. max.

8. Ester content (as CH3COOC2H5) 0.02 -- -- gm/100 ml. Max. 9. Copper (as Cu), gm/100 ml. Max. -- 0.0004 --

10. Lead (as Pb), gm/100 ml. Max. -- 0.0001 --

11. Methyl alcohol content -- To satisfy the -- requirement of the test 12. Fusel Oil content -- To satisfy the -- requirement of the test 13. Ketones, isopropyl alcohol and tertiary -- To satisfy the -- butyl alcohol requirement of the test 14. Total sulphur and compounds of sulphur 0.001 -- -- (as S) % by weight, Max.

15. Sulphur dioxide (as SO2), % 0.00005 -- -- by weight, Max.

Table 3.15 Requirements of Anhydrous Ethanol For Use In Automotive Fuel Sl. Characteristic IS:15464 (2004) No. 01 Relative density at 15.6/15.6°C, Max. 0.7961 02 Ethanol Content present by volume at 15.6/15.6°C 99.6 Min (excluding denaturant) 03 Miscibility with water Miscible 04 Alkalinity Nil 05 Acidity (as CH3COOH) Mg/lit., Max. 30 06 Residue on evaporation percent by mass, Max. 0.005 07 Aldehyde content (as CH3CHO) Mg/lit., Max. 60 08 Copper, Mg/kg., Max. 0.1 09 Conductivity, uS/m, Max. 300 10 Methyl alcohol, Mg/litre. Max. 300 11 Appearance Clear and bright

Anhydrous alcohol is water free ethyl alcohol and is generally used during World war-II in our country and the same was continued until 1963. The anhydrous alcohol denatured with 0.5% Kerosene was used to blend with petrol in the production of power alcohol of 20% alcohol and 80% petrol composition. Power alcohol act made it compulsory to supply only such mixtures at certain places known as power alcohol zone. As the demand of alcohol increased for manufacture of chemicals, the power alcohol act was abolished and production of absolute alcohol was totally suspended.

Developments with Major Ethanol Players:

As fuel ethanol is dominating the production portfolio, the largest players are to be found in those countries with a highly developed fuel ethanol programme.

The USA – a greater role for ethanol:

There were 184 plants in operation with total production reaching to 46.84 billion liters. Many plants will be added in next two years e.g. Archer Daniel is putting up two ethanol plants each of 500 million gallon per annum capacity.

As per the Department of Energy, US is proposing to produce 226.8 billion liters of fuel ethanol by the year 2030. Of this, 50% has to come from corn and remainder from cellulosic feedstock.

In State of Union address in January 2007, President Bush proposed to raise consumption of renewable fuels to 132.3 billion liters by 2017, which indicates that ethanol is going to be main pillar of future US energy policy.

Brazil-most economic ethanol producer: In the year 2010 Brazil produced 27.52 billion liters out of which 3.1 billion liters was exported. In the year 2012 Brazil produced 30.0 billion liters and in 2015 it exports 7.9 billion liters of fuel ethanol. Brazil is expected to require about 2.0 – 3.0 billion liters extra ethanol each year.

Companies from Japan, India, France, Germany, USA and others are queuing to build dozens of new distilleries in Brazil. 200 New mills, each costing about $ 200 m are planned for the next few years, while area under sugarcane is expected to double or even triple.

FUEL ETHANOL AS A OXYGENATE Fuel-ethanol could be used in petrol as an oxygenate. This reduces emission of carbon monoxide in the exhaust gases of vehicles, by taking combustion to completion. It is necessary and advisable to reduce emission of carbon monoxide because it is toxic to human beings. Completion of combustion also reduces emission of particulate carbon matter, which could cause respiratory disorders. Oxygenate has ‘in-built’ oxygen molecule which helps in completing combustion in a better manner. Oxygenates are organic compounds having boiling point in the vicinity of the boiling point range of petrol. These compounds mix easily and thoroughly with petrol.

Other compounds which are commonly used as oxygenates are tetraethyl lead, MTBE (Methyl tertiary-butyl ether), ETBE (Ethyl tert-butyl ether), methanol etc., These compounds also have oxygen molecules in them.Other function of the compounds added as oxygenates is octane enhancer and anti-knocking agent. These compounds improve the octane number of petrol, thus improving its combustion.

Tetraethyl lead is an oxygenate which is rich in oxygen. It has been traditionally used as an oxygenate in petrol. However, it emits poisonous and dangerous fumes containing lead, which are suspected to cause cancer. In order to replace tetraethyl lead, other substances are added to petrol like the aromatics fraction from crude petroleum distillation. This fraction containing BTX – benzene, toluene and xylene – is added to improve the octane number. However, emissions from such a mixture are poisonous and require a catalytic converter to prevent such emissions. Thus, vehicles using BTX fraction in petrol have to use a catalytic converter on the exhaust of their vehicle. When MTBE is used as oxygenating agent, there is a danger of it contaminating surface water making it unsuitable for use.

In order to get the required content of oxygen, various oxygenates have to be added in different proportion to petrol, based on their content of oxygen.

‘Lead – Free’ Petrol:

Tetraethyl lead is commonly added to petrol as oxygenate and an antiknocking agent. As its emissions are poisonous, substitutes have been developed. Either aromatic fraction of petroleum, containing BTX (benzene, toluene and xylene) – or other agents like ETBE or MTBE is added to make the petrol ‘lead-free’.

Oxygenates in India:

In India, MTBE is now used as oxygenate in petrol. ‘Lead-free’ petrol in India is now added with MTBE in place of tetraethyl lead used normally. Various studies carried out in the US have demonstrated that MTBE used in petrol gets settled onto surface water of lakes and dams and reservoirs. This contamination of water is dangerous and could be harmful to health.

Several States in the US have now banned use of MTBE as oxygenating agent in petrol and have advocated used of fuel-ethanol as safe alternative.

In India there is scope to change from MTBE by employing the alternative and easily available agent like ethanol. Ethanol is widely available in India and only needs to be converted to anhydrous form before blending it into petrol.

Advantages of Fuel-Ethanol:

Addition of fuel-ethanol to petrol has several advantages, especially in a country like India. Use of ethanol in place of tetraethyl lead or MTBE will prevent dangerous and poisonous emissions containing lead or MTBE from petrol. It will not require any catalytic converter for the vehicles.

Use of ethanol in petrol reduces emission of carbon monoxide. This will reduce pollution in India, as this is the most major cause of environmental pollution in India.

Ethanol is made from renewable sources of energy i.e. based on agricultural products. Thus, it is not a depleting resource like petrol. Ethanol is mainly produced from sugarcane molasses. Sugarcane is a renewable source of energy. Sugarcane cultivation is an efficient method of converting ‘solar energy’ into ‘stored energy’. Thus, use of ethanol as oxygenating agent or fuel-extender would conserve fossil fuels and would reduce dependence on fossil fuels.

Use of ethanol helps in maintaining the ‘carbon cycle’ of nature. Carbon dioxide in the atmosphere is converted by agricultural crops like sugarcane or corn into carbonaceous 28 materials like sugar and starch using solar energy. This sugar or starch can be converted into ethanol. This ethanol is used in vehicles to produce energy along with petrol. This combustion in internal combustion engines converts ethanol into carbon dioxide. This carbon dioxide can again be converted into sugar or starch. Thus, the ‘carbon cycle’ of nature continues. This ‘carbon cycle’ uses solar energy, which otherwise would have been wasted.

Use of fossil fuels alone to generate energy only increases content of carbon dioxide in the atmosphere, disturbing the natural balance. Sustaining the ‘carbon cycle’ reduces the ‘greenhouse effect’.

Use of ethanol, which is mostly a ‘home grown’ product reduces dependence on the politically sensitive Middle – East region.

India has vast agricultural waste resources like sugarcane molasses to gainfully convert into ethanol.

CONCLUSION: The demand of alcohol for industrial, potable & fuel alcohol in Karnataka as well as in whole country will increase significantly in coming years. The proposed enhancement / modernization of Siddapur Distilleries Ltd., will contribute to fulfill the demand for Rectified Spirit, ENA and fuel alcohol of Karnataka and neighboring states.

CHAPTER – IV MOLASSES BASED FERMENTATION TECHNOLOGY

During the last decade, interesting developments have taken place in the field of technology of fermentation of alcohol, which promise high yield of alcohol, economy in space, economy in steam consumption and sizable reduction of quantity of effluent.

After the Second World War, considerable research and developments in the continuous process for industrial fermentation have taken place and the processes have been perfected to make them viable. Continuous processes for alcoholic fermentation are now commercialized. This has been possible for the outstanding research and development work carried in Russia, Sweden, Austria and U.S.A. etc., many processes have been patented.

