EIA & EMP for 100 MW Thermal Power Plant at Delhienvironmentclearance.nic.in/writereaddata/Online/TOR/28_Nov_2017... · The total power requirement for the Sunlight Bio Fuels Project

Prefeasibility Report for Biomass Based Renewable Fuel Plant at Bhikhpur

village of Sitapur District in Uttar Pradesh

1

Pre-Feasibility Report

BIOIOMASS BASED RENEWABLE FUEL PLANT

Project Proponent:

M/s Sun Light Fuels Pvt. Ltd.

Village Bhikpur,Tehsil Hargaon, DistrictSitapur, U.P.

2017



2

CONTENTS

1 EXECUTIVE SUMMARY .................................................................................................................. 4

2 INTRODUCTION ............................................................................................................................... 6

2.1 BRIEF DESCRIPTION OF THE PROJECT ........................................................................................... 6

2.2 PROJECT PROPONENT: ................................................................................................................. 6

2.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO REGION ............................................................. 6

2.4 DEMANDS-SUPPLY GAP ................................................................................................................ 7

2.5 DOMESTIC/EXPORT MARKETS: ...................................................................................................... 8

2.6 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT ..................................... 9

3 PROJECT DESCRIPTION .................................................... ERROR! BOOKMARK NOT DEFINED.

3.1 TYPE OF PROJECTINCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS, IF ANY ..................... 9

3.2 LOCATION (SPECIFIC LOCATION AND PROJECT BOUNDARY & PROJECT LAY OUT) WITH COORDINATES9

3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING THE PROPOSED SITE,

PARTICULARLY THE ENVIRONMENTAL CONSIDERATIONS GONE INTO SHOULD BE HIGHLIGHTED ................. 10

3.4 TECHNOLOGY AND PROCESS DESCRIPTION ................................................................................. 10

3.5 MANUFACTURING PROCESS: ....................................................................................................... 14

3.6 BRIEF DESCRIPTION OF MANUFACTURING PROCESS: .................. ERROR! BOOKMARK NOT DEFINED.

3.7 RAW MATERIALS ......................................................................................................................... 16

3.8 ADDITIVES AND CHEMICALS ......................................................................................................... 17

3.9 RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY, LIKELY SOURCE, MARKETING AREA OF

FINAL PRODUCTS, MODE OF TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCT. ............................. 17

3.9.1 Transportation details of Raw Materials .............................................................................. 17

3.10 AVAILABILITY OF WATER ITS SOURCE, ENERGY/POWER REQUIREMENT AND SOURCE SHOULD BE

GIVEN 18

3.10.1 Fuel .................................................................................................................................. 18

3.10.2 Quantity of waste to be generated (liquid and solid) and scheme for their management

/disposal 18

3.10.3 Waste Water Generation and utilization: ......................................................................... 18

4 SITE ANALYSIS ............................................................................................................................. 22

4.1 CONNECTIVITY ............................................................................................................................ 22

EINVIRONMENTAL SENSITIVITY .............................................................................................................. 22

4.2 CLIMATIC DATA FROM SECONDARY SOURCES ............................................................................... 23

1.1.2. Climate & Rainfall ............................................................................................................... 25

1.1.3. Seismic Considerations ...................................................................................................... 26

5 PROPOSED INFRASTRUCTURE .................................................................................................. 27

5.1 INDUSTRIAL AREA (PROCESSING AREA) ........................................................................................ 27

5.2 RESIDENTIAL AREA (NON-PROCESSING AREA) .............................................................................. 27

5.3 GREEN BELT ............................................................................................................................... 27

5.4 DRINKING WATER MANAGEMENT (SOURCE & SUPPLY OF WATER) .................................................. 27

5.5 SEWAGE SYSTEM ........................................................................................................................ 27

5.6 INDUSTRIAL WASTE MANAGEMENT ............................................................................................... 27

5.7 POWER REQUIREMENT & SUPPLY/ SOURCE .................................................................................. 28



3

6 REHABILITATION AND RESETTLEMENTS (R& R) PLAN .......................................................... 29

6.1 POLICY TO BE ADOPTED (CENTRAL/STATE) IN RESPECT OF THE PROJECT AFFECTED PERSONS

INCLUDING HOME OUSTEES, LAND OUSTEES AND LANDLESS LABOURERS (A BRIEF OUTLINE TO BE GIVEN) 29

7 PROJECT SCHEDULE AND COST ESTIMATE ............................................................................ 30

7.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATA OF COMPLETION (TIME SCHEDULE FOR

THE PROJECT TO BE GIVEN) .................................................................................................................. 30

7.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC VIABILITY OF THE

PROJECT. ............................................................................................................................................. 30



4

1 EXECUTIVE SUMMARY

M/s. Sunlight Fuels Private Limited’ is a company registered in India on November 25,

2014 having its registered office at M-58, Market, Greater Kailash-II New Delhi, India -

110048.

M/s Sunlight Fuel Private Limited‟ plan to set up a Bagasse to Fuels Plant based on

Integrated Hydropyrolysis & Hydro treating Technology developed by M/s GTI Des Plaines,

USA and licensed to M/s Sunlight Fuels by M/s CRI Criterion Marketing Asia Pacific

(CCMAP) PTE Ltd, a Shell Subsidiary.

The proposed plant is planned to be located in state of Uttar Pradesh at Village Bhikpur, Dist

Sitapur in proximity to an existing sugar plant. The proposed plant shall be initially designed

considering sugarcane bagasse as the feedstock; however, other feed stocks like rice husks,

wheat straws etc can also be processed on the unit depending upon the availability.

S. No. Parameter Description

1. Project Location M/s. Sunlight Fuels Private Limited, Village Bhikpur, District Sitapur, Lucknow, Uttar Pradesh

2. Category of Project as per EIA Notification &Amendments

Section 5(f) / Sector No 21 Screening Category “A”

3. Project Cost Rs. 1,234 Crore (1233.92 Crore)

4. Plot Area Total Land Area: 90 acres

5. Proposed Product Biomass Based Renewable Fuel Plant („DROP-IN‟ BIOFUELS : Petrol/Diesel: 1,75,000 Liters Per Day)

6. Plant Capacity Biomass/MSW: : 500 Metric Tons Per Day (Moisture and Ash Free Basis) The plant will be designed with the potential to convert 500 tons/day of dry biomass/MSW into approximately 150 tons/day of liquid hydrocarbon transportation „drop-in‟ fuels.

7. Land Requirement 90 Acres

8. (i) Electricity Requirement

Source & Requirement of Electricity

The total power requirement for the Sunlight Bio Fuels Project is approximately 9-MW.

(Captive power generation using process char to meet partial power and steam requirements for the complex.)

Source State Grid,and Captive Generation

D.G. Sets DG Set – 2.0 MW

(2.0-MW Emergency power has been considered through D. G. Sets)

9. (ii)Water Consumption Total Requirement :1200 KLD

Source of Water Sourced from Ground water / Bore well

Waste water Generation Industrial effluent of 38-m3/hr is generated and will be treated in ZLD System.



5

Mode of Disposal Zero Liquid Discharge (ZLD)

10. (iii) Boiler Char based Steam Boiler (26.4 TPH) @ 79.4 kg/cm2a

11. (iv) Fuel (for H2 Plant) LPG to be sourced through tankers.

Seven (07) days storage facility (mounted bullets) is to be considered.

12. Employment Generation

Construction Period- 350 persons

Operation Period- 100 person

13. Nearest Highway State Highway No.21 (SH-21),2.0KM, West

Nearest Railway Station Hargaon Railway Station, 0.85 kms, SSW

Nearest Airport Nearest Airport is Lucknow, 106.0 kms , S

Prefeasibility Report for Biomass Based Renewable Fuel Plant at

Bhikhpur village of Sitapur District in Uttar Pradesh

6

2 INTRODUCTION

2.1 Brief Description of the Project

The proposed M/s Sunlight Fuels Pvt. Ltd., plant is planned to be located in state of Uttar

Pradesh at Village Bhikpur, Dist Sitapur in proximity to an existing sugar plant. The

proposed plant shall be initially designed considering sugarcane bagasse as the feedstock;

however, other feed stocks like rice husks, wheat straws,MSW, elephant grass etc can also

be processed on the unit depending upon the availability.

2.2 Project Proponent:

1. Mr. Sunil Singhal is the Director of the company. He has more than45years of

experience in sugar industry. He is a much respected individual in the Indian sugar

industry having helped establish many sugar refineries in India. Mr. Singhal holds

several patents on sugar & alcohol processing technology and has published and

delivered many papers at conferences worldwide. He is B. Tech. in Chemical

Engineering from Indian Institute of Technology, Kanpur. Mr Singhal is the promoter of

Chemical Systems Technologies Pvt. Ltd. (CSTPL) an ISO – 9001:2008 certified

Company.

