PRE - FEASIBILITY REPORTenvironmentclearance.nic.in/writereaddata/Online/TOR/01...dependent on fuel within the country, M/s. Piccadily Sugar & Allied Industries Ltd (PSAIL) has planned

Proposed Expansion of Grain/Molasses based (From 70 KLPD to 130 KLPD) by installation of 60 KLPD Grain/Molasses based Ethanol Plant along with 2 MW Co-generation Power Plant in Existing Distillery Plant (70 KLPD) At Village Hamjheri, Jakhal Road, Patran, District Patiala, Punjab

Pre - feasibility Report

M/s. Piccadily Sugar & Allied Industry Limited 1

PRE - FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY

i) Introduction

In line with the ambitious programme of Govt. of India like “MAKE IN INDIA” and to become self-

dependent on fuel within the country, M/s. Piccadily Sugar & Allied Industry Limited has planned for

proposing installation of Unit II – 60 KLPD Grain/Molasses based Ethanol Plant along with 2 MW Co-

generation Power Plant in Existing 70 KLPD Grain /Molasses based Distillery Plant at Village Hamjheri,

Jakhal Road, Patran, District Patiala, Punjab.

Molasses will be transported through pipelines from own sugar mill located next to Distillery &

nearby Sugar Mills.

The company has an existing 70 KLPD Molasses/Grain Based Distillery at Village Hamjheri, Jakhal

Road, Patran, District Patiala (Punjab).

As per EIA Notification dated 14th Sep., 2006 as amended from time to time; the project falls in

Category ‘A’, Project or Activity - 5(g).

Table – 1

Salient Features of the Project

S. NO. PARTICULARS DETAILS

A. Nature & Size of the Project Proposed Expansion of Grain/Molasses based (From 70 KLPD to 130 KLPD) by installation of 60 KLPD Grain/Molasses based Ethanol Plant along with 2 MW Co-generation Power Plant in Existing Distillery Plant (70 KLPD)

B. Category of the Project As per EIA Notification dated 14th September, 2006 and as amended from time to time; the project falls in Category ‘A’, S. No. - 5(g).

C. Location Details

Village Hamjheri, Jakhal Road

Tehsil Patran

District Patiala

State Punjab

Latitude 29° 55’ 14.90” N to 29° 55’ 26.80” N

Longitude 76° 02’ 01.88” E to 76° 02’ 26.60” E

Toposheet No. H43J16, H43K4, H43P13 & H43Q1

D. Area Details

Total Plant Area • Existing plant area: 70 Acres

• No additional land is required for the proposed expansion, as the same will be done within the existing plant premises

Greenbelt / Plantation Area 23 acres i.e. 33% of the total plant area has already been developed.

E. Environmental Setting Details (with approximate aerial distance & direction from plant site)

1. Nearest Village Hamjheri (1.0 km in SE direction)

2. Nearest Town Town - Patran (3.5 km in NNE direction)




3. Nearest National Highway / State Highway

NH - 71 (3.0 km in NE direction)

SH - 10 (1.0 km in East direction)

4. Nearest Railway station Jakhal Railway Station (~ 24.5 km in SW direction)

5. Nearest Airport Chandigarh (~ 110 km in NE direction)

6. Archaeological Important Site None within 10 km radius

7. National Parks, Wild Life Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors etc. within 10 km radius

No National Park, Wild Life Sanctuary, Biosphere Reserve, Tiger / Elephant Reserve, Wildlife Corridors etc. falls within 10 km radius of the plant site.

8. Reserved Forests (RF) / Protected Forests (PF) etc. within 10 Km. radius

Nil

9. River / Water Body (within 10 km radius)

River

• Ghagghar River (9.0 km in SE direction)

Nala/Drain

• Choa Nala (1.0 km in NW direction)

• Kalbhanu Drain (1.0 km in South direction)

• Main Drain n0 1 (9.0 km WNW direction)

Agricultural canal

• Alan Branch (0.5 km in East direction)

• Hariau Branch (4.0 km WSW direction)

• Bhakra Canal (6 km in ESE direction)

• Ladbanjara Distributary (7.5 km in WNW direction)

F. Cost Details

Total Cost of the Project Rs. 47.0 Crores

Cost for Environment Management Plan

o Capital Cost - Rs. 10 Crores

o Recurring Cost - Rs. 2.0 Crores / annum

G. Basic Requirements for the project

Main Raw Material – Molasses & Grain

Molasses - 282 to 300 MT/day Source:- Sugar Mills

Grain – 157 to 165 MT/day Source:- Nearby area

Water Requirement 526

Source:- Ground Water

Power Requirement 1.2 MW

Source: - 2 MW Co-gen Power Plant & D.G Set (for emergency).

Man Power Requirement 60

Source:- Unskilled / Semi-Skilled - Local Area; Skilled

H. Product Mix Ethanol

I. Working Days Working days - 330 Days per Annum




1.1 ENVIRONMENT MANAGEMENT PLAN

Particulars Details

Air Management � Boiler will be provided with ESP/Bag Filter to maintain PM emissions within permissible

limits.

� Boilers will be equipped with RCC stack of suitable height for discharge of pollutants

as per CPCB standards.