There are variations in different processes of continuous fermentation. Some use only single fermenter whereas some use two fermenters or battery of fermenters. The first fermenter favours rapid cell growth and the second fermenter favours high rate of fermentation. Yeast is recycled. The alcohol content in first fermenter is limited to not more than 4-6% v/v and alcohol content in second fermenter is 8% v/v.

During the last two years interesting development taken place in the field of new technology FED-BATCH fermentation, which promise high yield of alcohol, economy in space & sizable reduction of quantity of effluent .

PROCESS FOR MANUFACTURE OF ALCOHOL

Molasses is the chief raw material used for production of alcohol. Molasses contains about 50% total sugars, of which 30 to 33% are cane sugar and the rest are reducing sugar. During the fermentation, yeast strains to the species Saccharomyces Cerevisieae, a living microorganism belonging to class fungi converts sugar present in the molasses such as sucrose or glucose in to alcohol. Chemically this transformation for sucrose to alcohol can be approximated by the equation:-

I) C12H22O11 + H2O 2C6H12O6 Invertase Cane Sugar Glucose + Fructose

II) C6H12O6 2C2H5OH + 2CO2 180Zymase2 x 46 + 2 x 44 Glucose/Fructose Ethyl alcohol + Carbon di-oxide

Thus 180 gm. Of sugars on reaction gives 92 gms of alcohol. Therefore, 1 MT of sugar gives 511.1 kgs. of alcohol. The specific gravity of alcohol is 0.7934, therefore, 511.1 kg. of alcohol is equivalent to 511.1 / 0.7934 = 644.19 litres of alcohol. During Fermentation of other by-products like glycerin, succinic acids etc. also are formed from sugars. Therefore, actually 94.5% total fermentable sugars are available for alcohol conversion. Thus, one MT of sugar will give only 644 x 0.945 = 608.6 litres of alcohol, under ideal condition theoretically.Normally only 80 to 82% efficiencies are realized in batch type plant. One MT of molasses containing 45% fermentable sugars gave an alcoholic yield of 230 litres per MT. 30

For bringing out above biochemical reaction, we require proper and careful handling of yeast, optimum parameters like pH, temperature control and substrate concentration, which results into effective conversion of sugars to alcohol. For yeast propagation & multiplication separate equipment is required. Initially yeast is developed in the laboratory from the single cell yeast culture. In the laboratory, yeast is propagated in a test tube on 10 ml. Then it is transferred to a bigger flask of 500 ml. flask are transferred to 5 liter flask containing the sterilized molasses media solution. It is necessary to adjust the pH of the molasses solution in the range of 4.5 to 5.0 add necessary nutrients such as ammonium sulphate or urea, diammonium phosphate etc. Each stage of development of yeast from 10 ml to 500 ml and 500 ml to 5 litres requires 24 hours in the laboratory. On the plant side, there are again 3 stages of propagation namely 100 litres, 500 litres and 5000 litres. All these equipment’s are designed so as to facilitate boiling molasses solution in order to sterilize it and also cooling to bring it to the proper temperature of 33°C and letting in culture and taking out culture. Boiling, cooling, introducing culture etc. are done in aseptic manner, i.e. Keeping the fermentation medium free from any kind of infection. Further stages of yeast propagation are done in open tanks. i.e. pre-fermenter requires about 8 hours in order to build up necessary concentration of yeast in them. Finally pre-fermenter is emptied in an empty fermenter, which is previously cleaned and kept ready. Dilute molasses solution is allowed to flow in the fermenter so as to fill it to its working capacity say about one-lac litres.

Now a day, readymade compressed yeast is used directly in the pre-fermenters. Good quality of yeast is available for use in distillery. The yeast is manufactured under strict controlled conditions. This yeast is useful to obtain a good yield of alcohol by fermentation of molasses. The stages of yeast propagation as described above for producing yeast from laboratory scale to pre-fermenter stage may be totally eliminated. The fermentation of molasses in fermenters take about 24 to 30 hours for completely exhausting the sugars in molasses.

The average efficiency of conversion of sugars from molasses to alcohol is 80 to 85% of theoretical value in batch type distilleries. All the sugars are not converted to alcohol during the process or fermentation because chemicals like glycerin, succinic acid, etc. are also produced by yeast during their metabolic process. Therefore, it is not possible to have 100% efficiency of conversion of sugars to alcohol. The average yield of alcohol from molasses is about 230 litres from 1 MT of molasses in batch type distilleries.

Recently attractive developments have taken place in the field of fermentation and distilleries whereby one can get high yield of 265 to 270 litres per MT of molasses.

TECHNOLOGY FOR CONTINUOUS FERMENTATION PROCESS:

The continuous fermentationtechnology as compared to the old batch fermentation technology. It has many advantages like continuity of operation, higher efficiency and ease of operation. Continuous fermentation also results into consistent performance over a long period as compared with batch fermentation. Most modern ethanol production plants adopt this continuous fermentation technology.

1) “K-SUPER” CONTINUOUS FERMENTATION (KBK):

K-Super proposed to adopt the efficient continuous fermentation in the distillery. The fermentation process employs a special yeast culture, which can withstand variations in the molasses equality, temperature and other shock loads. Fermentation plant consists of three to four numbers fermenter tanks connected in series with all the accessories like plate heat exchangers for cooling, air & CO2sparger, broth mixers and air blowers etc., The yeast is immobilized using special media and it remains in the fermentation plant throughout and hence it gives tremendous advantages in maintaining the yeast population and in combating the bacterial infection. The technology is called continuous mixed bed fermentation (CMB) and which is the latest technology available in the industry at present. Molasses after weighing is diluted and also pre-treated to an appropriate sugar concentration while pumping through molasses broth mixer into the fermenter. The partial pre-treatment of molasses is required to reduce scaling of the equipment due to the sludge present in the molasses, which is separated out very easily in this pre-treatment. The fermenters are then inoculated with culture developed in the culture vessels. This culturing with suitable yeast is carried out only during the start-up of the plant. The culture thus developed maintains itself in fermenters on a continuous basis.

To help the fermentation sustain the assailable nitrogen are added in the medium in the form of Urea and DAP as required. Temperature in the fermenters is maintained to an optimum level as required for efficient reaction with the help of plate heat exchanger and recirculation pumping system. This recirculation also helps in proper mixing of fermented wash. The retention time for the reaction is about 24 to 32 hours. Air blower is provided to supply the necessary oxygen required for the yeast and also for agitation. After completion of reaction the fermented wash is delivered to wash settling clarifier. In Wash Settling Clarifier, settable solids settle down. The supernatant goes to Buffer Wash Tank (BWT) and sludge from bottom goes to Sludge Tank.

The CO2 which is liberated in fermentation is scrubbed in water, with the help of CO2 scrubber. This CO2 contains ethanol, which is recovered by collecting CO2 scrubber water fed into sludge trough. The diluted sludge is pumped into Sludge settling clarifier. The traces of ethanol present in diluted sludge are separated at the supernatant, which is collected into BWT through overflow and washed sludge from bottom is drained off. The fermented mash collected in the Clarified wash tank is then pumped to Mash or Primary column for distillation.

A closed loop cooling tower system with an induced draft-cooling tower with circulation pumps is also provided to ensure higher cooling efficiency and to minimize water wastages.

2) CASCADE (HIFERM-GR) Continuous Process with yeast recycling (PRAJ):

M/s.PrajIndustries Ltd., Pune, supply complete plants for the fermentation industry. The process is for continuous production of alcohol from sugar containing raw materials. The process developed by them for continuous fermentation is adopted for production of alcohol from raw molasses successfully in several countries like India, Thailand, Yugoslavia, Australia, Ghana, Kenya, USA etc.

A set of four fermenters is required for this process. This wort enters the first fermenter and is allowed to overflow to the second fermenter and the wash from 2nd fermenter goes to 3rd to 4th fermenter. The wash coming from the 4th fermenter, it contains 8-9.5% alcohol. Process water is also added to first one or two fermenters. Water ring blowers sparged fermentation air into first and second fermenters, carbon dioxide generated into the first and second fermenter is collected and it fed into the third fermenter for proper mixing of the fermented wash, while part of the carbon dioxide generated into the last fermenter is collected and it led into the CO2 scrubber. The CO2 which is liberated in fermentation is scrubbed in water, with the help of CO2 scrubber. This CO2 contains ethanol, which is recovered by collecting CO2 scrubber water fed into sludge trough.

The wash coming out last fermenter goes to yeast separator (yeast settling tank). In the yeast separator yeast cream is separated by gravity settling from the wash and returned back to the first fermenter by acidic treatment to avoid the contamination, nutrient dosing as well mixing of molasses by broth mixer with yeast cream and sparging the air in yeast activation tank (YAT), therefore yeast activity will be increases and it is fed to the fermenter No.1. The top fermented wash overflow collected in the wash settling tank (WST).