2. Mr. Chand Bihari Patodia : Director

3. Mr. Ashish Patodia : Director

4. Mr. Nishant Singhal : Director

2.3 Need for the Project and its Importance to Region

Bio diesel and bio ethanol have a distinct chemical nature and so they can be accurately

defined by their chemical composition alone. For example, bio ethanol is ethanol and

biodiesel is a fatty acid methyl ester (FAME). In contrast bio-fuels generally consist of a

mixture of many different types of hydrocarbons, the properties of which, just like petroleum

fuels, is typically characterized by the mixtures „functional characteristics such as , specific

gravity, distillation profile, molecular weight, viscosity, acidity, etc. A true bio-fuel should be

able to be readily-dropped into the existing petroleum infrastructure and be handled in much

the same way as petroleum fuels without requiring any significant infrastructure

adjustments.



7

Bio-fuels are currently attracting considerable attention. Some of the reasons are directly or

indirectly related to challenges to further increasing the markets for ethanol and biodiesel

bio-fuels such as their likely blend wall and supply constraints. Bio-fuels are better

positioned as they avoid blend wall concerns and also potentially make better use of

existing infrastructure (current inventory of petroleum refineries, supply channels and liquid

fuel powered combustion engines).

2.4 Demands-Supply Gap

GoI has set a goal of achieving 10% less import of crude and petroleum products by

2022.The bio-fuel projects will be able to fulfill this ambitious target by manufacturing in

India, using bio mass potentially available throughout the country. The current availability

of bio-diesel and bio ethanol is not sufficient to meet even 3.5% of the requirement for the

mandatory blending up to 10% which is proposed to be further increased to 20%. Only

such bio fuels as are proposed to be manufactured by this project can meet this vast gap.

During 2008-2013, global consumption of petroleum products (PETROL and HSD-64%

share in production) grew at 1.2% CAGR to 91.3 MBPD. Of these, light and middle

distillates grew at a CAGR of 1.5 and 1.3 %, respectively, while the consumption of heavy

distillates grew at a slower pace of 0.7%. Majority of the incremental demand in the past 5

years came from developing regions like Asia Pacific (4.5 MBPD), and Middle East (1.3

MBPD). Demand declined in most developed regions like the North America (-0.6 MBPD),

Europe and Eurasia region (-1.4 MBPD) due to a shift towards cleaner fuels and slower

GDP growth rates. While demand growth of non OECD countries slowed down to 3.1% y-

o-y, a 2% increase in demand from US (accounting for 21% of global petroleum product

demand in 2013) resulted in consumption remaining flat in OECD countries. Demand from

OECD countries declined by 1.1% y-o-y in 2012.

The crude oil demand shall record a CAGR of 1% during the next 5 years (as compared to

1.2%CAGR in previous 5 years) and reach 95.8 Million Barrel per day by 2018.



8

Region wise Oil Demand growth

2.5 Domestic / Export Markets:

Domestic petroleum product demand have picked up significantly by 3.2 % y-o-y in 2014-15,

as against a meager 0.6% y-o-y growth achieved in 2013-14. Diesel demand (accounting for

~43% of overall demand) is expected to be growth mode in the years to come due to

improvement in transportation activity and increase in consumption from the agriculture

sector (pump sets) due to the high probability of a poor monsoon. Along with diesel, healthy

growth in motor spirit Petrol will drive overall demand during the year.

As per various reports and market information available to us, from 2014-15 to 2019-20,

petroleum product demand is expected to grow at a faster pace of 4.7% vis-a-vis 3.4%

CAGR achieved in the previous 5-year period ending 2013-14. Demand for petroleum

products (Petrol and HSD-64% share in production)is expected to grow to 163.7MT in 2014-

15, as against 0.6% y-o-y growth seen in 2013-14 as mentioned above. Rise in growth rate

will be largely on account of higher demand for diesel, whose consumption fell during 2013-

14, as well as LPG and motor spirit (petrol).

Pick-up in transportation activity, on a y-o-y basis and higher demand from the agriculture

sector (for pump sets due to lower rainfall) would escalate diesel demand. However, diesel

consumption is expected to rise by 1-2% only as passenger car segment demand is likely to

dip, due to the narrowing price differential between diesel and petrol. Secondly, an

improvement in the power situation is expected to reduce industrial and household demand

for gensets, slower rise in commercial vehicle transportation activity, moderate growth in

sales of diesel cars as well as a contracting power deficit situation in India



9

In case of petrol, decline in petrol prices, reduction in gap between petrol and diesel prices

and healthy demand from the two wheeler segment (accounting for 2/3 of the total domestic

petrol demand) are some of the factors driving consumption. On a flip side slower rise in the

number of vehicles plying on petrol as well as improvement in fuel efficiencies will restrict

PETROL demand growth As per various report, in the long term, demand for petroleum

products (PETROL and HSD-64% share in production)is expected to rise at 4.7% CAGR to

~206-MTPA by 2019-20 vis-a-vis 3.4% CAGR recorded during 2008-09 to 2013-14.

2.6 Employment Generation (Direct and Indirect) due to the Project

The National Policy on Bio-fuels „released in 2009, foresees bio-fuels as a potential means

to stimulate rural development and generate employment opportunities, as well as aspires

to reap environmental and economic benefits arising out of their large scale use. The project

shall provide employment for 100 persons during operation phase and about 350 persons

shall be required during construction period of the project. Further Transport business,

vehicle drivers and attendants, repairing workshops, grocery and retail stores, school,

coaching centers, restaurants, self- employed persons like tailors, carpenters, plumbers,

electricians, etc will also get indirect employment / livelihood opportunity from this project.

2.7 Type of Project including interlinked and interdependent Projects, if any

The proposed project falls under „Section 5(f)’ / Sector-21 (Industries based on processing

of petroleum fractions & natural gas and/or reforming to aromatics) Production of Diesel

&„Category “A”. Proposed project is interlinked project.

Plant Capacity: The plant will be designed with the potential to convert 500 tons/day of dry

bio-mass into approximately 150 tons/day of liquid hydrocarbon „drop-in‟transportation fuel.

2.8 Location (specific location and project boundary & project lay out) with

Coordinates

The proposed project is located in Village Bhikpur, District Sitapur, Lucknow in Uttar

Pradesh. The site is located approximately at Latitude of 27°46.7‟ N and longitude

of80°43.8‟ E. Close view map of site showing coordinates is provided in Figure 3.1. Google

Map of 10 km area around the Project Site is shown in Figure-3.2.

The site is well connected by state highways (SH-81) and road network. It is located in

Lucknow. Nearest Railway station is Hargaon / Oel and nearest Airport is Lucknow. Plant

Lay Out provided in Figure-3.3.



10

2.9 Details of alternate sites considered and the basis of selecting the proposed site,

particularly the environmental considerations gone into should be highlighted

No alternate site considered due to availability of the raw material in proposed project

location. The proposed project is located in Village Bhikhpur, Tehsil / District Sitapur, in

Uttar Pradesh. The site is located approximately at Latitude of 27°46.7‟ N and longitude of

80°43.8‟ E.

The site is well connected by State Highways (SH-21)/SH-81 and road network. Nearest

Railway station is Hargaon / Oel and nearest Airport is Lucknow, hence no alternate site

considered.

2.10 Technology and Process Description

The process technology for the proposed plant is licensed to Sunlight Fuels Pvt. Ltd by

CCMAP, a Singapore-based affiliate of CRI Catalyst Company LP (CRI), a global catalyst

technology company of the Shell Group. This proprietary technology is licensed with name

„IH2 technology‟ which is based on continuous catalytic thermo-chemical process. This

technology converts agricultural, forest and sorted municipal residues into fungible

hydrocarbon transportation fuels.

“DROP IN” BIOFUELS: “DROP IN” bio-fuels are substitute for conventional fossil fuels(

Petrol/ Diesel/ ATF) that are completely interchangeable and compatible with conventional

fuels. A “Drop-in” bio-fuel doesn‟t require alteration or modification of the engine, fuel

system, or the fuel distribution network and can be used “ as is” in existing engines in pure

form and/or blended in any ratio with other fuels.

DESCRIPTION: Renewable hydrocarbon “ drop-in” bio-fuels are fuels produced from

Biomass/ MSW sources through hydro-catalytic pyrolysis route and are identical to the

Petrol/ Diesel /ATFin current use.“ Drop-In” refers to those renewable fuels that can be

readily put into an existing car/truck/ bus/ railway etc. engine, and used exactly as the

conventional fossil fuels without any further modification, and by using the existing

distribution infrastructure of the fuel outlets such as petrol pumps.

The “drop-in” bio-fuels shall conform at all times to the prevalent Indian BS standards ( IV.

VI) fixed by the Government of India for Petrol/Diesel/ATF.

Prefeasibility Report for Biomass Based Renewable Fuel Plant at Bhikhpur village of Sitapur District in

Uttar Pradesh

11

Figure-3.1: Location / Google Map of the Project Location


Uttar Pradesh

12

Figure-3.3: Plant Location (Google) Map


Uttar Pradesh

13

Figure-3.2: Plant Layout for the Proposed Project



14

2.11 Manufacturing Process:

The process technology for the proposed plant is licensed to Sunlight Fuels Pvt. Ltd by

CCMAP, a Singapore-based affiliate of CRI Catalyst Company LP (CRI), a global catalyst

technology company of the Shell Group. This proprietary technology is licensed with name

„IH2 technology‟ which is based on continuous catalytic thermo-chemical process. This

technology converts agricultural, forest and sorted municipal residues into fungible

hydrocarbon transportation fuels.