� CO2 generated during the fermentation process will be collected by utilizing CO2

Scrubbers and sold to authorized vendors.

� All the roads are asphalted to control the fugitive dust emissions

� Green Belt around the periphery and within premises already exists and the same will

be maintained after proposed installation.

� Ambient air quality will be regularly monitored.

� Online stack monitoring system will be installed in the plant premises.

Water Management � The project will be based on “Zero Effluent Discharge”.

Molasses Based Operation:

� Spent Wash generated during the process will be first treated in Bio-Digester (Bio-

Methanation) and thus production of useful Biogas (used as fuel in boiler), which will

be followed by concentration in Multi-effect Evaporator.

� Concentrated Spent Wash will be mixed with Press Mud generated from Sugar Unit

for manufacturing Organic Manure (Bio composting).

� Record of wastewater returned back to process for utilization in Fermentation/cooling

tower and to gardening will be kept.

� Process condensate from MEE will be treated and recycled back in the process.

Grain based operation:

� Grain slops (Spent Wash) will be taken care through Centrifuge Decanters for

separation of Suspended Solids separated as Wet Cake and which goes as cattle feed

as it contains high protein. (Also known as DWG – Distillers Wet Grains).

� Thin slops from the Decanter Centrifuge will be partly recycled back to process (30-

35%) and partly taken to the Thins Slops Evaporation Plant for concentration of

remaining solids to form a Syrup. This Syrup is also mixed into the Wet Cake coming

out of Centrifuge and forms a part of Cattle Feed. (Also known as Soluble –

Collectively known as DWGS).

� DWGS Drier – Wet Cake / DWGS will be passed through steam tube bundle drier for

drying with 10-12% moisture (max.) to give higher shelf life. Solid dry cakes will be

obtained finally as DDGS.

� The process condensate will be cooled and collected into a neutralization tank with

sufficient residence time. After neutralization and filtration this process condensate

will be recycled into process use.

� Regular monitoring of water quality will be carried out.

Noise Management � Personal Protective Equipment like earplugs and earmuffs will be provided to the

workers exposed to high noise level.

� D.G sets will be provided with acoustic to control the noise level within the prescribed

limit.

� Proper maintenance, oiling and greasing of machines at regular intervals will be done




to reduce generation of noise.

� Green Belt of inside the plant premises and at the plant boundary has been developed.

� Regular monitoring of noise level will be carried out.

Solid & Hazardous

Waste Management � Solid waste from the grain based operations generally comprises of Fibres and

proteins in the form of DDGS, which will be ideally used as Cattle Feed.

� Spent Wash generated during the process, will be first treated in Bio-Digester (Bio-

Methanation) and after that will be concentrated in Multi-effect evaporator and

concentrate is used for bio composting.

� Ash from the Boiler will be used in bio-composting & also given to nearby brick

manufacturers.

� Yeast sludge & Digesters sludge will be finally disposed as Mixing with Press Mud.

� The company will utilize the spent wash for manufacturing bio-compost within the

premises, with proper labelling and marketing of the finished compost, in sealed bags,

bearing the name and seal of our industry and the composition of the bio-compost.

� The company will not sell compost in open tractors/ trolleys.

� Used oil generated from the plant machinery/ gear boxes as hazardous waste is

being/will be sold out to the CPCB authorized recycler.

Green Belt Development / Plantation

Management � Green belt development in and around the plant site helps to attenuate the pollution

level.

� Out of the total plant area approx. 33% land is already developed as green belt and it will

be maintained in future also.

� Green belt has been developed as per Central Pollution Control Board (CPCB) guidelines.

� Native species have been planted in consultation with the local DFO.

Odour Management

Management � Adequate greenbelt all around the periphery of the plant.

� Efficient CO2 scrubbing to avoid carry over of alcohol vapours & other fumes.

� DWGS Dryer will be installed for complete drying of solids.

� Better housekeeping will maintain good hygiene condition by regular steaming of all

fermentation equipment.

� Longer storages of any product/by-products will be avoided & use of efficient biocides

to control bacterial contamination.

� Regular use of bleaching powder/formalin in the drains to avoid generation of

putrefying micro-organisms.




2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of Project and Project Proponent

Piccadily Sugar & Allied Industries Ltd (PSAIL) incorporated with a aim to provide boost to State

industry by establishing a eco-friendly sugar mill in the year 1994 & distillery in 2004 at Village

Himjheri, Jakhal Road, Patran, District Patiala in the State of Punjab. It manufacturers White Crystal

Sugar from Sugar cane cultivated in the surrounding rural area & Rectified Spirit, Extra Neutral

Alcohal (ENA) from molasses/Grain.

Piccadily Sugar & Allied Industries Ltd (PSAIL) is having an existing 70 KLPD Molasses/ Grain Based

Distillery at Village Himjheri, Jakhal Road, Patran, District Patiala (Punjab). Environmental Clearance

for the same has been obtained from MoEF, New Delhi vide Letter No. J11011/1263/2007 - IAII (I)

dated 16th September, 2008 and amendment on vide Letter No. J11011/240/2011 - IAII (I) dated 26th

February, 2013.