In wash settling tank sludge is settled at the bottom while top supernatant wash over flow to the wash charger (wash holding tank), then it is pumped to Mash or Primary column for distillation system to recover the alcohol.

The sludge drain from the bottom of WST is fed into sludge trough where it is diluted with CO2 scrubber water. The diluted sludge is pumped into Sludge settling tank (SST). The traces of ethanol present in diluted sludge are separated at the supernatant, which is collected into wash charger through overflow and washed sludge from bottom is drained off.

Fermentation auxiliaries like nutrient preparation, sulfuric acid dilution and antifoam agent dosing are prepared on the ground floor. Nutrient solution and dilute acid is fed to the first fermenter by metering or dosing pumps. In this manner by controlling parameters like molasses and water flows, pH, Nutrient and temperature, alcohol concentration between 5.5 and 9.5 % v/v is maintained in first and last fermenter respectively. Temperature of the individual fermenters is maintained in the desired range of 30 to 32°C by recirculating the fermenting wash through the individual plate heat exchangers. A separate cooling tower and pump is used for recirculating the cooling water for fermentation.

All the fermenters are covered and connected to a scrubber in order to recover alcohol from carbon dioxide. The yield of alcohol is 280 litres/MT of molasses containing 47% total fermentable sugars. Stillage would be appreciably less as alcohol concentration by `12-14 litres per litre of alcohol produced depending on alcohol produced in the wash.

Average residence time is in fermenters is 24-30 hrs. with alcohol % in fermented wash in the range 8-9% (v/v).

M/s.PLraj Ind. Ltd., Pune has introduced a system in the year 2001-02 in which a granulated flocculating type yeast strain is being used which has a property to settle down by gravitational force. This eliminates the use of yeast separators. The fermentation efficiency is claimed as 89-90%.

3) MojjEngg. Systems Ltd: Molasses after weighing is diluted and also pre-treated to an appropriate sugar concentration while pumping through molasses broth mixer into the fermenter. The partial pre-treatment of molasses is required to reduce scaling of the equipment due to the sludge present in the molasses, which is separated out very easily in this pre-treatment. The fermenters are then inoculated with culture developed in the culture vessels. This culturing with suitable yeast is carried out only during the start-up of the plant. The culture thus developed maintains itself in fermenters on a continuous basis.

Continuous yeast growth in yeast YV03 byadding pasteurized molasses and recycling partly, the yeast separated in yeast separator after acidification and activation treatment, which helps to avoid contamination and maintain consistency in operation.

To help the fermentation sustain, the nitrogen is added in the medium in the form of Urea and DAP as required. Temperature in the fermenters is maintained to an optimum level as required for efficient reaction with the help of plate heat exchanger and recirculation pumping system. This recirculation also helps in proper mixing of fermented wash. The retention time for the reaction is about 22 to 24 hours. Air blower is provided to supply the necessary oxygen required for the yeast and also for agitation.

This fermentation technology use genetically marked high osmotoleant yeast strain.

The system uses the cooling system to maintain fermented broth temperature to 32-35°C, which results in improve yeast cell mass activity.

The technology incorporated yeast recycle, which maintain high yeast concentration and reduced fermentation time result in lower fermenter volume, saving in capital and operating cost.

After completion of reaction the fermented wash is delivered to yeast separation centrifugal machine to separate the yeast cream. The technology incorporates yeast acidification and activation, which ensure the yeast, recycle in continuous propagation vessel and fermenter is bacteria free and ensures no contamination.

In Wash Settling Clarifier, settable solids settle down. The supernatant goes to clarified wash tank (CWT) and sludge from bottom goes to sludge tank. The fermented wash collected in the clarified wash tank is then pumped to stripping column for distillation.

The CO2 which is liberated, is scrubbed in water, with the help of CO2scrubber. This CO2 contains ethanol, which is recovered by collecting CO2 scrubber water into sludge decantation. The technology incorporated sludge decantation system, which consists of specially designed lamella separator as against conventional, designed to settle the sludge. The settled sludge after dilution, from CO2scrubber water pass through the decanter. This ensures the clarified wash going to distillation is free from sludge, which results in clean distillation column, re-boiler tubes and integrated spent wash evaporator tubes. This also helps to maintain consistency in operation and avoid losses due to stoppages. Alternatively the technology also offers pre-clarification of molasses for high sludge/VFA content in molasses.

A closed loop cooling tower system with an induced draft-cooling tower with circulation pumps is also provided to ensure higher cooling efficiency and to minimize water wastages.

The system incorporates mechanical ejector in place of air sparger, which results in increase the dissolved oxygen level, facilitate better contact between yeast and fermentable sugar avoid hydraulically dead zones, increase yeast cell mass activity for high efficiency and better yield.

The technology achieved 8-9% v/v alcohol percentage in fermented wash.

BIOSTIL:

Process developed for Continuous Fermentation is Biostil process patented by Alfa-Laval of Sweden. It has some special features. It is a very comprehensive and compact process aimed at only high yield of alcohol but also reduction of effluent substantially.

In this process, concentrated substrate of 40-45% of final molasses is fed to the fermenter at a constant flow rate. The process does not involve pretreatment or pasteurization of molasses. It envisages recycling of stillage to the extent of 70% of total volume in order to eliminate bacterial infection. The whole fermentation is carried continuously in two fermenters.

Molasses wortisfeeded at such a rate that the sugar percentage remains below 1.8 to 2 % w/w. Ethanol concentration is controlled at 6 to 7% w/w. Special kind of yeast known as Saccharomyces pombe is used in the process. The yeast propagates by splitting and not by budding. It stands high osmotic pressure. The process requires yeast propagation vessels, nutrient tanks and pumps, yeast separators, hydrocyclones, carbon dioxide scrubber to recover alcohol and efficient plate heat exchangers for cooling recycled stillage and for cooling fermented wash.

The distillation system differs from the conventional process as far as wash column is concerned. Other equipment’s are same as conventional plant.

The wash column divided into two sections:-i)Vaporizer ii) Stripper. The wash is de-yeasted and also free from sludge by yeast separators of suitable design, as the wash is pumped from fermenter to wash feed tank. The wash is plreheated by plate heat exchanger and outgoing stillage. It enters the top plate of vaporizing section of wash column. The wash is boiled by vapours coming up from the stripper section,. About 90% of ethanol is removed from the top through vapour pipe of the column. The concentration of alcohol in the vapor is approx. 50% v/v. About 70% of weak wash is pumped from the bottom of vaporizer through the regeneration heat exchanger to return to the fermenter via a trim cooler in the form of heat exchanger.

A minor stream of 30% remaining weak wash flows to another section of distillation column called as stripping column. This column is heated by re-boiler instead of heating by steam sparger employed in conventional plant. The vapours going out consisting of steam and weak ethanol enters the bottom of vaporizer and provides heat necessary for boiling the wash. The spent-wash leaving the column is free from alcohol and is concerned to 25% solids. The duel purpose of this column heated by re-boiler for evaporation and distillation lead to the highest possible stillage concentration without increase in steam consumption.

The recycling of spent-wash for dilution of molasses is a novel idea in this technique. This is useful to increase soluble salt concentration for optimum osmotic pressure, which is necessary to limit the growth of fermentation organism yeast without affecting the rate of fermentation and eliminate contamination.

2) Fed Batch Process:

Fermentation process in Fed batch mode is very feasible for the molasses having higher value of V.A by using culture yeast. We have adopted hyper fermentation system which offers the flexibility of running the process in Fed batch.

Process Description:

Inoculation of yeast culture is 20% filling of molasses for 13 hrs. Total fermentation period is 24 to 28 hrs. and residual sugars will be controlled at 1.20% to 1.30%and the average alcohol content in wash is 10.50% to 11%.Yield per MT of Molasses will be 270 to 280 BL.

In Fed batch fermentation the alcohol % in wash will be 10.50% to 11% as compared to 8.50% to 9.50% in continuous fermentation and the plant capacity will be increased by 10 to 15%. However, the steam requirement remains same and the generation of spent-wash will be reduced by 3 to 4%. By this process optimum efficiency can be achieved.

CHAPTER – V 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, method of distillation is employed.

The distillation column system consist of number of bubble cap plates where wash is boiled and alcoholic vapours are separated according to their boiling point and concentrated on each plate stage by stage.