IH2 Technology

The IH2 technology is an efficient conversion route for agricultural and other residues

which allows for production of clean transportation fuels from renewable resources. The

process was developed by Gas Technology Institute (GTI) of Des Plaines, IL in 2009.

GTI and CRI have jointly continued development of the technology since 2010. CRI has

been granted exclusive worldwide licensing rights.

The IH2 process has four primary elements. The first is biomass conditioning i.e. sizing

and drying to 10 – 30wt% moisture. The second element involves hydro de-oxygenation of

the volatilized biomass to produce a raw hydrocarbon product over proprietary CRI

catalysts in the presence of low–pressure hydrogen. This serves both to remove oxygen

and cap reactive free radicals to provide a stable hydrocarbon product. The third element

is a fixed–bed hydro treater, which uses other proprietary CRI catalysts to polish the first–

stage product and transform it into a finished hydrocarbon fuel or blend stock.

The fourth element is a Hydrogen Manufacturing Unit (HMU), which converts light gases

generated in the first–stage to renewable hydrogen, in sufficient quantity to supply all

process needs.

Further details of the process are presented in the subsequent chapters.

Flow chart for liquid hydrocarbon transportation fuel manufacturing is shown in Figure-3.4

Process Description: Detailed process description is provided in Annexure-I

Prefeasibility Report for Biomass Based Renewable Fuel Plant at Bhikhpur village of Sitapur

District in Uttar Pradesh

15

Figure-3.4: Generalized Flow Chart for Liquid Hydrocarbon Transportation Fuel Manufacturing



16

2.12 Raw Materials

RAW MATERIAL – BIOMASS

The IH2 Process is very versatile; it can process almost any Biomass, including MSW

(Municipal Solid Waste). Thus, some of the possible feedstock biomass possible is;

List of Raw Material

Wheat Straw

Paddy Straw

Millet

Bagasse (from Sugarcane)

Wood Waste

Saw Dust

MSW

Elephant Grass

The key issue with any Biomass based project is the aggregation and the transport cost of

biomass because of its low bulk density. This cost can exceed the cost of the biomass itself if

the distances from the farm to the production facility are more than 50 km.

Keeping this in view the project is being almost co-located adjacent to an operating sugar mill of

12,000TPD sugarcane crushing capacity. The bagasse produced at this factory is 4,100

tons/day out of which 3000TPD is used in their boilers for their power and steam requirements.

Thus, it has been ensured that 1000TPD of bagasse will be readily available for the proposed

project. The bagasse coming from the sugar mill normally contains around 47-48% moisture

and 2-3% ash. Therefore, we have ensured that 500 TPD of bagasse MAF (Moisture & Ash

Free) will be supplied to the project.

Attached is the letter from Birla Sugar Mills, Hargaon committing the supply of bagasse.

Sugarcane is a seasonal crop, with the season running 150 – 180 days between late October

&April. Therefore, if the project were to be based on only bagasse as the feed input, then the

question arises for the feedstock supply for the balance 180 – 150 days for the 330 days/year

manufacturing schedule of the project.

There are two ways that this has been approached.

1. A 20 acre area is planned to store the bagasse for the sugarcane off-season period

where bagasse will be stored after buying from the other sugar mills in the area. This

has been mapped-out, please see the attached map that shows each and every village

in a 50 km radius and also shows the several sugar mills in this area. We have data of



17

all the cane farmers in this area, their land holding size, and quantity of cane cultivated

per season.

2. The other initiative is to grow Elephant Grass on marginal land by introducing an elaborate

programme of buying back from over 3000 farmers their output of Elephant Grass that will be

scientifically cultivated.

Elephant Grass can give 3-4 crops per year and requires very little amounts of water and

fertilizer.

The farmers will get a better income from Elephant Grass compared to their growing sugarcane

on that land. Plus, they will have an assured sale of their crop.

Two neighboring districts have been surveyed in detail and the whole programme drawn-up for

this initiative.

This alternate biomass will also hugely DE-RISK the project by not making it dependent on a

single source of raw material.

2.13 Additives and Chemicals

Ethanol

LPG

Nitrogen

Amine

Water Treatment chemicals

Tankage: Total -12 No's

Petrol/Gasoline – 3 No's

Diesel – 3 No‟s

Intermediate – 2 No‟s

Off Spec- 1 No‟s

LPG – 2 No‟s Mounded Bullets

Ethanol – 1 No‟s

2.14 Raw material required along with estimated quantity, likely source, marketing area

of final products, mode of transport of raw material and finished product.

2.14.1 Transportation details of Raw Materials

The transportation of raw materials will be done by trucks and trolley using local existing road

network.



18

2.15 Availability of water its source, energy/power requirement and source should be

given

Water Requirement & Source

The proposed project is located in Village Bhikhpur, District Sitapur in Uttar Pradesh. The site

is located approximately at Latitude of 27°46.7‟ N and longitude of 80°43.8‟ E.

Total water requirement will be 1200 KLD, which is sourced from bore well. Permission for

drawing ground water shall be obtained from concerned authority. Recycled treated water

shall be used in fire fighting and greenbelt development. Water Balance diagram is provided

in Figure 3.5.

Energy/Power Requirement

The total power requirement for the Sunlight Bio Fuels project is approximately 9-MW.

Captive power generation using process char to be considered for power and steam

generation for the entire complex.

2.0-MW Emergency power has been considered through Diesel Gen sets.

2.15.1 Fuel

LPG is considered to be available for H2 generation plant.

LPG is to be sourced through road tankers.

Seven (07) days storage facility (mounted bullets) is to be considered.

2.15.2 Quantity of waste to be generated (liquid and solid) and scheme for their

management /disposal

2.15.3 Waste Water Generation and Utilization:

Industrial effluent of 38-m3/hr is generated and will be treated in ZLD System. Part of the

treated effluent will be used for firefighting and horticulture purposes and rest of the treated

water shall be reused in process

Introduction

Several measures are proposed to be incorporated at the designs stage towards minimizing

the generation of wastewater and treatment of the generated effluent.

Some of these measures are described below:



19

Appropriate segregation and collection philosophy (separate sewers for process waste,

contaminated rainwater, cooling tower blow down, boiler blow down, catalyst

regeneration waste, etc.) will be incorporated for various effluents depending on

individual stream characteristics.

A comprehensive wastewater management system consisting of state of art sequencing

batch reactor and tertiary treatment consisting of Reverse Osmosis membrane will be

adopted for maximizing reuse and recycle of treated effluent.

Closed blow down system will be incorporated for hydrocarbon liquid discharges in all

the process units, which will reduce the wastewater load to ETP both in terms of

quantum load and quality. This is another of the in-plant control measures.

Most of the stripped water from non-hydro processed Sour Water Stripper will be reused

as make-up water and the stripped water from hydro processed Sour Water Stripper will

be reused in hydro processing units. This in-plant control measure will reduce the net

wastewater load to the ETP considerably.

Process area will be paved to avoid contamination of soil/sub-soil/ground water in case

of accidental spill/leakage of hydrocarbon liquids.



20

Figure-3.5: Water Balance Diagram



21

Figure-3.6: Waste Water Treatment Scheme



22

3 SITE ANALYSIS

3.1 Connectivity

Location

Village Bhikhpur

Tehsil / Taluka / Mandal Hargaon

District Sitapur

State Uttar Pradesh

Nearest Railway Station / Airport / along with distance in km.

Hargaon Railway Station-0.85 kms, SSW Chaudhary Charan Singh International Airport, Lucknow is the nearest airport-106.0 kms, South

Nearest town, city, district headquarters along with distances in km

Hargaon (NP) Town, 0.85 km SSW

Village Panchayat, ZilaParisad, Municipal Corporation, Local Body (complete postal address with telephone nos. to be given)

Hargaon (NP) Town, 0.85 km SSW

Einvironmental Sensitivity

1 Areas protected under international conventions, national or local legislation for their ecological, landscape, cultural or other related value

No

There are no areas protected under international conventions, national or local legislation for their ecological, landscape, cultural or other related value

2 Areas which are important or sensitive for ecological reasons -Wetlands, watercourses or other water bodies, coastal zone, biospheres, mountains, forests

Yes A stream is flowing at a distance of 7.35km,NW

3 Areas used by protected, important or sensitive species of flora or fauna for breeding, nesting, foraging, resting, over wintering, migration

No

There are no areas protected under international conventions, national or local legislation for their ecological, landscape, cultural or other related value

4 Inland, coastal, marine or underground waters

Yes A stream is flowing at a distance of 7.35km,NW

5 State, National Boundaries No There are no state or National boundaries

6 Routes or facilities used by the public for access to recreation or other tourist, pilgrim areas

Yes SH-21,1.77km,W

7 Defense Installations No There are no Defense installations

8 Densely populated or built-up area Yes Hargaon,1.52km,W



23

9 Areas occupied by sensitive man-made land uses (hospitals, schools, places of worship, community facilities)

Yes

Padmasini Vidya Vihar High School,NW,10.18km BCM Hospital,28.43km,S

10 Areas containing important, high quality or scarce resources (ground water resources, surface resources, forestry, agriculture, fisheries, tourism, minerals)

No -

11 Areas already subjected to pollution or environmental damage. (Those where existing legal environmental standards are exceeded)

No -

12 Areas susceptible to natural hazard which could cause the project to present environmental problems (earthquakes, subsidence, landslides, erosion, flooding or extreme or adverse climatic conditions)

Yes Project area falls in the Seismic Zone-III (Moderate Risk Zone)

Topo sheet map is shown as Figure 3.7



24

Figure-3.7: Toposheet Map of the Study Area



25

3.2 Climatic Data from Secondary Sources

1.1.1. Climate & Rainfall1

The climate is sub-humid and it is characterized by a hot dry summer and a bracing cold

season. The average normal rainfall is 288.60 mm. About 87% of rainfall takes place from June

to September. During monsoon surplus water is available for deep percolation to ground water.