(ii) Brief description of nature of the project

In line with the ambitious programme of Govt. of India like “MAKE IN INDIA” and to become self-

dependent on fuel within the country, M/s. Piccadily Sugar & Allied Industries Ltd (PSAIL) has

planned for proposing installation of Unit II – 60 KLPD Grain / Molasses based Ethanol Plant along

with 2 MW Co-generation Power Plant in Existing Distillery Plant at Village Himjheri, Jakhal Road,

Patran, District Patiala (Punjab)

Molasses will be transported through pipelines from own sugar mill located next to Distillery &

nearby Sugar Mills.

M/s. Piccadily Sugar & Allied Industries Ltd (PSAIL) has an existing 70 KLPD Molasses/Grain Based

Distillery at Village Himjheri, Jakhal Road, Patran, District Patiala (Punjab)

As per EIA Notification dated 14th September, 2006 and as amended from time to time; the project

falls in Category ‘A’, S. No. - 5 (g).

(iii) Need for the project and its importance to the country and or region

Advancement in science and technology has created so many products that have enhanced the

quality of human life in every passing year. The human race is largely dependent on industrialization

for up gradation in quality of life. Progress of the nation is judged through its economic growth

which is largely dependent on industrial productivity. In Indian economy (which is agro based) many

industries are dependent over agricultural produce for production of luxury and need based

commodities. Alcohol has assumed a 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 revenue by way of excise duty levied by

the State Government on alcohol liquors. The use of alcohol for the purpose of potable liquor is as

high as its use for industrial purposes.

According to analysts, the Indian Ethanol industry is expected to witness accelerating growth in

coming years. Ethanol is an alcohol fuel that is added to petrol in some countries to lower cost to the

consumer, reduce consumption of oil, and lessen the environmental impact of transportation. Mixed




fuels are rated by the amount of ethanol contained; for example, common blends are E10, which

contains 10% ethanol, and E15, which contains 15% alcohol. Another common blend is E85, also known

as flex fuel, in which the ethanol ranges from 51% in winters to 83% in summers.

In addition, though ethanol reduces air particulate pollution, its production results in fairly high

greenhouse gas emissions and negates any the environmental benefit of the shift from fossil fuel.

The biggest concern with the addition of ethanol to India's fuel supply is that it will take up scarce

land set aside for grazing and other crops to grow fuel. With the demand likely to be huge, there is

bound to be a shift in land use from food crops to fuel crops. Agriculture will become even more

intensive. Without adequate reforms and education in the agricultural sector to increase

productivity, the shift to fuel crops will result in food price inflation. The savings from reduced oil

imports will be spent instead on subsidies and higher food prices.

Furthermore, technology can improve at two ends - energy efficiency at the EV end and greater

storage capacity at the EVB end. The latter would translate into better performing vehicles without

the consumer having to regularly upgrade his EV.

In the path of company’s growth and development this proposed project will serve as yet another

milestone.

(iv) Demand- Supply Gap

Not required in this Project. This depends on excise Department.

(v) Import vs. Indigenous Production

Indian market could not meet present alcohol demand. So they import alcohol 5-7% of total demand.

As far as ethanol production is concerned, Indian market play a vital role at both domestic &

international level. So they require producing more alcohol to meet the demand.

(vi) Export Possibility

Export of ethanol is currently governed by Govt. policy.

(vii) Domestic / Export Markets

Sales and Marketing division has always been a key focus area for our company. Over the years we

have reached a number of key customers through our initiatives. We have a thrust on institutional

Buyers which is a paradigm shift from the tradition of selling to wholesale market.

(viii) Employment Generation (Direct and Indirect) due to the project

For smooth functioning of the plant, the company needs a team of 60 persons. These persons are

responsible towards their respective department such as Process Plant, Boiler Operating Plant and

administrative block.

3.0 Project Description

(i) Type of Project including interlinked and independent projects, if any.

There are no interlinked projects related to this project.

ii) Location (map showing general location, specific location, and project boundary & project site

layout) with coordinates




Figure - 1: Location Map

Proposed Expansion of Grain/Molasses based (From 70 KLPD to 130 KLPD) by installation of 60 KLPD Grain/Molasses based Ethanol Plant along with 2 MW Co-generation Power Plant in Existing Distillery Plant (70 KLPD)

At Village Hamjheri, Jakhal Road, Patran, District Patiala, Punjab



(ii) Key Plan

Figure - 2: Key Plan




(iv) Details of alternative sites consideration and basis of selecting the proposed site, particularly the

environmental considerations gone into should be highlighted.

The proposed installation of Unit II will be done within the existing Distillery plant premises and no

additional land will be required; therefore, no alternative site has been considered.

(v) Size or magnitude of operation

M/s. Piccadily Sugar & Allied Industries Ltd (PSAIL) has planned for proposing installation of Unit II –

60 KLPD Grain / Molasses based Ethanol Plant along with 2 MW Co-generation Power Plant in

Existing Distillery Plant at Village Himjheri, Jakhal Road, Patran, District Patiala (Punjab). Molasses

will be transported through pipelines from own sugar mill located next to Distillery & nearby Sugar

Mills. The company has an existing 70 KLPD Molasses/Grain Based Distillery at Village Himjheri,

Jakhal Road, Patran, District Patiala (Punjab).