Atmospheric Distillation:

The fermented wash first enters the beer heater, which is a condenser for condensing alcoholic vapours by using wash as cooling medium. The objective of this beer heater is to recover the heat from the hot vapours of alcohol. Fermented wash from the beer heater goes to degasifying column, degasifying column bottom goes to the top plate of the wash column. Thiscolumn consists of 18 plates. The steam is admitted through the steam sparger situated at the bottom of the column. As the steam rises up, the wash descending from the top to the bottom of the column gets heated and by the time it reaches to bottom plate, it consist practically no alcohol. The wash going out is called spent wash, which is discharged to the drainpipe. The vapours coming from wash column now consists approximately 50% alcohol and 50% water with impurities such as higher alcohol’s, aldehydes, acids, sulphur dioxide etc. Part of these vapours are led to Pre-rectifier column where low boiling impurities are separated from spirit which is produced at the rate of total production depending on the extent of purity required and stored separately. Other portion of the vapours, which is major quantity, is led to rectifying column. This column consists of 44 plates, which helps the removal of bad smelling fusel oil, which is a mixture of higher alcohol. As the vapours coming from wash column rise to the concentration of 95.5% alcohol. The alcoholic vapours from rectifying column are condensed in the beer heater, principle condenser using water as a coolant and finally vent condenser. The condensates of all three condensers go back to the top of the rectifying column and uncondensed gasses are let out from the vent pipe. Actual product of rectified spirit is drawn from the 3rd plate from the top and cooled in alcohol cooler and taken out as a product.

The fusel oil which is a mixture of higher alcohol is drawn from the 6th to 10th plate from bottom of rectifying column as a stream of vapours, it is condensed, cooled & led into a decanter where it is mixed with water. Fusel oil being immiscible with water collects at the top and is decanted through a funnel and sent to storage. The lower portion contains water and alcohol and is sent back to wash column for recovery of alcohol. Fusel oil is recovered at the rate of 0.2% of alcohol produced.

The alcohol both pure and impure is first led into separate receivers. The quantity of alcohol produced is assessed daily in the receivers and it is finally transferred to storage vats in the warehouse. The spirit from storage vats could be issued for denaturation or for own consumption, or directly to the tankers of the customer depending upon the type of requisition.

MULTI-PRESSURE VACUUM DISTILLATION: Multi-pressure vacuum distillation system for production of Rectified Spirit consists of distillation columns namely –

For-Rectified Spirit: 1. Degasifying cum analyzer column – Operation under vacuum 2. Pre-rectification column – Operation under vacuum 3. Rectification cum Exhaust Column – Operated under pressure 4. Fusel Oil Concentration column – Operated under atmospheric

For-ENA: 5. Extractive distillation column – Operated under atmospheric 6. Simmering column – Operated under atmospheric. Fermented wash is preheated in pre-heater and fed at the top of the Analyzer column, Analyzer column is fitted with thermosyphonreboiler. Top vapours of analyzer column are sent to pre-rectifier column. Rest of the fermented wash flows down and is taken as spent wash from analyzer column bottom. Pre-rectifier/stripperbottom liquid is preheated with thermosyphonreboiler and fed to rectifier cum exhaust column. Low boiling impurities are concentrated in the pre-rectifier column. A top reflux draw of condenser is taken out as impure alcohol from the top of the pre-rectifier column. Rectifier exhaust is operatd under pressure and bottom liquid is preheated with thermosyphonreboiler. Alcohol is enriched towards the top and is drawn out as Rectified Spirit. Fusel oil build-up is avoided in the Rectifier column by withdrawing out side streams of fusel oil. These are sent to fusel oil concentration column from where the fusel oil is sent to decanter for further separation. The fusel oil wash water is recycled back to the column. A top draw is taken out as impure alcohol from the top of fusel oil column.

The design of the re-distillation plant is made in such a way that the Extra Neutral Alcohol quality and the production does not get disturbed due to varying quality of rectified spirit. The plant may be preferably in copper. As the plant deals with the rectified spirit, there is no risk of corrosion and the quality of spirit produced will be superior.

In the proposed project, ENA will be produced directly from wash. The concentrated vapours from the rectification/exhaust column will be fed directly to the ENA section of distillation columns (Extractive distillation and simmering column). The ENA-distillation columns will work on multi-pressure principle so that maximum heat economy can be achieved with improved quality of ENA.

Benefits of Pressure Vacuum Distillation: Following are the advantages of pressure vacuum distillation.

 Since the analyzer column operates under vacuum, the formation of by-products such as acetal may minimize there by improvement in quality of alcohol.  Pre-rectification column ensure removal of sulphur compounds/mercaptans and also reduces load of lower boiling volatile compounds passing on to Rectifier cum exhaust column.  The changes of scaling due to invert solubility of certain precipitating inorganic salts are minimized in vacuum distillation.  Vacuum distillation requires low steam consumption with reboiler i.e. 2.2 Kg/lit. of Rectified Spirit & 3.2 Kg/lit. of ENA.

MANUFACTURING PROCESS FOR FUEL (ANHYDROUS) ALCOHOL Anhydrous alcohol is an important product required by industry. As per IS Specification it is nearly 100% pure / water free alcohol. Alcohol as manufactured by Indian Distilleries is rectified spirit, which is 94.68% alcohol and rest is water. It is not possible to remove remaining water from rectified spirit by straight distillation as ethyl alcohol forms a constant boiling mixture with water at this concentration and is known as azeotrope. Therefore, special process for removal of water is required for manufacture of anhydrous alcohol.

In order to extract water from alcohol it is necessary to use some dehydrant or entrainer, which is capable of separating, water from alcohol.

Simple dehydrant is un slacked lime, Industrial alcohol is taken in a reactor and quick lime is added to that and the mixture is left over night for complete reaction. It is then distilled in fractionating column to get anhydrous alcohol. Water is retained by quick lime. This process is used for small-scale production of anhydrous alcoholby batch process.

The various processes used for dehydration of alcohol are as follows: I) Azeotropic Distillation II) Molecular Sieves III) Pervaporation / Vapour permeation system.

The salient features of each of the processes are given herewith:- I) Dehydration with Entrainer Process (Azeotropic Distillation):- For manufacture of anhydrous alcohol on large scale, Cyclohexane is used as entrainer. When 94.68% alcohol is mixed with Cyclohexane and distilled a ternary azeotrope is formed e.g. If a mixture of ethanol, water and cyclohexane as given below is distilled and condensed then the condensate forms two layers with following composition.

Azetrope Composition (%) Decanter Upper Layer (%) Lower Layer (%) Alcohol 18.50 14.50 53 Cyclohexane 74.10 84.50 11 Water 7.40 1.00 36

The system consists of two to three columns. First is a dehydration column followed by recovery column. The Rectified Spirit is fed into the dehydration column. Cyclohexane is also introduced in this column. Vapour of ethanol, water and cyclohexane close to its azeotropic concentration is collected from the top whereas anhydrous alcohol is collected from the bottom of the column.

Ternary mixture of ethanol, water and cyclohexane is condensed and sent for decantation where it forms two layers. Top one is cyclohexane rich layer whereas bottom one is water rich layer. Top layer is refluxed back and bottom layer is sent to recovery column. Water is collected from the bottom of the recovery column whereas ternary mixture of cyclohexane, water and ethanol comes out of the top, which is condensed and partially sent to dehydration column. Any cyclohexane lost in the system is taken care by adding make-up cyclohexane in the system.

One thousand litres of industrial alcohol of 94% v/v contains 940 litres of anhydrous alcohol and 60 litres of water. For a capacity of 20 KLPD anhydrous alcohol plant make-up cyclohexane required shall be 90 Kg/day. The cyclohexane is continuously recovered in the process and recycled as entrainer. About 20 to 30 litres of cyclohexane will be required every day to meet losses of cyclohexane in process. The process is rather simple and well established and given good quality of anhydrous alcohol.

In another method, glycerin is used as dehydrant. Glycerin is fed counter current wise to the rising alcohol vapours in a column. Glycerin absorbs all the water and leaves from the bottom of the column, which consists of glycerin, water and some amount of alcohol. Distillate at the top is anhydrous alcohol. Glycerin water mixture is sent first to alcohol recovery column and then to vacuum evaporator for recovery of glycerin and removal of water. Glycerin is recycled. This process is also effective giving good quality of anhydrous alcohol.

The steam requirement in the above two processes is around 2.6% / litre of anhydrous alcohol produced.

II) Dehydration with Membrane Process:-

A) Pervaporation:-

Introduction:-

The developmentof system of dehydration with membrane for bulk water removal has advantage of very low operative cost. Continuously working Pervaporation units are fed with wet feed and produces on sea product directly. The liquid feed mixture is continuously pumped through a series of membrane modules. The number of modules depends on the capacity and the required final water content. If necessary, a reduction in product water content can be achieved by reducing the feed rate. Pervap SMS modules are heated and facilitate continuous isothermal pervaporation. No heating is required between membrane modules. This technology is not available commercially in India.

Unit Description:- --- Perevap SMS modules, with membranes R101 Recuperator H101 Feed heater C301 Permeate condenser C302 Permeate cooler VP401 Vacuum Pump as well as all piping, valves, instrument and insulation. All parts in contact with feed and product are in SS-304 (Options-other SS grades)

Membrane Modules:- The Pervap SMS unit is equipped with tubular micro-porous membrane installed in isothermal high flux modules. Ceramic membrane tubes are installed co-axially in the tubes of the module, which is similar to a shell, and tube heat exchanger. Feed passes through the annular passage and permeate is collected from the inside of the ceramic tubes and plassed to the permeate condensation system. Steam is fed to the module shell to offset the heat of Pervaporation.