There is a meteorological observatory at Hardoi, the records of which has been taken as

representative meteorological condition for Sitapur district. January is the coldest month with

minimum temperature of the order of 90C. May and early June form the hottest period of the

year. The mean monthly maximum temperature is recorded as 31.70C and mean monthly

minimum temperature is 18.70C.

During March to May the air is least humid with relative humidity high in the morning and less in

the evening mean. Monthly morning time relative humidity is recorded as 70% and mean

monthly evening time relative humidity is recorded as 53%.

During monsoon season the winds blow predominantly from east or southeast. The mean wind

velocity is 5.6 km/hr. The potential evapo-transpiration is 1494.0mm.

Soil Classification2

Soils of Central Plain Agro-climatic zone of Uttar Pradesh: Central plain agro-climatic zone is

represented by Barabanki, Sitapur and Unnao districts of Uttar Pradesh. Dominant soils are

Typic, Aquic and Fluventic Haplustepts, and Typic Ustipsamment.

Being a part of Indo Gangetic alluvial plain the area is almost a flat terrain with master slope

towards southeast. Geomorphologically the area can be divided into younger alluvial plain and

older alluvial plain. The younger alluvial plain forms flat to gently sloping, low lying, undulating

surface of large areal extent formed by river deposition and consisting of fluvial land forms such

as oxbow lakes, paleo-channels etc. The younger refers to later cycle of deposition and

constitute unconsolidated coarse to fine sand, silt and clay. The effect of high soil moisture is

observed in the vicinity of canal. The older alluvial plain is similar to younger alluvial plain but

1

1(Source-http://cgwb.gov.in/District_Profile/UP/Sitapur.pdf)

2krishikosh.egranth.ac.in/bitstream/1/2034162/1/134.pdf



26

formed at earlier stage of depositional regimes, comprising older unconsolidated alluvium. The

paleo-channels are buried channels filled in with sand silt and clay of varying lithology, where as

oxbow lakes are crescent shaped cut off meander with water and composed of unconsolidated

alluvial materials. The area is characterized by ravines. These are small, narrow, deep

depressions dissected and irregular surface usually produced by surface run off. These occur

along Gomti River& its tributaries. The ravines comprise unconsolidated alluvial material of

varying lithology mainly with fine sediments and developed in older alluvium. The chief verities of

soil are bhur or sand, dumat or loam and matiyar or clay. Bhur is formed along the high banks of

rivers and streams, matiyar is found in depressions in the upland while dumat occurs in rest of

the district.

1.1.2. Seismic Considerations

According to the Seismic Zonation and Intensity Map of India, the state of Uttar Pradesh falls

under Moderate Risk Zone-III.As per the 2002 Bureau of Indian Standards (BIS) map, study

area falls in Moderate Risk Zone-III.

Zone-III

The Andaman and Nicobar Islands, parts of Kashmir, Western Himalayas fall under this zone.

This zone is classified as Moderate Damage Risk Zone which is liable to MSK VII and also 7.8

The IS code assigns zone factor of 0.16 for Zone 3.

Source-https://www.mapsofindia.com/maps/india/seismiczone.htm

Figure-3.8: Seismic Zone Map of India



27

4 PROPOSED INFRASTRUCTURE

4.1 Industrial Area (processing area)-Not applicable

4.2 Residential Area (non-processing area)

The proposed project is located in Village Bhikhpur, Tehsil Hargaon, District Sitapur, Lucknow in

Uttar Pradesh. So, nearest inhabited area is Bhikhpur village.

4.3 Land Requirement

At present M/s Sunlight is in possession of 90 Acres of land at Village Bhikpur, DistrictSitapur, Uttar Pradesh. The land requirement for the total complex is estimated as below:

Basis Raw water bore well is located within the plot area Raw Water storage shall be provided equivalent to 12 hours consumption 180 days equivalent bagasse storage shall be provided within complex 7 days Intermediate product storage 7 days of product and LPG storage Truck loading gantries for liquid products within complex No rail loading gantries for liquid products within complex

4.4 Greenbelt: About 33% of total plot i.e. 90 acres area will be developed as greenbelt.

4.5 Drinking Water Management (Source &Supply of Water)

Source through Borewell(Ground water abstraction)

Total Requirement: 1200 KLD

Cooling water = 2000 m3/hr, (Raw water system = Bore well-Raw water-100m3/hr)

4.6 Sewage System

Sewage waste water is treated in sewage treatment plant. Treated sewage waste water

proposed to use for horticulture (gardening) purpose.

4.7 Industrial Waste Management

Generated waste has been categorized in below categories. Water balance diagram is provided

in Figure 4.1.



28

Domestic waste Liquid, solid and gases with nature of discharge and treatment system including segregation of

waste and treatment facilities. Ash from the char boiler will be packed in drums and sent to potential users (*brick

manufacturer, cement manufacturer etc) other solid waste are expected are as below:

S. No Solid Waste Quantity, MT Frequency

1 Guard Bed Fill 2.0 Once in six months

2 Hydroconversion Catalyst 69.5 Once in 4 years

3 Vapour Phase HDS Cattalyst 8.5 Once in 4 Years

4 Zinc Oxide 30.0 Once per year

5 LT Shift Catalyst 27.0 Once in 5 Years

6 Liquid Phase HDS catalyst 3.0 Once in 4 Years

7 Aromatics Saturation catalyst 4.7 Once in 4 years

8 Steam Methane Reforming Catalyst

11.5 Once in 5 Years

9 H2 Plant LT Shift Catalyst 11.7 Once in 5 Years

10 H2 Plant HT Shift Catalyst 11.0 Once in 5 years

Hazardous waste shall be disposed as the Norms. 4.8 Power Requirement & Supply/ Source

The total power requirement for the Sunlight Bio Fuels project is approximately 9.0-MW.

(Captive power generation using process char to be considered for power and steam generation

for the entire complex)

D.G. Sets:2.0-MW Emergency power has been considered through D. G. Sets



29

5 REHABILITATION AND RESETTLEMENTS (R& R) PLAN

5.1 Policy to be adopted (central/state) in respect of the project affected persons

including home oustees, land oustees and landless laborers (a brief outline to be

given)

No settlement or any man made structure is present on the identified land proposed for the

project. No displacement shall be done within the land identified for the project. Hence no

R&R issues related to project. However the land shall be purchased through mutual

agreement with the land owner. Compensation shall be made as per the state R&R policy.



30

6 PROJECT SCHEDULE AND COST ESTIMATE

6.1 Likely date of start of construction and likely data of completion (time schedule for

the project to be given)

Project work will be started after getting the environmental clearance.

(It is necessary to make a detailed schedule of things to do for each activity and a time frame for

each activity. Proper project management and regular follow up of these activities are necessary

for overall achievement of the deadline as per the implementation schedule and to avoid any

time and cost overrun. The company proposes to avail the services of EIL for EPC/EPMC to

ensure that the implementation schedule is met.)

6.2 Estimated Project Cost along with Analysis in terms of Economic viability of the

Project.

Cost of Estimates of the Greenfield ProjectRs. 1,234 Crore (1233.92 Crore)(INR).

The financial projections for the project have been prepared based on the initial information

given by EIL Ltd. with respect to sale price, operating expenses, capital expenditure phasing,

product yield etc., with other information. These financial projections with present assumptions

are subject to change once the documents such as technical project report, detailed feasibility

report, various quotations, certified material balancing chart, quotations for selling prices of

output and operating expenses etc. are finalised. With the above assumptions, the average debt

service coverage ratio (DSCR) of the project works out to be 1.90 times with minimum DSCR of

1.62 times for base case and project internal rate of return (IRR) is 18.01%(against a weighted

average cost of capital of 8.52%).