(vi) Project Description with Process Details

Project Description

Units Existing Capacity Additional Total After Distillery

Distillery Plant

(Grain / Molasses Based)

70 KLPD 60 KLPD 130 KLPD

Process Description

A. Molasses Based Operation

Alcohol is produced from carbohydrates by fermentation with yeast. Yeasts are unicellular,

uninucleate fungi that can reproduce by budding, fission or both. They have been used for centuries

to brew alcoholic beverages and are the most commonly used micro-organism in the industrial

production of alcohol by fermentation. Ethanol production by fermentation comprises four steps:

• Yeast propagation from yeast slant from the laboratory.

• Fermentation to produce fermented wash containing alcohol.

• Recovery, enrichment and purification of alcohol from fermented wash to produce 95.5 V/V

alcohols.

• Production of absolute alcohol by dehydration of 95.5% V/V alcohol to produce absolute alcohol.

A proper choice of appropriate technology in each of these steps governs the efficient and viable

operation of fermentation alcohol plant.

Yeast Propagation

Yeast, for the production of alcohol is characterized by high selectivity of the yeast species, low

production of by-products (side products), high ethanol yield, high fermentation rate, good

tolerance towards both high ethanol concentration and high in organics in the fermenting substrate,

high temperature tolerance, land high genetically stability. Although finding a strain that has all

these characteristics is difficult, a proper selection and development of the best possible strain is

needed. Sacharomy-cervisiae is the commonly deployed yeast strains in alcohol fermentation of




sugars. The purity and sterility of yeast culture used as inoculums have great influence on the

alcohol yield and longevity of yeast in fermenter. Flocculating yeasts are deployed for continuous

fermentation particularly with yeast recycle system. The selectivity of yeast is also essential to

maintain the required metabolic reaction pathways specific to conversion of sugars to alcohol. The

side products are higher alcohols, acids, etc. which naturally reduce the alcohol yields and final

quality of alcohol. It is, therefore, customary to propagate yeast from laboratory strain in increasing

volumes under sterile and aerobic conditions protecting the same from other wild yeasts and

moulds during their growth. This is done in 3 or four stages starting from a 1 lit inoculums developed

in laboratory from a well preserved yeast culture slant.

Yeast will be developed in plant from fresh slant to laboratory flash culture and then in 3 stage S.S.

yeast propagation vessels (VO1, VO2 and VO3) which operate in series but in batch mode. When

enough bio mass strength is developed, it is pitched Into Fermenter (VO4).

Fermentation

The yeast propagation is only at the start and stabilization of the fermenter. When once the

continuous fermentation is on, the yeast propagation is stopped and only a periodic continuous

addition of small make up of fresh culture from yeast vessel is done to maintain the activity of yeast

in the active yeast count in the fermenter. The yeast vessels are fitted with jacket for sterilizing and

cooling the medium in situ. Sterile air is supplied to these vessels through compressor (G-01) and the

sterilization-system comprising a series of fine filters followed by HEPA filters. Molasses from the

molasses tank T-01 in the yard are pumped to transfer pump (P-02) into tipper type molasses

weighing system W-01 and weighed molasses feed tank (T-03) from where molasses feed pump it to

yeast vessels (when necessary) or to fermenter (V-04) through a static mixer type molasses diluter.

Main fermenter could be one or two stages depending on the control system envisaged based on

the final designs. The heat of fermentation is extracted by circulating the fermenter contents

through wort coolers (EO1 & EO3). Temperature in the fermenter is to be maintained at 32 – 34°C.

Carbon dioxide evolved during fermentation is vented out through scrubber (C-03) to recover

entrained alcohol vapors. Dilute molasses are fed to the fermenter continuously. The final

fermented wash is transferred by wash pump (P-05) to yeast separation system comprising

hydrocolones F-01 & F-02 and centrifuge F-03. The sludge and dead yeast are purged into sludge

tank and yeast cream is returned to the fermenter (V-04) while clear fermented wash is collected in

wash tank V-02. Sludge from sludge tank is fed to the bottom of Analyzer Column (C-01) in the

distillation section. Part of spent wash from a selected tray in the column C-01 is returned to

fermenter V-04 after cooling the same to as near to ambient temperature as possible. Anti-foam oil

is added from T-04 whenever necessary when the level in the fermenter rises beyond a limit due to

foaming because of runaway fermentation rate. The operations in the fermenter can be controlled

closely through automation. Process water is taken into scrubber water tank from where it is fed to




scrubber (C-03) and overhead water tank (T-12) by water pump (P-10). All process water in the

fermentation section is supplied by gravity from this overhead tank (T-12).

RS/AA /ETHANOL/ENA Spirit Distillation

Fermented wash from wash holding tank T-01 is pumped by wash feed pump P-01 to the top of

degassing column (C-2) after preheating the same in beer heater E-02 and spent wash heat

exchanger E-01. The vapors along with non-condensable gases from the top of degassing column (C-

02) are rectified in Heads column (C-03), to expel the high volatiles, technically know as heads.