This equipment has the following advantages:-

i) High operating temperatures and pressures can be accommodated and maintained providing high driving forces for Pervaporation. ii) High mass transfer rate is obtained. iii) Stainless steel materials of construction with graplhitegaskeeting – compatible with virtually all-solvent systems. iv) Standard module geometry allowing for easy membrane replacement, spare holdings etc. v) Individual membrane tubes can be disconnected / replacement if required.

Process Description:-

Continuously operating pre-vaporation units run at steady state conditions. Feed is passed continuously through the unit and product leaves the unit at the desired water content.

Refer to the flow sheet to follow the function of the various equipment items included in the skid. Feed from pump is first passed through a double filter station to prevent any fine suspended soils reaching the membranes. Feed flow is controlled by a throttle valve/rotameter combination. Feed is then preheated in recupereate, heated to operation temperature in heater and then passed to the first membrane module. As the solvent passes across the semi-permeable membranes, contained water diffuses through the membranes and exists as vapour which passes to the permeate condensation system. 41

Peremeate condensation and Discharge:-

Permeating water is condensed in condenser and collects in the built-in sump. Vacuum pump continuously removes non-condensable from the system.

Permeate is continuously removed from by permeate pump. The discharge rate of this pump is throttled to maintain the set liquid level in condenser. Recycle line with cooler is provided to prevent overheating of the system at low permeates rates.

Nitrogen System:- A nitrogen system is installed to ensure trouble-free shutdown of the unit and to facilitate draining and purging of the unit when solvents are changed.

B) Vapour Permeation System:-

In this system, the liquid is vaporized and the vapour as a feed is fed to membrane module. The membrane selectively separates water molecules from alcohol. The vapourpermeation system is preferred if the liquid contains some dissolved particles suspended.

The advantage of membrane system:- i) Easy operation ii) Very low energy requirement / litre of Anhydrous alcohol. Hence the operating cost is least. iii) No toxic or hazardous chemical required. iv) The life of system may be around five to seven years.

In this industry, effluent produced is only water. Therefore, problems of pollution hazard are nil. Consent from Environmental Department and Pollution Control Board can be easily obtained as a matter of routine.

III) Dehydration with Molecular Sieve Process:- The rectified spirit from the rectifier is superheated with steam in feed super heater. Superheated rectified spirit from feed super heater is passed to one of the pair of molecular sieve beds for several minutes. On a timed basis, the flow of superheated rectified spirit vapour is switched to the alternate bed of the pair. A portion of the anhydrous ethanol vapour leaving the fresh adsorption bed is used to regenerate the loaded bed. A moderate vacuum is applied by vacuum pump operating after condensation of the regenerated ethanolwater mixture. This condensate is transferred from recycle drum to the Rectified Column in the hydrous distillation plant via Recycle pump. The anhydrous alcohol draw is condensed in product condenser and passed to product storage.

The life of molecular sieve may be around five to seven years. However, the operating cost is considerably less than azeotropic distillation.

Requirement of Input:-

Cooling Water *** Power Plant *Cooling **Steam (RS to Make-up (KwH/hr.) Capacity Water Abs. Alc.) (M3/day) (KLPD) (M3/hr.) (Kg/lit.) Connected Operaing

60 275-300 200-230 0.55 80 40 * Cooling water recirculation rate 200-230M3/hr for Molecular Sieve plant only @ 30°C maximum and 4 Kg/Cm2 (g) pressure at cooling water header,

T=8°C

** Steam requirement will be at full capacity operation @ 3.5 Kg/Cm2 (g) pressure in steam header.

*** Electricity will be 440 V, 3 ph, 50 Hz, AC Electric supply. The power requirement will be for Molecular sieve plant only, which excludes utilities like boiler, cooling tower, etc.

Integrated Multi-product Concept:-

It is now possible to install a distillation system, which can produce different products i.e. in the proposed scheme; we have considered the 70 KLPD production of Rectified spirit or ENA after enhancement of existing 60 KLPD plant and 55.20 KLPD Anhydrous alcohol from existing molecular sieve plant. This will allow flexibility of operation and different products can be produced depending on the market demand. This integrated multi-product system involves less capital investment as compared to independent system and offers good advantage of energy conservation.

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 multipressure principle with few columns operating under vacuum, atmospheric and few under pressure. In the multi-product concept few columns are common and depending on the final product required, additional columns are operated.

CHAPTER – VI DISTILLERY SPECIFICATIONS

The factory management has proposed to expand existing Continuous Fermentation with multi-pressure vacuum distillation of 60 KLPD distillery plant to 70 KLPD with the same technology configurations. The proposed expansion includes addition of one fermenter, wash holding tank, agitators for all fermenters with all auxiliaries in fermentation section. In distillation section one De-Gasifier column with their condensers.Overall efficiency of existing and new plant capacity to produce excellent quality of R.S/ENA &55.20 KLPD Fuel alcohol. For 55.20 KLPD existing Ethanol plant, modification is not required.

Alcohol Production:-

1) Rectified Spirit conforming to Indian Standards. 323/1959, Grade-I will be minimum 95% v/v strength 2) Extra Neutral Alcohol conforming to Indian Standards – 6613/1972 3) Anhydrous alcohol conforming to Indian Standards 321/1964, Grade-I will be minimum 95% of total (99.5% v/v at 15.6°C)/IS:15464 (2004)(99.5% v/v at 15.6°C) 4) Impurealcohol 5% during Rectified Spirit production 6% during ENA production 5% during fuel alcohol production

The impure alcohol is also marketable as such in the form of Ordinary denatured spirit.It can be disposed off by blending it with Grade-I, Rectified Spirit in a proportion, which will give Grade –II spirit. This can be sold as special denatured Industrial Alcohol.

During the process of distillation, a by-product known as fusel oil separates out. It is a mixture of higher alcohol’s. The production of fusel oil is in the range of 0.2 – 0.3% of alcohol production depending upon quality of molasses and fermentation operations.

EXISTING SET – UP FOR SIDDAPUR DISTILLERIES LTD.(60 KLPD Molasses Based Distillery)

Plant Capacity – 60 KLPD Total Spirit a. Fermentation Section: 1) Continuous Fermentation System with 3 fermenters 2) Alcohol content in fermented wash was around 8.5 % v/v – 9.5 % v/v 3) Fermented Wash – 640 m3/day

b. Distillation Section : 1) Type – Multipressure – 8 Columns 2) The generation of Spent Wash was around 520 m3/day (around 9 lit / lit of total spirit).

c. Integrated Evaporator Section : 1) Evaporation System for Raw Spent Wash 2) Concentrated Spent Wash generation for 60 KL operation was around 420 m3/day (7 lit / lit of Total Spirit) 3) Type - Integrated & cross flow type with triple effects 4) Integrated with Analyzer column Vapours to concentrate the Spent Wash

d. Biomethanation Section : 1) Type – LESMAT (Fixed Film Media Reactor) 2) Digester – 1 No. 3) Biogas Generation

The total steam consumption for the 60 KLPD Distillery Plant was around 9 TPH

CALCULATIONS: Fermented wash generated with continuous fermentation @ 9.5 % avg. alcohol in wash = 60000/0.094 = 640 m3/day Alcohol in Fermented Wash = 60 m3/day

Spent Leese in Fermented Wash = 80 m3/day

Analyzer top vapours – 120 m3/day

Spent wash Generated at Analyzer = 640 – 120 = 520 m3/day Evaporation Achieved – 80 m3/day Conc. Spent Wash Generated - 420 m3/day

PROCESS DESCRIPTION 1. FEED PREPARATION AND WEIGHING Molasses Stored in a storage tank is first weighed in a tank with load cells so that accurate quantity can be fed to the fermentation section. The weighed molasses then transferred from tank to the dilutor in fermentation section where it is diluted with water and fed to the Fermenter.

2. YEAST PROPAGATION AND FERMENTATION The Yeast from Slant is transferred to Shaker Flasks and grown to the required volume.This “genetically marked” yeast strain is then further propagated, under aseptic conditions, in yeast culture vessel. These vessels are equipped with eductors which are designed to achieve enhanced efficiencies through better sugar / yeast contact by shearing and mixing, efficient oxygen transfer etc. The ready yeast “seed” is then transferred from culture vessel to fermenter. The molasses is diluted by process water. The glucose in the Feed media gets converted to ethanol, in each of the 3 Fermenters operating in Continuous mode. A plate heat exchanger and a circulation pump are provided to each fermenter, which will continuously re-circulate the Fermenting Wash through PHE for maintaining the Fermenters at 30 deg C. The nutrients, biocide, acid and anti-foam agents are fed to the fermenters as per process requirement. The CO2 liberated during fermentation is sent to CO2 Scrubber for recovery of ethanol otherwise being lost in vent. The Fermented Wash is then sent to the Clarification Tank equipped with Lamella Separator. The settled sludge is sent to Sludge Washing Tank for recovery of alcohol.