Project Cost and Means of Finance

Project Cost

Sr. No Particulars Cost (Rs. Crore)

1 Land & Site Development 36.42

2 Building Works 50.09

3 License Fees 19.73



31

4 Plant and Equipment 942.99

5 Upfront fee & financing charges 31.03

6 Preliminary & Preoperative Expenses 23.20

7 Contingency 53.62

8 Interest During Construction 70.78

9 Margin Money for Working Capital 6.06

Total 1,233.92

Means of Finance

Sr. No. Description Amount(Rs. Crore) Ratio

1 Promoters and Equity Investor 370.12 30.00

2 Rupee Term Loan 863.44 70.00

Total Project Cost 1,233.92 100.00

ANNEXURE-I PROCESS DESCRIPTION

1.1.1 INTRODUCTION

This section details the process description of the proposed technology. The process

description is to be read with reference to the Process Flow Diagram , the entire plant

complex is divided in to 16 UNITS detailed as below.

Unit No. Unit Title

01 Biomass Handling & Preparation

02 Biomass Conversion Process

03 Fuel Gas treatment

04 Liquid Hydrotreater

05 Aromatic saturation

06 CO2 Recovery

07 Hydrogen Plant

08 Sour Water

09 Char Processing

20 Utility Plants

21 Intermediate and Product Storage

22 Utility Headers

23 Power Generation

24 Waste Water Treatment

25 Site Infrastructure

26 Buildings

1.1.2 BIOMASS FEED PREPARATION SYSTEM - (UNIT 01) The moisture content of raw/untreated bagasse received from sugar mill is approx.

48%. The IH2 process requires that the moisture in the feed bagasse is limited to ~11%

wt. Treatment and conditioning of raw bagasse is outside the scope of technology

licensor therefore details of the same are not provided in the FEL2 package. M/s

Sunlight fuels has lined up M/s Swedish Exergy for basic design and supply of Biomass

Feed Preparation System. Though there are other suppliers of the same internationally,

for the project the system offered by M/s Swedish Exergy is considered.

According to preliminary feedback from M/s Swedish Exergy, the biomass feed

preparation system utilizes hot air dryer for drying biomass within acceptable limits. The

air dryer will be an open system where in the material to be dried will be exposed to hot

air heated indirectly by hot water. Dried material will be separated in a cyclone

separator. The dried biomass is conveyed in, in an inert atmosphere, tubular conveyer

system utilizing carbon dioxide as carrier medium. The feed preparation system will

require ~20MW of energy to dry the biomass from 48% moisture to ~11% moisture. The

energy from hot water circuit shall be utilized to meet this requirement.

The biomass (bagasse) will be received with in plant premises through trucks and will

be unloaded in storage yard, designed for 6 months storage. The bagasse from storage

yard shall be conveyed to dryer feeding bin using belt conveyer.

1.1.3 BIOMASS CONVERSION PROCESS - (UNIT 02) The Biomass Conversion Process Unit utilizes a two stage reactor system that converts

biomass into inert gases, water, and hydrocarbons (methane thru diesel). This unit

contains a lock hopper system to get the biomass into the process, the Hydropyrolysis

reactor (first stage fluidized bed reactor), a cyclone and char depressuring system to

remove solids from the process, the Hydroconversion reactor (second stage fixed bed

reactor), and the reactor effluent cooling and separation system.

1.1.4 FEED LOCK HOPPER SYSTEM The lock hopper system consists of two identical trains that include a pressurization

drum, a feed drum, live bottoms screws for both the drums, double block isolation

valves with a high pressure purge between them, a transfer screw, a rotary valve, and

an injection screw. Each train is sized to provide 50% of the total required feed. Lock

hopper trains operate in tandem with the other train.

The Pressurization Drums operate on ~22 minute cycle to pressurize the feed from

ambient pressure to the operating pressure of the Feed Drum and then transfer the feed

into the Feed Drum. At the start of the cycle, the Pressurization Drum is at atmospheric

pressure and filled with inert gas. Then it is charged with feed from outside the battery

limits. The Pressurization Drum is then pressurized using hydrogen gas from the

depressurizing of the other lock hopper train’s Pressurization Drum. The cycles are

timed such that when one Pressurization Hopper is pressurizing the other is

depressurizing. After the drums are equalized then the Pressurization Drum is isolated

from the other train and pressurized from the hydrogen pressurization system to final

pressure. Once the Pressurization Drum is at pressure, the outlet valves on the drum

are opened and the feed in the Pressurization Drum is fed into the Feed Drum.

Once the transfer is complete the Pressurization Drum outlet valves are closed and the

drum is depressurized in three steps. The first step is to depressurize to the other

Pressurization Drum, second is to depressurize to the four Hydrogen Recycle Drums,

and finally to the auxiliary boiler. There are four Recycle Drums which operate at four

different maximum pressures to allow for quick depressurization of the Pressurization

Drums. These Recycle Drums are always feeding the Hydrogen Pressurization

Compressor except when the drum is being pressurized from the Pressurization Drum.

The Hydrogen Pressurization Compressor feeds the High Pressure Hydrogen Surge

Drum. This drum increases in pressure when not feeding a Feed Pressurization Drum

and decreases when it does. After the Pressurization Drum is at the auxiliary boiler

operating pressure, it is purged to the auxiliary boiler with inert gas to remove any

remaining hydrogen.

Hydrogen is used to maintain the Feed Drum at a pressure slightly above the pressure

of the Hydropyrolysis Reactor at all times. The Feed Drum is intermittently fed from the TEMPLATE NO. 5-0000-0001-T2 REV. 2 / 28.11.2014 COPYRIGHTS EIL – ALL RIGHTS RESERVED

Pressurization Drum above and is sized to hold 2 cycles of the Pressurization Drum at a

time. The Feed Drum utilizes live bottom screws to maintain a controlled feed to the

transfer screw. The Transfer Screw and Live Bottom Screw speeds are changed to

control the feed rate to the Injection Screws and into the Hydropyrolysis Reactor. The

Injection screw is blanketed by a constant flow of hydrogen. If the Hydropyrolysis

Reactor or Injection Screws are at a higher pressure than the Transfer Screw, a valve

between the Transfer and Injection Screw shuts for safety reasons. The Injection Screw

takes the feed from the Transfer Screw and feeds it into the Hydropyrolysis Reactor at a

higher RPM than the transfer screw. Both cooling water (jacket and shaft cooling) and

hydrogen blanketing serve to keep the Injection Screw and its contents from elevating in

temperature, the feed from reacting, and the screw plugging.

1.1.5 FIRST STAGE REACTOR SYSTEM (Hydropyrolysis Reactor) The Hydropyrolysis reactor is a fluidized bed reactor that uses recycle gas to fluidize the

catalyst and biomass inside. The recycle gas is gas from a membrane plus pure H2

makeup from the Hydrogen Plant with an overall purity of ~97% H2. It enters the bottom

of the Hydropyrolysis reactor through a plate distribution grid. The reactor operates are

a pressure of about ~36.5 kg/cm2 and temperature of 425 deg C. Cold hydrogen can

also be fed to the reactor bed to as a quench to control a reactor exotherm. Also being

fed to the reactor just above the plate grid is the biomass via two injection screws. Fresh

catalyst is added at the reactor top on a regular basis since catalyst attrition and

deactivation are constantly occurring. The catalyst make up rate will be 5% reactor

volume per week. This catalyst is pressurized and dense phase conveyed via a shot

pot. The reactor includes numerous temperature and level indicators as well as

differential pressures. This reactor requires shed decks (slug breakers) to eliminate any

large vapor bubbles in the bed. At the top of the reactor is an expanded section which

serves as a disengagement zone to minimize the loss of catalyst.

Because the Hydropyrolysis reactor is a fluidized bed reactor, a “rock-pot” is available to

remove any large material that does not fluidize and may accumulate on the grid. This

material is designed to be removed manually on an as-needed basis while the unit is

running. The operation consists of pressuring the rockpot with hydrogen to the same

pressure as the reactor and opening the dual dump solids valves. Once the heavies are

dumped these valves are shut, the rockpot cooled (it is a jacketed vessel with cooling

water), depressured, purged with inert CO2, and then dumped to a final drum. There is

also the ability to purge the opening in the bottom of the reactor to keep the material

from blocking the opening. There is also a second rockpot at a takeoff at 50% of the

normal reactor level. This would be used if char accumulation occurs.

1.1.6 CYCLONE / SOLIDS CAPTURE SYSTEM

The reactor effluent leaves the top of the reactor and contains the reactor products,

char, ash, and a small amount of catalyst fines. This material travels to the first stage

cyclone where the majority of the solids are removed and stored in the Solids Holding

Drum. The reactor effluent and the remaining solids then go to the second stage

cyclone which is housed in a separate vessel in order to seal the gas from having back

flow between the stages. The solids out of each cyclone will continuously fill both Solids

Holding Drums that contain the cyclones before the solids are transferred out of the

process into the Char Depressurizing system.

99.99% + of the solids are removed from the reactor effluent vapor stream by the

cyclones. After the cyclones, the stream goes to the Hydrotreating Guard Bed where

any remaining solids are trapped to protect the Hydroconversion Reactor from high

pressure drop buildup over the course of the run. The Guard Bed can be changed out

as needed during normal operation when it fills up with fines.