Bottom liquid from the degasser flows into analyzer column (C-01) where alcohol is stripped from

the liquid. The liquid from bottom of analyzer column (C-01) is completely stripped of alcohol and is

pumped out by spent wash discharge pump P-02 through heat exchanger E-01 where it preheats the

fermented wash before it enters degassing column. Part of spent wash from a tray, few numbers

above the bottom tray is cooled and returned to the fermenters as a measure of water saving and

reduction of effluent discharge.

The dilute alcohol vapors from near the top of analyzer column (C-01) are condensed first in beer

heater (E-02) while exchanging heat with wash feed and then in analyzer condenser (E03). Degasser

and analyzer operate under vacuum. The condensate from E-02 and E-03 is collected in Rectifier

Feed Tank V-02. The vapors for stripping alcohol are generated from analyzer column bottom liquid

in the analyzer column re-boiler (E-04) by using the rectified column top vapors, as discussed

subsequently.

Vapors from the top of heads column (C-03) are condensed in heads column condenser (E-06) and

then in head column vent condenser (E-07). Part of the condensate is returned to column C-03 as

reflux while a small portion is taken out as an impure spirit cut. Liquid from bottom of C-03 is also

taken into Rectified feed tank V-02.

Dilute alcohol water mixture from rectifier feed tank (V-02) are pumped by rectifier feed pump (P-

04) through rectifier feed pre-heater E-11 in to rectifying column (C-04). Rectifier and its associated

equipment work under pressure so that these vapors can supply the necessary heat for generating

the vapors.

The condensate from E-04 is then pumped as Reflux to rectifying column C-04. Rich alcohol vapors

at a concentration of 95.5% v/v from top of rectifying column (C-04) are condensed first in Analyzer

(E-04) and then in Reflux Vent Condenser (E-05). The liquid from E04 and E-05 are collected in

Rectifier Reflux Tank (V-01). Part of the liquid from E-05 may be drawn off as impure spirit. The

impure spirit cut will be maintained as little as possible to maintain aldehyde levels to meet the

required limits in Absolute Alcohol.

Liquid from the reflux tank (V-01) is pumped by Product Pump (P-03) partly as product and partly as

reflux to the top of the Rectifying Column (C-04). The necessary rectifying vapors to C-04 are

generated by boiling the C-04 bottom liquid in Rectifier Column Re-boiler E-08 using medium

pressure steam. Some side streams are drawn from rectifier column as light and heavy fractions of




higher alcohols called fusel oils and cooled in fusel oil coolers E-09 and E-10 and are mixed with water

and allowed to separate out in fuel oil separator F-01. All vents from E-03, E-07, V-02 and E-05 are

connected to Vent Gas Absorber (C-05) where the vent gases are scrubbed with water to recover

entrained alcohol. The scrubber water is used for washing the fusel oils in fusel oil separator to

recover alcohol from the fusel oil fractions. The absorber vent is connected to vacuum pump (G-01)

which is used to create vacuum in the analyzer and degasser.

The products Rectified Spirit and Impure Spirit, are cooled in product coolers and collected in the

respective receiver tanks prior to pumping the same through respective transfer pumps into storage

tanks in the excise godown. Impure spirit, is however, returned to Ethanol plant along with the

rectified spirit feed, subject to maintaining, the Absolute Alcohol quality required for blending with

petrol.

Fuel Grade Ethanol

Absolute alcohol is manufactured by dehydration of Rectified Spirit. The process adopted here is

based on Pressure Swing Adsorption (PSA) system using Molecular Sieves (3-A). The flow scheme is

shown in above referred flow diagram.

Rectified spirit, after preheating by waste hot streams, is vaporized and superheated in E-03 and E-

04 by using medium pressure steam at 6 Kg/cm2g pressure. Hot vapors at kg/cm² g pressure and

130° C temperature pass through PSA column S-01A/S-01B where the water vapors are retained while

water free alcohol is released as vapors. The vapors are condensed in E-07 and E-08 and collected as

Absolute Alcohol. When the molecular sieve bed is saturated with water the alcohol vapors are

shifted to the other tower and the first tower is taken for regeneration. Regeneration is done first

by pressure releasing and creating vacuum and then by elutriating with dehydrated alcohol vapors

from the tower in dehydration operation. The vapors are condensed in E-06 and E-05 and the vent

vapors are recovered through scrubber C-02. Vacuum can be created vacuum by P-04. (Eductor may

also be considered for this duty). Product is cooled in E-09 and transferred to Absolute Alcohol

receiving tank and then on to storage tank.




Figure 3: Molasses Based Distillery Process

Effluent Handling Section

Effluent discharged from the distillation process, commonly known as Spent Wash, is one of the

most polluting effluents with very high values of BOD and COD. It is first treated in a Bio-

methanation System, which not only reduces the effluent load, but also produces methane rich

biogas. Biogas is a high calorific value fuel and is used as fuel for boiler to produce power and steam

to run distillery plant. The production of extra power from biogas improves the economics of the

ethanol project. The effluent after Bio-methanation is being/will be concentrated in Multi-effect

evaporator and then used for Bio-composting.