3. MULTIPRESSURE DISTILLATION (RS) The fermented wash is fed to CO2 stripper column to remove CO2 gas present in wash. Alcohol is stripped off water in stripper column. Bottom of Stripper (Spent Wash) is fed to Integrated Evaporator. Conc. Spent Wash is then fed to Biogas Plant. The top vapours [alcohol + water] are fed to Calendria. Distillate from Calendria is pre-heated before being fed to rectifier column. In rectifier column RS is taken out from top tray.

The impure spirit from top of CO2 stripper column, rectifier column, fed to fusel oil column. The final impure spirit cut is taken out from the fusel oil column and partly alcohol is recycled to rectifier column. The alcohol containing fusel oil from rectifier column is fed to fusel oil column.

Rectification column works under pressure. The CO2 stripper, stripping column, works under vacuum and fusel oil column works under atmospheric condition.

The top vapours from rectifier column are condensed in Stripper Reboiler. The alcohol water vapours from stripping column are partly sent to CO2 stripper bottom for heating. The Rectifier column and fusel oil column gets heat from steam.

4. MULTIPRESSURE DISTILLATION (ENA) WITH ETHANOL The fermentation mash containing Alcohol, non-fermentable solids and water is supplied to Distillation to separate the alcohol and other impurities, as a continuous flow. The Distillation system is designed for premium quality extra neutral alcohol. The system details are as below: The system consists of 8 main columns, namely, CO2 Stripper, Stripper Column, Pre- rectifier Column, Extraction Column, Rectification Column, Refining Column, and Fusel Oil Column.

Wash is fed to CO2 stripper column to remove CO2 gas present in wash. Alcohol is stripped off water in stripper column. Bottom of Stripper (Spent Wash) is fed to Integrated Evaporator. Conc. Spent Wash is then fed to Biogas Plant. The top vapours from stripper column are fed to Calendria. Distillate from calendria is fed to pre- rectifier column as feed and steam is supplied as heat source. Pre-rectifier remove most of the fusel oils. Top of the Pre-rectifier column are fed to Reboiler of Refining Column and part of the distillate from pre-rectifier column is fed to extraction column after dilution where process water is used as dilution water and remaining return back as a reflux. In extraction column most of the high boiling impurities separate from ethanol in presence of water. The bottom ethanol water mixture is pre-heated before being fed to rectifier column. Top vapours of Rectifier column are fed to Stripper Reboiler as a heat source. In rectifier column product rectified spirit is taken out from top tray and fed to refining column where mainly methanol impurities are separated. Pure ENA is obtained at bottom of Refining column, which is cooled and stored. The impure spirit from top of CO2 stripper column, extraction column, rectifier column and refining column are fed to FO column. The final impure spirit cut is taken out from FO column top and balance alcohol is recycled to pre-rectifier column. The alcohol containing fusel oil from pre-rectifier and rectifier column is fed to fusel oil column.

The rectifier column, fusel oil column, HC column and pre-rectifier column get heat from steam at 3.5 bar (g). Rectification column and pre-rectifier column works under positive pressure. The top vapours from rectifier column are condensed in stripper column for giving heat to stripper re-boiler. Most of the other columns work under vacuum.

The Distillation process is operated through PLC.

The distillation system also is operated with Ethanol (Fuel Alcohol) mode with feed to fuel alcohol plant given directly from the pre – rectifier column

MODIFICATIONS TO BE DONE FOR CAPACITY ENHANCEMENT(60 KLPD TO 70 KLPD Molasses Based Distillery)

Plant Capacity – 70 KLPD Total Spirit

a. Fermentation Section: 1) To convert the existing “Continuous Fermentation System” into “Fed Batch System” 2) Alcohol in Fermented Wash – 10.5 % to 11 %. 3) Fermented Wash Generation - 660 m3/day. b. Distillation Section : 1) Type – Multipressure – 8 Columns 2) The generation of Spent Wash will bearound 520 m3/day (around 7 lit / lit of total spirit).

c. Biomethanation Section : 1) Type – LESMAT (Fixed Film Media Reactor) 2) Digester – 1 No. 3) Biogas Generation

d. Integrated Evaporator Section : 1) Concentrated Spent Wash generation for 70 KL operation will be around 420 m3/day (6 lit / lit of Total Spirit) 2) Evaporation System for Biomethanated Spent Wash installing Degasifying section to existing system. 3) Type - Integrated &Feed Forward flow type with triple effects 4) Integrated with Analyzer column Vapoursto concentration of Spent Wash The total steam consumption for the 70 KLPD Distillery Plant would be around 9 TPH CALCULATIONS: Fermented wash generated with Fed - Batch fermentation @ 11 % avg. Alcohol in Wash = 70000/0.106 = 660 m3/day

Alcohol in Fermented Wash = 70 m3/day

Spent Leese in Fermented Wash = 70 m3/day

Analyzer top vapours – 140 m3/day

Spent wash Generated at Analyzer = 660 – 140 = 520 m3/day

Evaporation Achieved – 100 m3/day

Conc. Spent Wash Generated - 420 m3/day

The ready yeast “seed” is then transferred from culture vessel to fermenter. The molasses is diluted by process water. The glucose in the Feed media gets converted to ethanol, in each of the 4 Fermenters operating in Batch mode. A plate heat exchanger and a circulation pump are provided to each fermenter, which will continuously re-circulate the Fermenting Wash through PHE for maintaining the Fermenters at 30 deg C. The nutrients, biocide, acid and anti-foam agents are fed to the fermenters as per process requirement. The CO2 liberated during fermentation is sent to CO2 Scrubber for recovery of ethanol otherwise being lost in vent. The Fermented Wash is then sent to the Clarification Tank equipped with Lamella Separator. The settled sludge is sent to Sludge Washing Tank for recovery of alcohol.

3.MULTIPRESSURE DISTILLATION (RS) The fermented wash is fed to CO2 stripper column to remove CO2 gas present in wash. Alcohol is stripped off water in stripper column. Bottom of Stripper (Spent Wash) is fed to Integrated Evaporator. Conc. Spent Wash is then fed to Biogas Plant. The top vapours [alcohol + water] are fed to Calendria. Distillate from Calendria is pre-heated before being fed to rectifier column. In rectifier column RS is taken out from top tray. The impure spirit

from top of CO2 stripper column, rectifier column, fed to fusel oil column. The final impure spirit cut is taken out from the fusel oil column and partly alcohol is recycled to rectifier column. The alcohol containing fusel oil from rectifier column is fed to fusel oil column.

Rectification column works under pressure. The CO2 stripper, stripping column, works under vacuum and fusel oil column works under atmospheric condition.

The Distillation system is designed for premium quality extra neutral alcohol. The system details are as below:

The system consists of 8 main columns, namely, CO2 Stripper, Stripper Column, Pre-rectifier Column, Extraction Column, Rectification Column, Refining Column, and Fusel Oil Column.

Top of the Pre-rectifier column are fed to Reboiler of Refining Column and part of the distillate from pre-rectifier column is fed to extraction column after dilution where process water is used as dilution water and remaining return back as a reflux. In extraction column most of the high boiling impurities separate from ethanol in presence of water. The bottom ethanol water mixture is pre-heated before being fed to rectifier column. Top vapours of Rectifier column are fed to Stripper Reboiler as a heat source. In rectifier column product rectified spirit is taken out from top tray and fed to refining column where mainly methanol impurities are separated. Pure ENA is obtained at bottom of Refining column, which is cooled and stored. The impure spirit from top of CO2 stripper column, extraction column, rectifier column and refining column are fed to FO column. The final impure spirit cut is taken out from FO column top and balance alcohol is recycled to pre-rectifier column. The alcohol containing fusel oil from pre-rectifier and rectifier column is fed to fusel oil column.

The rectifier column, fusel oil column, HC column and pre-rectifier column get heat from steam at 3.5 bar (g).

Rectification column and pre-rectifier column works under positive pressure. The top vapours from rectifier column are condensed in stripper column for giving heat to stripper re-boiler. Most of the other columns work under vacuum.

The Distillation process is operated through PLC.

