REVISED PRE- FEASIBILITY REPORT For RADICAL BIO-ORGANICS LIMITED (Distillery plant expansion from 60 KLPD to 90 KLPD) In Sy.Nos. 36, 38, 41 & 43 of Jekkepally Village, Yalal Mandal, Vikarabad (Earlier Rangareddy District) District, Telangana. PREPARED BY ISO 9001: 2008 Certified Accredited by 6-3-652 | Flat # 7-3 | Dhruvatara Apartments | Amrutha Estates | Erramanjil | Somajiguda | Hyderabad- 82 | E mail: [email protected], [email protected]|www.pioneerenvirolabs.com | PEOPLE WHO CARE FOR ENVIRONMENT | SAVE ENVIRONMENT | INDEX S.NO ITEM PAGE NO 1. EXECUTIVE SUMMARY 2 2. INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION 5 3. PROJECT DESCRIPTION 10 4. 21 SITE ANALYSIS 5. 22 PLANNING BRIEF 6. 23 PROPOSED INFRASTRUCTURE 7. REHABILITATION AND RESETTLEMENT (R & R) PLAN 25 8. PROJECT COST 26 9. ANALYSIS OF PROPOSALS (FINAL RECOMMENDATIONS) 27 Pre-feasibility Report P a g e | 1 1.0 EXECUTIVE SUMMARY Radical Bio-Organics Limited was obtained Environmental Clearance from MOEF&CC New Delhi vide order F.No.J.11011/57/2010-IA II (I) dated 05/10/2010 and 12/10/2012 for 60 KLPD Distillery plant and 7.0 MW Biomass based captive power plant in Sy.Nos. 36, 38, 41 & 43 of Jekkepally Village, Yalal Mandal, Vikarabad (Earlier Rangareddy District) District, Telangana. Total land already in possession of the management is 27.28 acres. 60 KLPD plant commenced operation from November 2012. Consent to Operate are being obtained from TSPCB regularly and the latest CTO is valid till 31/08/2019. Now the company proposed to enhance the distillery plant capacity from 60 KLPD to 90 KLPD in the same premises by doing process modifications and Distillation columns modifications. The following is the summary of the proposed expansion project. S. NO. PARAMETERS DESCRIPTION 1. Plant capacity for which Distillery : Environmental Clearance obtained RS/ENA/Ethanol – 60 KLPD from MOEF&CC & CTO obtained Co-gen power – 7.0 MW from TSPCB. 2. Proposed Enhancement proposal Distillery (capacity enhancement from 60 KLPD to 90 KLPD (Capacity enhancement will be achieved through by doing process modifications and Distillation columns modifications) 3. Total land already in possession 27.28 acres 4. Sy. numbers of the total land 36, 38, 41 & 43 5. Expansion Project cost Rs. 2.0 Crores 6. Water requirement a. Water requirement for existing The water requirement for 60 KLPD distillery and 7MW plant Power plant is 1077 KLD. b. Water requirement for the 90 KLPD There will be no increase in water requirement due to plant the present enhancement. The total water requirement for 90 KLPD distillery and 3 MW power plant will also be 1077 KLD, which is being taken from Kagna river. c. Source of water Permission for drawing of water from Kagna river has already been obtained from Irrigation Department, Government of Telangana. Pre-feasibility Report P a g e | 2 7. Waste water generation a. Spent wash – Thin Slop quantity 360 KLD from the 60 KLD distillery for which Environmental Clearance obtained b. Spent wash – Thin Slop generation The total spent wash generation from 90 KLPD distillery from the 90 KLPD plant will also be 360 KLD and there will be no increase in spent wash due to the proposed capacity enhancement. 8. Effluent treatment for 60 KLPD The thin slop generated from the distillery will be treated in Multiple Effect Evaporators to concentrate the solids to 30% w/w. Thick slop from MEE and wet cake from Decanter will be taken to a drier and will be dried to 90% solids concentration which is known as DDGS. 9. Effluent treatment for The existing spent wash treatment system, non process enhancement proposal effluent treatment systems are adequate to treat the effluents from 90 KLPD capacity also. 10. Steam requirement for existing Steam requirement for 60 KLPD distillery plant and 7MW plant power plant is sourced from 37 TPH Boiler. 11. Steam requirement (enhancement) Management has decided to reduce the boiler capacity from 37 TPH to 27.25 TPH, thereby the power generation capacity will also reduced to 3 MW. Hence the steam requirement for 90 KLPD distillery and 3MW power plant will be sourced from 27.25 TPH Boiler. 12. Air emissions (existing) Emissions from Boiler are Particulate matter, SO2 and NOx. Electro Static Precipitator is provided to 37 TPH Boiler to bring down the particulate matter in the exhaust flue gases to below 50 mg/Nm3. The exhaust flue gases from the boiler discharged into the atmosphere through a stack of 43 m height for effective dispersion of gases into the atmosphere. 13. Air emissions (enhancement) The same existing control system is adequate for 27.25 TPH Boiler. Hence no increase in fuel for the boiler and no increase in air emissions from the boiler. 14. Solid waste generation DDGS – sold as cattle/Fish/Prawans feed. (existing) Ash generated from the boiler is being giving to brick Pre-feasibility Report P a g e | 3 manufacturing units. 