1.1.7 SECOND STAGE REACTOR SYSTEM (Hydroconversion Reactor)

After the guard bed, the effluent goes to the First Stage Reactor Effluent Hot Oil Heater

which cools the vapor stream down to the desired Hydroconversion Reactor inlet

temperature (~295 deg C). The vapor stream then goes to the Hydroconversion Reactor which is a fixed bed

reactor in vapor phase operation. The reactor consists of two beds with a quench in

between the beds. It has numerous temperature indicators and a differential pressure

indicator to measure the reactor pressure drop. This reactor primarily converts any

nitrogen to ammonia and sulfur to hydrogen sulfide and completes the de-oxygenation

reaction.

The reactor effluent then cools down through exchangers that heat the hot oil and hot

water services. After this, the material is cooled the rest of the way with cooling water

and then sent to a three phase separator. From the drum, the mixed hydrocarbon gas

goes to Unit 03 for gas cleanup, the hydrocarbon liquid goes to Unit 04 for third stage

reactor feed preparation, and the water goes to the Sour Water Degassing Drum at

Unit-08.

1.1.8 CHAR DEPRESSURIZING SYSTEM

On 30 minute cycles, the first Solids Holding Drum will transfer the accumulated solids

into the Char Balancing Drum. The Secondary Solids Holding Drum will transfer its

solids on a manual basis as level in the drum dictates. All char handling drums use a

live bottom/transfer screw system to ensure the char material flows from one vessel to

the next. Steam is injected when the dumping occurs in order to minimize product loss. The Char Balancing Drum will be pressurized with inerts to minimize the pressure

difference when the dumping occurs in order to minimize erosion.

The Solids Holding Drum will always maintain a solids seal in order to minimize

hydrogen and products going to the Char Balancing Drum. This drum will be isolated

once the solids are in the Char Balancing Drum. Isolation is achieved between all solids

drums by using two specialty valves in series with a bleeder valve that is pressurized

with inert gas or vented to flare in order to minimize leakage. After the isolation occurs,

this drum is equalized in pressure with the Depressurizing Drum. The solids are then

transferred via live bottom screw(s) from the Char Balancing Drum to the

Depressurizing Drum and then these two drums are isolated from each other. Again,

steam is injected in order to minimize any loss of products.

The Depressurizing Drum is then depressurized thru the Depressurizing Filter which sits

on top of the drum to the CO2 Surge Drum and then finally to the Char Boiler. Any

solids that carry over are captured in the Depressurizing Filter. Recoverable solids from

this filter are backpulsed to the Depressurizing Drum. The Depressurizing Drum and the

Depressurizing Filter are then purged with inerts to the boiler again to remove any

remaining flammable gases from the process. While the Depressurizing Drum is being

purged and emptied of solids, the Char Balancing drum is being pressured up with

inerts for the start of the next cycle.

The CO2 Surge Drum is used to keep the rate of gas being sent to the Char Boiler

relatively constant. There are four steps to the operation of this drum. These are: 1. Depressurizing of the Depressurizing Drum with the flow split between the surge

drum and the Char Boiler. The rate to the boiler is set constant while the rate to the

surge drum starts high and decreases to the constant rate of the boiler. 2. In the second step, the flow is shut off to the surge drum and all the gas goes

directly to the boiler from the depressurizing drum starting at the rate in step

one and decreasing close to zero when the Depressurizing Drum is close to

atmospheric. 3. In the third phase, CO2 is used to purge the char in the Depressurizing Drum to

remove any residual volatiles. This rate is constant and is equal to the rate in the

first step. 4. In the final step, the purge is stopped and the surge drum is opened and

depressurized to the boiler.

The char exits the Depressurizing Drum, on a batch basis, by dilute phase transport to

the Char Surge Bin. This bin goes to char cooling screws and then to the Char Boiler.

This bin separates the batch operation of depressurizing the char from the steady state

operation of burning the char. The hot char is conveyed using CO2 from the Char

Transport Blower to the bin where the CO2 is filtered and returned to the blower. Before

the CO2 returns to the blower it goes through hot and cooling water exchangers where

it is cooled.

The char leaves the Char Surge Bin feeds via the live bottom /transfer screw. Next is

the cooling screw. This screw has cooling water going through the annular area as well

as the housing jackets. The cooled char is then sent to the Char Passivating Screw.

Here the char is sent countercurrent against a mixture of air and inerts to minimize

oxygen concentration. The passivation reaction is exothermic and is further cooled with

the cooling water going through the screw in the same two locations as above. The

oxygen gets consumed in this screw. This exiting gas stream, which is now all inerts, is

filtered with a backpulse filter.

From the passivation screws, the cooled and passivated char is fed via dilute phase

transport to the Char Storage Bin by the Char Transport Blower. The Char Storage Bin

\ then goes to the Char Boiler in Unit 20 for steam production for the Turbo-Generator.

1.1.9 FUEL GAS TREATMENT- UNIT 03 The gas from the Unit 02 separator joins vapor streams from the Liquid HDS separator

and the Depropanizer both in Unit 04 and any LPG required for hydrogen production.

The vapor streams contain H2S which is partially removed by Sulfur Reduction

chemicals injected via a quill. An aqueous solution of water and sulfate is removed in

another separator. The water is sent to the Waste Water Treatment Plant, Unit 24. The

final vapor stream has over 90% of the H2S removed leaving just enough for proper

activation of the Vapor HDS catalyst.

This vapor stream then goes to the HDS-LTS Reactor Feed-Effluent Exchanger and

then to the Hot Oil Vapor HDS Feed Heater which is used to set the reactor temperature

for the Vapor HDS Reactor. This reactor converts organic sulfur to H2S. From there, it

goes to ZnO beds where the H2S is removed. Water is then added in the form of boiler

feed water and high pressure steam before going to the Low Temperature Shift (LTS)

Reactor. The water serves to cool the temperature down to the LTS inlet temperature.

In this reactor, the CO is converted to CO2 to minimize the CO going to the Hydrogen

Plant. It also makes hydrogen thereby decreasing the Hydrogen Plant size. From the

LTS reactor, the material goes through the combined feed exchanger for cooling. This

material then goes through a hot water exchanger, a cooling water exchanger, and to

another separator. Any hydrocarbon liquid from this separator goes to the HDS Stripper

in unit 04. The water goes to the Waste Water Treatment Plant, Unit 24.

The gas is then sent to the Fuel Gas CO2 Amine Contactor where the CO2 is removed.

After this, the gas goes to a two stage Membrane Unit where the hydrogen is recovered

and purified into permeate streams before finally being compressed in the Recycle

Compressor and then sent back to Hydrogen Distribution system in Unit 07 as recycle

gas. The first stage of the membrane concentrates the heavier hydrocarbons and any

KO liquid is sent to the Vapor Splitter.

The hydrocarbon gas stream or resid is also sent to the Vapor Splitter to recover any

Petrol/Gasoline compounds (C4+ material) in the overhead as needed to make

Petrol/Gasoline RVP before it becomes feed to the Hydrogen Plant, Unit 07. The

overhead has a cooler and then a chiller to condense the overhead material since it is

very light material. The tower bottoms goes to the HDS Stripper.

1.1.10 LIQUID HDS -UNIT 04 The Liquid HDS gets its feed from the Unit 02 separator. This reactor section of this unit

consists of a combined feed exchanger, a reactor to convert sulfur to H2S and effluent

cooling. The combined feed of the liquid and hydrogen is heated up with a hot oil.

Hydrogen is cascaded from the Aromatic Saturation Unit 05 separator although if that

unit is down it can come from the Unit 07 Hydrogen Distribution system directly. Hot

water is also made in the reactor effluent cooling system. Liquid is recycled from the

separator to minimize the reactor delta temperature. The separator liquid goes to the

HDS Stripper. The separator gas goes back to the Vapor HDS reactor in Unit 03. There are four columns in the fractionation section in this unit. These are the HDS

Stripper, Depropanizer, Primary Fractionator, and the Benzene Splitter. The HDS

Stripper Column gets feed from this unit as well as the light naphtha returning from the

Vapor Splitter located in Unit 03. The HDS Stripper runs at low pressure and uses hot

oil for reboiling to strip most of the pentane and lighter material out the top of the tower

(almost all of the benzene remains in the bottoms product). The bottoms are sent to the

Primary Fractionator. The Stripper Overhead Gas is sent to the recycle gas compressor.

The liquid from the overhead drum is sent to the Depropanizer tower.

The Depropanizer Column runs at a higher pressure and separates the sour light ends

(C3 minus) from the butane to hexane cut material. This tower is reboiled with hot oil.

The Overhead Gas and Liquid are sent back to the Vapor HDS Unit 03 to remove any

H2S with the Sulfur Reduction Chemicals System. The tower bottoms material is sent

as a Petrol/Gasoline product.

As mentioned before, the HDS Stripper bottoms material goes to the Primary

Fractionator which runs at low pressure and uses LP Steam to strip the Naphtha from

the Diesel. The diesel material is sent to Unit 05 to be saturated. The overhead naphtha

material goes to the Benzene Splitter Column.