The distillation system also is operated with Ethanol (Fuel Alcohol) mode with feed to fuel alcohol plant given directly from the pre – rectifier column

Raw materials and other products use in proposed distillery

(Existing 60 KLPD & after expansion to 70 KLPD)

BLOCK DIAGRAM of 70 KLPD PROPOSED PLANT

Steam 216 MT

CO254 MT

Process Fresh

Water 245 KL Distillation Molasses Fermented Fermentation RS ENA 260 MT Wash 660 KL

Ethanol

Alc + Water Vap

Biogas to Boiler Spent Leese 70 KL

Spent Wash

Evaporator Bio-Gas Plant 520 KL Spent Wash

Process Condensate Water 100 KL Treated with Physiochemical treatment

TRSW 420 KL

Bio-Composting Processing

Treated Water Used for Process (170 KL)

ADDTION OF EQUIPMENTS FOR CAPACITY ENHANCEMENT ARE AS FOLLOWS:

I. Fermentation Section: To convert the existing “Continuous Fermentation System” into “Fed Batch System” to increase Alcohol content in Fermented Wash from 10.5 % to 11% v/v

1. Supply & installation of 1 No. of Pre-Fermenter with a capacity of 60 m³ and increasing the capacity of existing Pre-Fermenter from 30m³ to 60m³. 2. Supply & installation of 1 No. New (4th) Fermenter capacity of 362 m³ 3. Supply & installation of new PHE 4. Supply & installation of 1 No. Clarified Wash Tank (CWT) with capacity of 100 m³ 5. Supply of all required pipe fittings, valves & flow meters etc. to convert Continuous Fermentation System” into “Fed Batch System”

“Advantages of Fed Batch Fermentation”

 High Brix fermentation & more Alcohol % in wash i.e 11% to 12% v/v, when compared to Continuous Process 8% to 9% v/v.  For every batch fresh culture is to be added. This will avoid bacterial contamination.  Changing process parameter for every batch depending on the Molasses characteristic.  Minimize the acid formation in Fermentation Media for getting good quality of Alcohol & to increase the yield.  Due to increase in the Alcohol % in wash, the plant capacity will be increased by 10 to 15%. However the steam requirement remains same.  The generation of spent wash will be reduced by 3 to 4%.  The term fed signifies that fed is provided at a required rate to fermentation system without getting accumulated.  Simple to operate.  Proper control on operating parameters.  Optimum efficiency can be achieved.

II. Distillation Section:

1. Supply & installation of Reboiler for existing refining column to increase the heating Surface area.

2. Increasing 4 Nos of trays in existing stripper column. 3. Supply & installation Reboiler for existing stripper column.

4. Supply of new pump to transfer the existing CO2 stripper to stripper column due to increase in height of stripper column. 5. Supply condenser on stripper vapours to maintain the stripper vacuum. 6. Pre-rectifier top vapor ducting to be changed to handle the increased alcohol vapours.

7. New pump unit installation for stripper column to handle the increased volume due to increase in capacity. 8. Supply & installation of 1 No Vacuum pump & motor for higher capacity.

III. Evaporator: Addition of degasifying section to handle the Biomethanated spent wash. 1. Supply & installation of De-Gasifier column for the purpose of removal of dissolved gases. 2. Supply & installation of BMSW feed pump & motor to existing degasser column. 3. Supply & installation of piping, valves, ducting, flow meter, LT etc. 4. Supply & installation of Condensers of 60m² & 25m² 5. Supply & installation of PHE 2 Nos one for Biomethanated spent wash Pre-Heater & another one for Re-Boiler. 6. Supply & installation of vacuum pumps (2 Nos) with a capacity of 725 m³/hour

IV. Distillation Cooling Tower: Supply & installation of new pump unit capacity from 950 to 1200 m³/hour

Conclusion:

Presently you are preparing fermented wash and distilling 640000 liters per day to produce 60000 liters. However after caring out all necessary additions, alterations & modification in the plant as stated above, SDL will be able to produce as per below production combinations;

ENA + FA = 70000 liters/day

RS + FA = 70000 liters/day

Apart from this generation of spent wash per liter of spirit will be around 6 liters instead of 7 liters by making the existing evaporator operation system in series.

Presently 60 KL plant is generating 420 m³/day spent wash whereas after addition & modification for 70 KL plant capacity, the spent wash generation will be 420m³/day same as previously 60 KLPD plant.

4.0 Makes of bought out items (under R.S./ENA) D.O Copper - Alcobax / Multimetal SS & MS Sheet - SAIL/Tata/Jindal SS Tubes - Ratnamani/Divine GI nut & bolt - Tata / GKW MS channel, beams, angles - SAIL/Tata HDPE pipes - Hasti/Nocil C.S.Pipes - Tata PHE - Alfa-Laval/GEA/Tranter Centrifugal Pumps - Microfinish/Kirloskar/KSB

Motors - Crompton/Siemens Valves - Audco/intervalve/Saunder/Aqua (Ball/butterfly/Gae/Globe Control Valves - Keystone/Dembla/RK Air blower & vacuum pump - PPI PRDS - Forbes Marshall/Arca/Precision controls Rotameter - Eureka Temp. sensors - Eureka/Radix/Pyro Pressure Indicator - H. Guru/Wika Pressure, Temp.level, flow Transmitter - Emersion/E.&H Flow meter (Turbine) - Toshniwal/Rockwin PLC - Allen Bradlley/Siemen/ABB/Microset PC with monitor printer - IBM/HP/Compaq Variable frequency drive - Hitachi/ABB/Toshiba/L & T Electrical cable - Finolex/CCI/Polycab Instrument Cable - Polycab/Gemscab *Supplier will submit & get approval of makes from sugar factory/its inspection agency.

Project Cost for expansion of Distillery Plant capacity from 60 KLPD to 70 KLPD. I - Fermentation House Expansion Work

Sl Approx Value of Description Remarks No Project Cost (`) 1 SS 304 Fermenter Tank Capacity -350 m³ 2220000.00 Fermenter tank Centrifugal Pumps with Motor 2 315000.00 Model: 150/26N (2 Nos) 3 Fermenter & Pre - Fermenter Plate Heat Exchanger 1000000.00 Magnetic Flow Meter for F3, F4 & pre - Fermenter 4 3150000.00 tank Digital Variable Area Flow Meter for pre - 5 20000.00 Fermenter Tank Consumable Materials including Welding Rod & 6 150000.00 Gas Pipe & Pipe Fittings including Butterfly Valves & 7 600000.00 Ball Valves 8 SS 304 Ejector 180000.00 9 SS 304 Pre-Fermenter Tank Capacity -60 m³ 325000.00 10 Pre - Fermenter Tank Pump with Motor 350000.00 Total- A 4575000.00

II - Distillation Plant Expansion Work for De-Gasifier Column Sl Approx Value of Description Remarks No Project Cost (`) 1 Civil Foundation for De-Gasifier Column 2000000.00 De-Gasifier Column & Vent Condenser 2 2100000.00 MOC:SS 304 3 SS 304 Re Boiler with Pipe Ducting 1050000.00 4 SS 304 Ducting Pipe 250000.00 5 Kirloskar make centrifugal Pumps with Motors 650000.00 Pipe & Pipe Fittings including Butterfly Valves & 6 3500000.00 Ball Valves 7 De-Gasifier Column Plate Heat Exchanger 500000.00 8 Vacuum Pumps with Motors 750000.00 De-Gasifier column control Valves 9 350000.00 Make :Samson (3 Nos) 10 Level Transmitter Make : Yokogowa (2 Nos) 260000.00 11 PLC Materials 175000.00 Temp Gauge, Pressure Gauge, Diapram Gauge & 12 40000.00 Vacuum Gauge etc 13 De-Gasifier Column Structure Building work 1500000.00

Total -B 13125000.00

Total (A+B) 17700000.00

EXISTING & PROPOSED ENVIRONMENTAL MANAGEMENT PLAN (EMP) Treatment of Distillery Spent Wash The existing Distillery plant capacity is 60KLPD and the spent wash generated per liter of alcohol is maximum 7.0-7.5 liters. However with the changes / optimization made in our fermentation & Evaporation plant we are generating about 6.0 liter of spent wash per liter of Alcohol.

We have changed the Continuous fermentation process to Fed Batch system where the spent wash generation is reduced, further to this we are concentrating the Biomethanated spent wash in distillation column re-boiler so there will be further reduction in the spent wash generation. The process condensate generated will be treated through Physio Chemical treatment and recycled back to process plant.

We propose to increase the Distillery capacity from 60 KLPD to 70 KLPD and we have adequate Spent wash treatment facility in existing Effluent treatment Plant.

The spent wash is Anaerobically treated in the digester. During this anaerobic degradation, the organic matters are converted into Bio-gas (55% contains methane) which brings down the BOD value to 7000 – 8000 mg/lit, from the original level of about 45000 – 50000 mg/lit. The generated Bio-gas is used as fuel in the boiler of our parent sugar factory.

Further, the concentrated spent wash is utilized for Bio-composting using sugar factory press mud, boiler ash and other waste bagasse to produce useful organic manure.