1) Bio-methanation Process

Bio-methanation involves conversion of organic compounds present in the effluent, using a

consortium of bacteria under anaerobic conditions. During their life cycle, the bacteria break down

these organic compounds into methane and carbon dioxide. The bacteria, being living organisms,

require specific conditions to prosper. This is achieved by controlling the following parameters:

Temperature

Acidity

Organic Loading

Nutrient Balance




The existing bio-methanation system uses a specially designed CSTR, called bio-digester, to convert

organic matter into useful energy in the form of biogas. The biological process of conversion takes

place at mesophilic temperature in a controlled atmosphere, ensuring maximum conversion

efficiency and production of biogas.

Following are the salient features of the process:

• Pre - Settling

Before entering the bio digester, the spent wash from the distillery unit is received into a

spent wash pit to enable settling of suspended solids. The pre-settling system ensures

consistent operation by reducing the solid build up in the bio digester. The settled solids are

removed periodically from the pit for further disposal.

• pH Control

Spent wash pH is adjusted to 6.5-7.0 by recycling part of the treated effluent.

• Mixing in Bio digester

Mixing is done by recirculation of biomass, using a specially designed mixing system and is

further enhanced by gas propagation. Efficient mixing helps micro organisms to reach fresh

nutrients in a favourable living condition and convert organic matter into methane and carbon

dioxide. Various sample points are provided in the biodigester to measure the concentration

of sludge. Drain points are provided to drain the sludge from the bio digester. The sludge is

settled in the parallel plate clarifier, which is recycled to increase solid retention time in the bio

digester. Supernatant liquid from the clarifier is sent for further treatment. Excess biomass

and sludge is removed from the bottom of the bio digester regularly and sent to sludge drying

beds for disposal.

• Gas Collection & Handling

Biogas produced in the bio digester is collected from the top of the digester and flows to the

gas holder. The gas holder acts as an intermediate gas storage and pressure control device.

Biogas is transferred to a biogas power plant to produce power. A flare unit is provided for

excess gas burning.

• Safety Systems

For safe operation, flame arresters are provided on gas lines to protect the bio digester from

backfire & pressure relief valves are provided on bio digester to protect from excess pressure

or vacuum.

• Control Systems

Controlling pH ensures the smooth and safe operation of the system. Temperature, volatile

acidity and alkalinity are also controlled, using various control features provided.

• Type of Bacteria

Anaerobic digestion of organic compounds is carried out, using different bacteria. Three main

groups of bacteria, used in the process are indicated below:




� Hydrolyzing bacteria ( Solubilising bacteria)

� Acetogenic bacteria ( Acetate forming bacteria)

� Methanogenic bacteria ( Methane forming bacteria)

2) Multi-Effect Evaporation

Direct spent wash will be concentrated in a multistage vacuum evaporator from 5-7% to 30-35%

solids. The total process is under vacuum and the vapours generated in the system are

compressed in a TVR to economize steam consumption. Condensate water generated from

the evaporation system will be recycled back in the process. The concentrated effluent is used

in Bio-composting

3) Bio Compost Plant

The composting process consists of converting the spent wash into useful manure. This is

done with the help of specialized microbial culture or using fresh compost as seed for the

micro-organisms. The raw materials required for composting are concentrated spent wash

from multi effect evaporator, bacterial culture, Press mud from the sugar factory, ash from

boiler

Composting is a biological oxidation process for decomposing organic material by a mixed

microbial population in a suitably warm and moist environment under aerobic conditions. The

degradation converts the material to a stable organic fertilizer which is also a soil improver.

The aerobic composting process involves arranging the press mud (filler material) in 300 to

400 m long windrows of triangular section of about 1.5 m height by 3.0 m. width on

impervious ground usually with the help of front end loaders. The windrows are sprayed with

a measured quantity of spent wash, in the ratio of 3.5:1 (spent wash to press mud). The ratio

will vary depending on the moisture content of the filler materials. The spraying of spent wash

is done when the moisture content of the press mud drops to 50%. The moisture content is

not allowed to exceed 65% as at that moisture anaerobic condition start prevailing which is

detrimental to the composting process. The windrows are inoculated with the seed material

after the first spray. About 1 Kg. of bio culture is required per ton of press mud. From ambient

temperature at start up the temperature rises to 65 Deg. C. by the second week and continues

up to the 4th week. The total duration for completion of the reactions is about 6 weeks by

which time the temperature returns to ambient. A further 2 weeks is allowed for curing.

Carbon to nitrogen ratio is the deciding factor to determine the completion of the bio

composting process. Specialized mixing machines called aero-tillers, traveling along the length

of the windrows are used to mix and aerate the decomposing mass, about once in three days.

This results in increased spent wash absorption, oxygen supply for proper growth of micro-

organisms and dissipation of heat, which is liberated due to metabolic activity of micro-

organisms. The moisture content during composting is maintained at 50-60% by periodic

spraying of the spent wash. Adequate holding capacity (min. 30 days) is to be provided for the




spent wash in lined lagoons to cater to any demand mismatch. The lagoons should be duly

lined and pitched by stone/bricks with cement mortar to prevent leachate. Composting is to

be carried out on a raised impervious floor protected by bunds with provision for leachate

collection and surface runoff and it’s pumping to the holding lagoon. Pipe network is laid for

automatic spraying of spent wash.