The Benzene Splitter runs at low pressure and is reboiled by low pressure steam. The

target is to make a bottoms material which is a heavy naphtha stream containing less

than the maximum amount of benzene material that is allowed in the finished

Petrol/Gasoline product. This material is sent straight to Petrol/Gasoline. The Benzene

Splitter overhead material contains the rest of the benzene and lighter compounds and

goes to Unit 05 to be saturated.

1.1.11 AROMATIC SATURATION- UNIT 05 The CO2 rich off gas from the process is sent to the two Amine Contactors in Units 03

and 07. Lean amine from this unit feeds these two contactors and absorbs the CO2.

The rich amine from the bottom of these contactors combines and is flashed in the rich

amine flash drum. Some light hydrocarbon and CO2 material is flashed, scrubbed in the

vapor outlet line and used as fuel gas for the hydrogen plant via an ejector. The rich

amine outlet from the flash drum is pumped to the amine regenerator via the lean/rich

exchanger on flow control.

The rich amine is stripped of CO2 in the regenerator tower using an LP steam reboiler.

The overhead is condensed with an acid gas vapor product being recovered. It is

important to note that unlike a lot of Amine units, this acid gas contains no H2S. The

overhead liquid is returned to the tower as reflux. Should the amine concentration drop

in the system, water can be removed from the overhead system to return to the desired

concentration. Conversely, if the activated MDEA concentration drops, MDEA or the

active agent can be added. The stripped lean amine from the bottom of the tower is

cooled in the lean/rich exchanger and pumped back to the amine contactors. A slip

stream of lean amine will be filtered to remove particulates and other impurities to keep

the amine clean and minimize the amine foaming tendencies.

Provisions for storing make up amine and amine system inventory are provided. The

lean amine is MDEA with an activating agent (called activated amine) and allows for

higher recovery of CO2. The CO2 rich off gas from the regenerator is dried and

compressed for use in the inert gas system.

An inert gas system is required for the purging of the feed and char handling systems

and pressuring of the char system. The inert gas source will be CO2 from the Amine

Unit Regenerator overhead. The inert gas from the amine unit will be compressed with

an inert gas compressor and dried. Some of the inert gas will then be used at low

pressure. The remaining gas will be compressed to a higher pressure and used in the

Char System for repressuring.

1.1.12 HYDROGEN PLANT- UNIT 07

The Hydrogen Plant feed comes from the Vapor Splitter column in Unit 03 and will be

converted in the steam methane reformer into hydrogen. Any excess feed will be used

as the fuel gas to fire the reformer furnace. If more feed is required to make hydrogen,

LPG can be sent to front of Unit 03. This gas will eventually make its way to the

Hydrogen Plant.

For this project the core hydrogen plant components are being provided by a licensed

vendor. The vendor will be responsible for creating hydrogen syngas that will be sent to

an Amine contactor tower. This contactor is utilized to recover the CO2 which will be

sent to the Amine Unit 06 and used as a source of inert gas. They will also be

responsible from final clean up of the hydrogen syngas via a pressure swing absorption

(PSA) unit. The hydrogen plant requires steam which will be generated in the vendor

package. Demineralized water will be provided to the package and high pressure steam

and boiler blowdown will be additional export streams of the package.

The Hydrogen Distribution system heats, cools, and distributes the hydrogen to a

variety of locations. The main location is the Hydropyrolysis reactor. Another portion

which is cooled is sent to the Feed Screws and as quenches to the Hydropyrolysis and

Hydroconversion reactors if needed. Uncooled hydrogen can be also sent to the

Aromatic Saturation Reactor. It can also go to the liquid phase HDS reactor for startup

or when the Saturation Unit is down. The gas can be also heated via high pressure

steam and then by the Hydrogen Gas Feed Heater for startup or if needed during

normal operation. However, the gas normally is only heated by the heat exchange

before going to the Hydropyrolysis reactor. It is also used as makeup for the Hydrogen

Pressurization System.

1.1.12.1 SOUR WATER STRIPPER- UNIT 08 Water is introduced into the process in multiple ways. It evolves from the moisture in the

wood feeding the unit, it is generated in the IH2® Reactors, and it is added as steam

and/or boiler feed water injection points throughout different stages in the process.

Almost all of this water is captured in knockout drums, overhead water boots, and three

phase separators and contains ammonia, carbon dioxide, and a small amount of H2S.

This water is collected in a header before being sent to the Sour Water Stripping Unit.

This water must be treated in a Sour Water Stripper Unit to remove the NH3, CO2, and

H2S. The Sour Water Stripping Unit will consist of a degassing drum and associated

pumps, sour water feed tank with associated pumps, a feed/effluent exchanger, a sour

water stripper tower, steam reboiler, and stripped water cooler. The NH3, CO2 and a

small amount of H2S are stripped out in the stripper tower. The stripped sour water from

the bottom of the stripper tower is cooled and sent to the cooling tower in Unit 20.

The overhead acid gas stream containing NH3, CO2, and H2S goes to the Char Boiler.

1.1.13.1 UTILITIES PLANTS- UNIT 20

1.1.13.2 Raw Water System The water used to meet the plant demands is supplied from well pumps. The Tube Well

water is collected in feed collection tanks. Raw water from feed collection tank will be

routed to Degasser tower filled with PP raschig rings and Air is forced from the bottom

of the tower by Centrifugal Blowers, while the water flows down through the packed bed

of PP rings. The carbonic acid present in the water splits up into carbon dioxide gas and

water. This carbon dioxide gas is stripped off and escapes from the top of the tower.

The degassed water is collected in the degassed water tank and is pumped to Basket

Strainers & Ultra filtration. This filter is a guard filter for ultrafiltration system.

Filtered water is routed to Ultra filtration system to maintain SDI (Silt Density Index) <3

which is necessary to maintain at inlet of RO system to safe guard membranes. Ultra

filtration is a membrane process in which a porous membrane is used to separate or

reject colloidal and particulate matter. Water is pressurized through the membrane and

particulates are left at membrane surface. Due to small pore size of the membrane,

effectively all suspended solids are removed from the filtrate.

The modes of operation of Ultrafiltration are: Processing, Backwash and Cleaning

System is automated to switch between these modes. However, cleaning and integrity

testing modes is manual.

UF treated effluent will be processed through cartridge filters which will be used as

pretreatment step before RO-I system to safeguard RO-I membranes. Micron cartridge

filter is provided in order to remove micron size particles, which are not removed by the

sand filter. These Cartridges are disposable type and should be replaced if differential

pressure across cartridges approaches pre-specified level.

Processed effluent from cartridge filters will be route d to RO-I system to process the

FEED water and remove TDS, & Silica to the extent as desirable. Reject from RO-I will

be stored in reject disposal tank. Reject shall be used for Horticulture purpose with

TDS<2100 PPM The recovery from RO-I shall be 80%. Permeate water from RO will be

stored in storage tank from where it will be pumped to Mixed Bed Exchanger for final

polishing and for DM water production.

Permeate water from RO will be stored in storage tank from where it will be pumped to

Mixed Bed Exchanger for final polishing and for DM water production. MB unit has both

Strong Acid Cation Resin and Strong Base Anion resin mixed in a single vessel. The

regeneration of these resins is carried out in simultaneous regeneration, i.e. cation by

Hydrochloric Acid in countercurrent and anion by caustic in co-current. The MB bed

exchanger functions as multiple cycles of cation and anion exchanges and thus polishes

the water to best extent possible.

1.1.13.3 Potable Water system The potable water system is supplied by water after it passes through the Ultrafiltration.

It is stored in the potable water tank and pumped to users. A small recycle stream is

drawn from the pump supply, treated with chlorine, and returned to the potable water

tank.

1.1.13.4 BOILER FEED WATER PREPARATION Service water requires further treatment before being used for steam generation. First it

is treated in an ion exchange demineralization unit to further reduce the hardness.

Backwash from the unit is sent to the cooling tower while acidic/basic liquid used in

regeneration is neutralized and sent to waste water treatment. The water is collected in

a demineralized water storage tank and then pumped, as needed, to a deaerating unit.

The deaerating unit removes any dissolved gasses and brings the water to boiler feed

quality.

1.1.13.5 STEAM/CONDENSATE/POWER GENERATION Superheated high pressure steam (~80 kg/cm2) is produced by the Char Boiler and

auxiliary boiler(s). High pressure steam is created in the Hydrogen Plant. Low pressure

steam is produced as a side stream from the turbo generator. The superheated high pressure steam is used to generate electricity via a turbo

generator. A side draw is used to supply the rest of the plant with low pressure steam.

As the low pressure steam has a slight super heat it is saturated using a desuperheater

before entering into the low pressure steam header. The outlet of the generator goes to

a surface condenser which condenses all of the steam and sends it to the low pressure

condensate system. Additional desuperheater capacity is provided to break down

superheated high pressure stream and high pressure stream as needed to supply the

low pressure steam header, if required.