Bio-composting Process:-

In the Bio-composting system, the process is carried out on a concrete floor yard by aerobic windrow technology using special aerobic microbial culture. The sugar industry press mud, boiler ash, waste bagasse and yeast sludge from the distillery are mixed suitably and bio-activated on the concrete floor. The reaction is an exothermic one which helps to evaporate the water content and gasses. The necessary windrow moisture for the process is maintained by spraying of concentrated treated RSW through tanker on the windrows uniformly and aerotiller machine is used to turn the material, the composting process is aerobic condition. The Bio-composting process would take about 60 days for completion and the ready Bio-compost manure is enriched and distributed to the farmers.

Thus, the entire spent wash generation during the alcohol production will be converted into valuable Bio-compost manure. This environmental management plan is of “ZLD” (Zero Liquid Discharge) Environmental concept of Pollution Control Boards.

Spent Lees & Process Condensate Water Treatment Plant System

Spent lees and the process condensate water is generated in the range of 200m3/day we are treating this effluent through the most advanced treatment technique i.ephysio- chemical treatment and treated water is reused in the process plant.

Waste Water Generation From Existing & Proposed Distillery

The source of waste water generation from the existing and proposed distillery unit is as below:

Sl.No. Waste Water Source Qty. in Mode of Disposal (M3/day) 01 Sewage water Domestic 3.20 Fed to Septic tank & soak pit 02 Spent wash Process 420.00 Bio-metehanization followed by Bio-composting 03 Spent lees Process 80.00 Treated with physiochemical treatment reused in process plant 04 Process condensate process 120.00 Treated with physiochemical treatment reused in process plant

Note :- There is no difference b/w Existing and proposed waste water generation. Solid Waste Generation from the Existing & Proposed Distillery

Sl. Solid Waste in MT No. Existing 60 KLPD Proposed 70 KLPD Mode of Disposal

01 20 .0 26 .0 Mixed with Bio-composting

EXISTING AND PROPOSED ENVIRONMENT MANAGEMENT PLAN (EMP) FLOW DIAGRAM

Raw Spent Wash

Anaerobic Digester

Re-Boiler/ Evaporation

Concentrated Process Spent Wash Condensate

Storage Treated with Physio- chemical Treatment Lagoon

Reused in Process Section

Bio-Composting Press Mud from Process Sugar Factory

Compost Manure to Farmers

Annexure - I (c)

NORTH

MAIN GATE 147000 10000 377999 43000 40 KL DIESEL FITTERS ROOMS ELE ROOM

2100 38613 1500 STORAGE TANK FENCING LINE

GARDEN DRAINAGE GARDEN 6000 RAMP COLLECTION 15000 74000 10 MTR WIDE COMPOST ROAD PIT MOLS. D D D BLOWER 10000 ROOM KSBCL COMPRESSOR T-421 A STORAGE

GARDEN TANK 21000 OFF. SHED T-422 T-422 T-422 FA-02 19518

FA FA FA 01 28000 EXE. TANK TANK TANK T-421 A F.A.DAY Capacity SMAT Reactor OFF. C B A FA-01 19500 6000 MT 1500 STORAGE DG SET 25000 T-421 A STORE TRO STORAGE TANK 30000

35000 35220 GREEN BELT PLANTATIONSECURITY CABIN SHAMY UNIT FA-03 Ø24000 Ø DISPENSING 04 2500x2500 TREE CAR WATER HOUSE Godown Rain Water Harvesting Pit SERVICE POINT General Store 8600 GARDEN 18500 FERMENTATION LOADING 02 8500 10000 PLAT FORM RAMP PLAT FORM WATER GARDEN TANK 4000 GATE LOADING MOLASSES 05 10 MTR WIDE ROAD 40 MT WEIGH BRIDGE 10 MTR WIDE ROAD 10 MTR WIDE ROAD GARDEN SHED PLAT FORM 20000 STORAGE TANK CABIN 2000 x 3000 RAMP Capacity GARDEN 6000 MT 600x 600 DRAINAGE NEEM TREE CHAMBER T-424 DYKE WALL 4500 3 MTR HEIGHT 24000 37638 6000 RS Ø

12000 DE-GASSEFIER TANK VEHICLE SHED T412 T412 COLUMN

115900 ENA 4000 10000 1500 2250 ENA ENA TANK

15000 MOLASSES 10000 COOLING TOWER WEIGH BRIDGE CABIN TANK TANK B DISTILLATION A RECEIVING B PLANT 18000 PANEL ROOM General Store General Store IS- 403 T-405, IS-01 MCC 5000 Room TANK 2000 T-411 T-401 13900 Godown Godown T412 T402 ENA B IS-02 ENA-1 RS-1 20000 TANK T-423 10 MTR WIDE ROAD

T-404 Lab

RAMP 10000 ENA RS FO TANK TANK TANK IS -T414 IS-03 DS-1 A A ENA-2 RS-2 T-413, IS-01

24000 18000 GARDEN OFFICE FOR DISTILLERY ENA DISTILATION Pre-aeration TANK OFFICE Tank IS-02 DS-2 ENA-3 RS-3 GARDEN

FERMENTATION 2350 IS-03 COOLING STORE GODOWN Clarifier GARDEN GARDEN DRAINAGE Existing Drain TOWERS 8500 03 22000 MOLASSES Biomethanated Effluent Sump Pump 06 Pad 24400 STORAGE TANK Capacity 36500 44000 14700 6500 MT 16500 20000 15000 Pump R.S.& ENA Pad DAY STORAGE DYKE WALL Buffer Tank-I Rain Water Harvesting Pit 3 MTR HEIGHT Ø24000 GARDEN Buffer Tank-II GREEN BELT PLANTATION FENCING LINE GARDEN

Aeration Fountain FEED Pump House TANK C h a n n e l

512500

OTHERS TANKS DAILY STORAGE TANK BULK STORAGE TANK TANK CAP. SL.NO FLUID QTY TANK CAP. DIMENSIONS FLUID CODE NO. QTY EACH DIMENSIONS FLUID CODE NO. QTY TANK CAP. DIMENSIONS Unit 01 550 CU.MTR(800MT) RS TANK T-402 1 NO 950 CU.MTR Name of Units Size MOLASSES DAY STORAGE 1 NO [ RS TANK T-401A 3 NOS 70 CU.MTR [ No. [ ENA TANK EXISTING- 2Nos.A T-412 3 NO 950 CU.MTR 1 Aeration Fountain 4100 Ø All Dimensions Are in mm 02 FERMENTER TANKS 350 CU.MTR PROPOSED -1No.B [ 4 NOS [ ENA TANK T-411 3 NOS 60 CU.MTR [ FA TANK- A T-422 1 NO 2 Channel (2 Nos) 750 Wide 850 CU.MTR [ Project :- DISTILLERY & ETHANOL PLANT ( 60 KLPD ) 03 REC. MOLASSES TANK 1 NO 800 CU.MTR (1100MT) 20000x20000x2000 IS TANK T-405 3 NOS 20 CU.MTR 3 Feed Tank 11500 Ø x1500 SWD+500 FB [ FA TANK- B & C T-422 2 Nos 950 CU.MTR [ 4 Buffer Tank (2 Nos) 12500x8000x3000 SWD+500 FB SIDDAPUR DISTILLERIES Name Date 04 TRO STORAGE TANK 1 NO 10 CU.MTR ; IS TANK T-413 3 NOS 20 CU.MTR IS TANK T-403 1 NO 100 CU.MTR [ [ 5 SMAT Reactor 32100 dia, 9000 liquid height, 11000 Total height Drawn Dayanand 01/05/03 IS TANK T-414 1 NO 150 CU.MTR 05 MOLASSES STORAGE TANKS 2 NOS 6000 MT RS TANK T-424 1 NO 150 CU.MTR [ 6 Pre-aeration Tank 4400 Ø x3500 SWD+500 FB LIMITED ; [ Checked DS TANK T-404 2 NOS 70 CU.MTR 7 Clarifier 7100 Ø x3000 SWD+500 FB 1 NO VICE 06 MOLASSES STORAGE TANK 6500 MT ; FUSEL OIL TANK T-423 1 NO 10 CU.MTR [ [ ENA TANK T-413 A 1 NO 249 CU.MTR 8 Biomethanated Effluent Sump 5000x5000x2000 SWD+500 FB SIDDAPUR PRECIDENT [ APPROVED FA TANK T-421 A 3 NO 60 CU.MTR ENA TANK T-413 B 9 Blower Room 4000x5000 [ 2 NOS 190 CU.MTR [ TOTAL 10 MCC Room/ Lab 10000x4000 Scale Title Drg. No. 17 NOS 850 CU.MTR TOTAL NOS OF TANKS 14 NOS 7569 CU.MTR 1 : 500 SDL/DSTL/002 - R1 Revision Master Plan of Distillery Plant (60 KLPD) R 1 SHEET NO - NO OF SHEET