15. Solid waste generation Additional DDGS generated due to the enhancement (expansion) proposal will be – sold as cattle feed. There will not be any additional storage of DDGS due to the enhancement proposal. Since the boiler capacity is reduced to 27.25 TPH boiler, which is adequate for 90 KLPD also, no additional fuel consumption. Hence no additional ash generation due to the enhancement proposal. Pre-feasibility Report P a g e | 4 2.0 INTRODUCTION 2.0 Introduction Ethanol is a clear, colorless liquid with a characteristic, agreeable odour. In dilute aqueous solution, it has a somewhat sweet flavor, but in more concentrated solutions it has a burning taste. Ethanol melts at - 114.1°C, boils at 78.5°C, and has a typical density of 0.789 g/ml at 20°C. Ethanol has been made since ancient times by the fermentation of sugars. All the beverage ethanol, and more than half of industrial ethanol, is still made by this process. Simple sugars are the raw materials. Enzyme from yeast, changes the simple sugars into ethanol and carbon dioxide. Starches from potatoes, corn, rice, wheat, and other grains can also be used in the production of ethanol by fermentation. However, the starches must first be broken down into simple sugars. The Enzymes used in Liquefaction & Saccharification stages help convert the starches into sugars, which can then be fermented using appropriate Yeast to convert into Ethyl Alcohol (Ethanol), grades of Extra Neutral Alcohol (ENA) or Rectified Spirit (RS). This Ethyl Alcohol (Extra Neutral Alcohol / Grain Neutral Spirit may also be utilized for Blending & Bottling and Potable purpose for making IMFL / IMIL / Liquors, etc. Present Grain Spirit / Ethanol Production in Telangana: 1) Radical Bio-Organics Limited : 60 KLPD 2) Haritha Bioproducts : 60 KLPD 3) Sasta Biofuel : 120 KLPD 4) Nadhi Bioproducts : 75 KLPD 5) EMPEE Distilliries : 60 KLPD 6) NSL Krisnaveni : 120 KLD 7) Madhuon : 65 KLD Total Production of Grain ENA / Ethanol is presently estimated as 1.34 Crore Liters per month against the State’s demand of 1.5 Crore Liters per month. Hence, there is a scope of expansion Distillery to be set up to cater to Telangana. Hence, our company having focus on Bio-Fuels & Bio-Chemicals based on Absolute Alcohol (Ethanol) are envisaging to set up this multi-grains / multi-product project in Telangana State, which is presently short of capacity and needs several such projects for meeting the state’s demand in future. 2.1 Identification of project and Project Proponent Radical Bio-Organics Limited is operating 60 KLPD Grain based distillery and 7.0 MW Biomass based captive power plant in Sy.Nos. 36, 38, 41 & 43 of Jekkepally Village, Yalal Mandal, Vikarabad (Earlier Rangareddy District) District, Telangana. The existing plant has procured land of 27.28 acres envisaged for Pre-feasibility Report P a g e | 5 establishment of 60 KLPD distillery and Biomass based captive power plant. Now management decided to Enhancement of distillery plant production capacity from 60 KLPD to 90 KLPD by doing process modifications and Distillation columns modifications & Reduction power generation capacity from 7 MW to 3.0 MW. The Promoters The proposed expansion project of the Ethanol Plant would be undertaken & implemented by the management of ‘Radical Bio-Organics Limited. The promoters are experienced in operating the existing 60 KLPD unit & have made a thorough study of entire project, planning as well as implementation schedule. The names and designations of the Promoters are as under: S.NO NAME DESIGNATIONS 1. Sri.Salike Sanjay Managing Director 2. Sri. Buyyani Srinivas Reddy Executive Director 3. Sri.Aravapalli Venu Executive Director 4. Sri.Mahesh Reddy Koppula Director 5. Sri. Satish Kumar Palabatla Director 2.2 Brief Description of nature of Product: The Bio-energy industry across the world has the potential to make significant contributions to meet the world’s energy needs. In India, Bio-energy can contribute towards achieving the country’s energy security and help reduce the dependence on fossil fuels. Large possibilities exist for biomass resources, in particular energy crops to penetrate into Power Generation, Transport Markets, Pharmaceutical Markets and Potable alcohol markets. This proposed expansion project of Radical Bio-Organics Limited aims to be part of the Agro-Based Industry for manufacturing Rectified Spirit/ ENA / Ethanol by using agricultural not for human consumption crops such as Maize, Sorghum grain, broken rice and starch based cereals. 2.3 Demand – Supply Gap: Alcohol has assumed very important place in the Country’s economy. It is a vital raw material for a number of chemicals. It has been a source of a large amount of revenue by way of excise duty levied by the Govt. on alcoholic liquors. It has a potential as fuel in the form of power alcohol for blending with petrol & Diesel.