The char from unit 02 is sent to a surge bin equipped with live bottom screws. The feed

screws will discharge to the “in-bed” feeder system furnished by the fluid bed boiler

supplier. The char will be injected below the surface of the fluidized bed after the bed

material is brought up to temperature using LPG.

LPG will be used to warm the bed and to maintain a minimum bed temperature until the

char flow and combustion is able to sustain it. LPG will also be used as supplemental

fuel when the fuel demand exceeds the available char.

Accessories and emission controls include a proprietary bed media cleaning and re-

injection system, bed media storage, FD and ID fans, access stairs and platforms,

economizer, SNCR and SCR for NOx control, limestone injections for SOx control,

baghouse, stack, CEMS and ash collection systems.

1.1.13.6 COOLING WATER SYSTEM

The cooling water system consists of a closed loop cooling water circuit with a cooling

tower. Makeup water is taken from the outlet of the lime softening unit, the stripped sour

water, boiler blowdowns, and demineralized water backwash.

1.1.13.7 CHILLED WATER SYSTEM The chilled water system uses an adsorption process to supply the plant with chilled

water. Gas is adsorbed and desorbed in order to chill a water stream. Cooling water is

used to adsorb a refrigerant, cooling the chilled water. The hot water is used to

regenerate the adsorbent.

1.1.13.8 HOT WATER SYSTEM

The hot water system supplies low level heat to dry biomass of the plant (Refer unit-01).

It gets it heat from various waste heat locations in the process with the majority from the

reactor effluent in Unit 02. After coming from the process, the water is further heated by

low pressure steam, if needed, to get to the required temperature of 120 C. After being

used to dry biomass, the cooled hot water is returned back to the process. A portion of

the water will be sent to a separator that will provide surge/thermal expansion capacity

and also allow any oil that enters the system via leaks to be skimmed off and removed

from the system. An air cooler is used to handle unbalanced heat loads and emergency

cooling if dryer operation is shut down.

1.1.13.9 HOT OIL SYSTEM The hot oil system is a closed loop system. The hot oil is pumped to equipment that

requires cooling, which heats the oil, and then to heat exchangers that require heat

inputs, cooling the oil. The Hydropyrolysis and Hydroconversion Reactor effluents utilize

the hot oil loop for cooling and the Hot Oil Heater (H-2055) provides supplementary heat

to reach the required temperature. The heated oil is then used in eight heat exchangers

to supply heat to the system.

1.1.13.10 INSTRUMENT AIR/PLANT AIR/NITROGEN

The instrument/plant air system will be supplied by air from two air compressor skids.

The two compressors will discharge to a common air receiver. The plant air will come

directly from the air receiver, but the instrument air will meet the moisture dew point

requirement by passing through a dryer before entering the instrument air header. Nitrogen shall be sourced from outside in industrial cylinders. 2 days equivalent nitrogen

storage in the form of industrial cylinders is recommended.

1.1.13.11 FLARE FLARE SYSTEM EQUIPMENTS

The plant will have one flare to handle all relief loads. The flare system will include the

following items:

1) Flare header

2) Flare knock out drum (D-2070)

3) Flare knock out drum pumps (P-2070 A/B & P-2071A/B)

4) Flare Stack (ML-2070) and Flare Tip (The flare tip pilots will be lit with LPG). ROUTING OF PRODUCT FROM FLARE KNOCK OUT DRUM The product from flare knock out drum is routed to off spec tank (Unit-21) and to sour

water header (Unit-08) using dedicated pumps (P-2070 A/B & P-2071A/B respectively).

The flare drum has an over flow weir so that water can be separated from liquid

hydrocarbon and recycled accordingly.

1.1.13.12 FUEL GAS SYSTEM The fuel gas system has a Fuel Gas Balance Tank that is the destination for gas from

the Saturator Reactor Feed Surge Drum and the Secondary Fractionator Overhead

Drum. The pressure is controlled by adding LPG as needed. The balance tank gas goes

to various destinations throughout the plant where fuel gas is required.

1.1.14 TANKS AND PUMPS- UNIT 21

1.1.14.1 FINISHED PRODUCTS STORAGE

Finished products are received in day tanks which are subsequently transferred to

product storage tanks. The system for the naphtha and diesel products consists of two

day tank for each product namely TK-2100/2101 & TK-2110/2111. Each product system

will have transfer pumps (1W+1S) to move the product from the day tanks to product

tanks. The product tanks have the capacity to have 7 days storage.

1.1.14.2 PRODUCT DISPATCH

The products are dispatched using trucks. Truck loading stations are included to fill

truck with Petrol/Gasoline and diesel products. Dedicated bays along with product

transfer pumps (1W+1S) and metering assembly are provided.

1.1.14.3 OFF-SPEC PRODUCT STORAGE TANKS

Off spec product tank and associated pumps will be provided to allow the rerunning or

selling of the off spec product. The naphtha and the off spec tanks will be equipped with

floating roofs.

1.1.14.4 ETHANOL BLENDING

Facility for ethanol blending is also provided so as to have 10% ethanol blended

Petrol/Gasoline. An ethanol tank along with pumps P-2102A/B (1W+1S) is included to

blend ethanol into the finished Petrol/Gasoline for the same. Ethanol is received via

road trucks and is stored in ethanol storage tank.

1.1.14.5 INTERMEDIATE PRODUCT STORAGE & TRANSFER SYSTEM

Intermediate tankage is provided for sweet and sour products. The sour tankage will be

used if the liquid HDS unit is down while the sweet tankage is required for a shutdown

of the Aromatic Saturation unit. The products from intermediate storage tanks are

routed to Liquid Hydrotreater unit (04) & Aromatic Saturation Unit (05) respectively.

1.1.14.6 OTHER STORAGE The facility requires LPG which will be supplied by truck. LPG truck unloading facilities

as well as LPG storage in the form of bullets is provided. Two LPG storage bullets are

provided each of capacity 1000 cu m. Vaporized LPG is supplied to the plant via LPG

pump and LPG vaporizer (E-2142) utilizing LP steam for heating.

1.1.14 WASTE WATER TREATMENT PLANT- UNIT 24 Waste water from Oily water sewer, cooling tower blow downs, Brine from diesel dryers,

Water from contact sewer are routed to TPI Separators to remove the free oil and

suspended solids. Free oil (Dia.>60m) present in the above streams is removed with the

help of density difference between the dispersed phase (oil) and the dispersion medium

(water). In order to provide effective surface area, numbers of inclined oleophilic plates

are provided. To achieve this Tilted Plate Interceptors (TPI) system is envisaged. Due to the possibility of VOC emissions, both the units shall be covered and provided

with suitable vents connected to VOC handling system, safety system and access. To

skim the free oil from the surface, slotted pipe skimmer shall be provided. Sludge

settled at the bottom shall be scrapped off through the sludge pit.

In addition to the contact retention pond there is also a non-contact pond. Area drains

from non-process parts of the site flow into the non-contact pond. The run off is retained

in the pond for testing to ensure compliance with environmental regulations for

discharge. If the testing fails to meet regulations the pond water can be metered into the

wastewater treatment package. All retention ponds can be pumped directly to

environmental discharge in an emergency event where storm water rates are higher

than design. The FEL-2 assumption is that the ponds are large enough to contain any

fire water event which is not expected to occur at the same time as a major storm event.

After pH adjustment, the oil free effluents to be pumped to the biological treatment unit,

the Sequencing Batch Reactor to remove BOD along with corresponding COD,

Ammonia, Residual Sulfides and Phenols, Phosphorus etc. Effluent equalization shall

be of a part of the Sequential Batch Reactor. The Sequential Batch process shall be

well proven for this type of effluent and shall have high end outlet performance. The

sequencing batch reactor shall perform Nitrification, Denitrification, and control of

phosphorus. The reactors shall be installed in such a way that they allow continuous

operation with continuous influent and discharge. It shall be capable of simultaneous

sludge stabilization. The oxygen required shall be through diffused aeration system with

intelligent control of oxygen level in the tank. The system shall be designed in such a

way that growth of filamentous bacteria is suppressed and high settling rate of sludge is

achieved. SVI < 120 shall be achieved in the process. All the recycling of effluent,

monitoring of critical data, oxygen level in the tank and decanting shall be through PLC

based control system. Minimum three Nos. of tanks shall be provided based on the

process requirement.

Biological Sludge generated shall be routed to Sludge handling section comprises

handling of various types of sludges generated through the treatment, viz., Oily &

Chemical sludges and Bio sludges, with sludge thickening, mechanical de-watering, oily

sludge confined bioremediation, etc.

A Package Treatment Plant has been envisaged to treat Sanitary Effluent & Canteen

Waste. Sanitary Effluent shall be treated in the Sanitary Treatment Unit to meet all the

Statutory Discharge norms and the final Effluent shall be treated and used for

horticulture.

Documents

EIA & EMP for 100 MW Thermal Power Plant at Delhienvironmentclearance.nic.in/writereaddata/Online/TOR/28_Nov_2017... · The total power requirement for the Sunlight Bio Fuels Project