B. Grain Based Distillery Process

Process Description of Grain Based Operation

a) Grain Storage Silos, Cleaning, Handling and Milling Section:

Grain is received from various sources and is pre-cleaned off stones, husk, etc. and then stored

in specially designed storage silos. Grains are continuously lifted from the bottom of the silos

and screened followed by removal of stones in de-stoner and iron matters in magnetic

separators. Cleaned Grains are then milled using dry milling process in Hammer Mills. The flour

is fed through the bucket elevator and conveyed to the Batch Tipping Machine through a

Screw Conveyor.

b) Slurry Preparation / Liquefaction

Slurry from pre-masher is taken to Initial liquefaction tank where liquefying enzyme is added.

The mixture of slurry and steam is then passed through the retention vessel (cook tube)

having sufficient capacity to provide the desired retention time at a given flow rate. The

cooked mash is discharged to a flash tank for liquefaction.

The gelatinized mash from the flash tank is further liquefied in a final liquefaction tank where

liquefying enzyme is added. Then the liquefied mash is cooled in slurry cooler and transferred

to Fermentation section.

c) Fermentation Section

The purpose of fermentation is to convert the fermentable substrate into alcohol. At the start

of the cycle, the fermenter is charged with mash and contents of the Yeast Activation Vessel.

Significant heat release takes place during fermentation. This is removed by passing cooling

water through the Fermenter PHE’s to maintain an optimum temperature. The recirculating

pumps also serve to empty the fermenter into Beer Well.

d) Distillation Section

Wash to ENA Multi-pressure: -

Pre-heated fermented wash is fed into a series of Distillation Columns to increase the alcohol

concentration and remove various impurities .The columns are termed as below:

Degasifier

Analyzer

Pre Rectifier

Extractive Distillation

Exhaust




Recovery

Simmering

ENA drawn from the Simmering Column is taken to the receiver after cooling in ENA cooler.

e) Evaporation Section

The slop discharged from the Analyzer column is taken to the evaporation section for

concentrating the slop up to 40 % w/w solids.

Treatment scheme is a series of evaporation effects working on the principle of falling film

Evaporation & Forced circulation.

f) Dryer Section

The concentrated syrup is mixed with the wet cake from the decantation section .This mixture

is termed as DWGS which is then fed in Dryer to reduce the moisture of upto 10 %. This by

product is termed as DDGS which is in a powder form.

g) Process Condensate Treatment Section

The process condensate from the evaporation section is treated in this unit and this treated

condensate is then recycled back to process thus reducing the fresh water consumption.

Fig. 4: Process flow chart For Grain Based Distillery




C. Power Co-generation 2 MW

OPERATIONS

The unit proposes to set-up boiler and power turbine.

In this proposed expansion project a 25 TPH boiler will be installed and based on Bagasse/Rice

Husk/Coal and Biogas as available fuel options. This Boiler will operate mainly to feed steam to

Molasses based operations and 2 MW power generations from Turbine.

Proposed 2 MW co-generation plant consists of a high pressure water tube steam boiler

extraction cum condensing steam turbine. Fuel in the steam boiler will be burnt with the help

of air in the boiler furnace. Water will be circulated in the boiler drum and tubes thus getting

heated by the flame burning in the boiler furnace. Water comes out of the boiler drum located

at the top of the boiler as steam. Flue gases rise in the boiler furnace and come in contact with

the steam coming out of boiler drum. Steam after coming in contact with flue gases gets

heated up further thus getting superheated. Super heated steam leaves the boiler in a pipe.

Flue gases after super heating the steam pass through economizer where they pre-heat the

boiler feed water before it enters the boiler drum. After economizer, flue gases pass through

air pre-heaters where they heat the air which is fed to the boiler furnace for burning the fuel.

After air pre heaters flue gases pass through Bag Filter/ESP where the dust particles are

collected.

High pressure superheated steam from boiler will be passed through a steam turbine, which

will be used for distillery process operations. While passing through the turbine, the high

pressure and temperature steam rotates the turbine rotor and an electric alternator mounted

on the same shaft. Electric power will be generated by the alternator. This electric power

generated will be consumed in house i.e. for running the distillery and utilities like boilers

auxiliaries etc.




Figure 5: Process Flow Chart for Cogeneration Power Plant

(vii) Raw material required along with estimated quantity, likely source, marketing area of final

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

(a) Raw Material Requirement

The raw materials required for the Grain / Molasses based distillery can be broadly categorized as

follows:

• Molasses

• Grain

• Enzymes & Chemicals

Details regarding quantity of raw materials required their source along with distance & mode of

transportation for proposed project are given in Table below.

Table 2

Raw Material Requirement for Molasses Based Distillery

S. No.

Particulars Total Requirement Source and mode of transportation

1. Grain 157 to 165 MT/day Nearby Area

Molasses 282 to 300 MT/day Own sugar mills through pipelines/ road

2. Chemicals

Sodium Hydroxide (Caustic) 600 kg/day Nearby market

NH2-CO- NH2 (Nutrients) 50 kg/day

Enzymes As per requirement

Antifoam Agent 100 Kg/day

Yeast (Active Dry Yeast/Distiller’s Yeast)

Own Propagation




(b) Fuel Requirement

S. No. Fuel Total requirement for proposed 25 TPH Boiler Source

1 Biogas 32000 m3/day Own plant through pipelines

2 Bagasse 84 ton/day Own plant through conveyor belt

Rice Husk 100 Ton/Day Nearby area

Note: 15% Auxiliary Fuel will be used such as Coal.

(viii) Resources optimization/ recycling and reuse envisaged in the project, if any, should be briefly

outlined.

Water as a resource will be recycled at each possible step of the process and latest technology and

methodology will be adopted to conserve and reuse the resources.

(ix) Availability of water it’s source, energy /power requirement and source should be given.

(a) Water Requirement and Source

Total fresh water requirement for proposed 60 KLPD Ethanol Plant will be 526 KLPD.

Source of Water: Ground Water

60 KLPD Molasses Based operations – Water Balance

Table – 3 (A)

Total Water Input

S. No Section Water quantity (KLD)

1 Process Water in Fermentation 455

2 DM Water for RS Dilution 575

3 DM Water for Boiler Feed 480

4 Soft Water for analyzer flash tank 104

5 Soft Water for Make for vacuum pump and others 30

6 Soft water makeup for cooling tower 290

7 Water in Molasses 56

8 Other Domestic Use (Provisional) 10

9 Miscellaneous Washing (Provisional) 10

TOTAL WATER INPUT 2010




Table – 3 (B)

Total Water Output

S. NO. SECTION Water quantity (KLD)

1 Steam Condensate 364

2 Water in Spent wash 590

3 Spent lees(rectifier) 575

4 Spent Lees ( Pre-rectifier) 76

5 CT Evaporation & Blowdown 290

6 Domestic Consumption 10

7 Boiler Blowdown 65

8 Vacuum Pump Sealing/Purge 30

9 Miscellaneous Washing (provisional) 10

TOTAL WATER OUTPUT 2010

TABLE – 3 (C)

RECYCLING & UTILIZING STREAM

S. No. SECTION Water quantity (KLD)

1 Lees recycle for RS dilution 495

2 Steam Condensate recycle for boiler 364

3 Spent lees(Rect) cooling tower Make up 80

4 Process condensate recycle to process& CT 520

5 Vacuum Pump water recirculation 25

TOTAL RECYCLING/RE-UTILIZATION OF WATER PER DAY 1484

TOTAL FRESH WATER INPUT 526

� Hence, fresh water Requirement is 526 KLD

� Water requirement for first run would be 2010 KLD




Figure 6: Water Balance of 60 KLPD Molasses Based Ethanol Plant




60 KLPD Grain Based operations – Water Balance

Table – 3 (A)

Total Water Input

S. No Section Water quantity (KLD)

1 Process water in Liqn & Fermentation 356

2 DM water for RS Dilution 543

3 DM water for Boiler Feed 440

4 Soft Water for Analyser Flash Tank 102

5 Soft Water for Vacuum Pump & Others 50

6 Blending (5000 Cases ) 25

7 Bottle washings 12

8 Soft water Makeup for Cooling Tower 360

9 Misc. Washing Water 10

10 Other Domestic Usage 5

TOTAL WATER INPUT 1902

Table – 3 (B)

Total Water Output

S. NO SECTION Water quantity (KLD)

1 Steam Condensate 353

2 Spent Lees PR 95

3 Spent Lees Rectifer 543

4 Spent Wash (Grain Slops) 450

5 Soft Water For Vacuum Pump & Others 50

6 Water in Product 25

7 Bottle Washing 12

8 CT Evaporation & Drift Losses 360

9 Misc. Washing water 10

10 Domestic Consumption 5

TOTAL WATER OUTPUT 1902

Table – 3 (C)

Recycling & Utilizing Stream

S. No. SECTION Water quantity (KLD)

1 Lees recycle for RS Dilution 416

2 Steam condensate recycle for Boiler 353

3 Spent Lees (Rect) - Cooling tower makeup 127

4 Thin slops recycle to Liqn & Distn Process 209

5 Process Condensate to process & CT 176

6 PR lees to process 95

TOTAL RECYCLING/RE-UTILIZATION OF WATER PER DAY 1376

TOTAL FRESH WATER INPUT 526




Figure 6: Water Balance of 60 KLPD Grain Based Distillery Plant




(b) Power Requirement and Source

The total power requirement of the plant will be 1.2 MW which will be sourced from proposed

2.0 MW Co-Generation Power Plant.

(c) Steam Requirement

The total steam requirement of the plant will be 18.5 TPH. The source will be proposed 25 TPH

boilers.

(d) Boiler Details

One Boiler with 25 TPH capacity is proposed to be installed. Others details regarding this are

mentioned in the table given below

Table – 5

Boiler Details

S. No. Details Proposed

1. Type of Fuel Bagasse/Rice Husk/Coal and Biogas

2. Capacity of Boiler 25 TPH

3. Stack Height 35 m

4. Pollution Control Equipment Measures ESP/Bag Filter

(e) Details regarding the D.G. Sets

1 D.G. sets of 500 KVA will be installed for the power backup. Details regarding the D.G. Sets

are mentioned in the table given below:

Table – 6

Details Regarding the D.G. Sets

S. No. Details

1. Type of Fuel HSD

2. Capacity 500 KVA

3. Stack Height (above roof level) As per CPCB/SPCB norms

4. Pollution Control Equipment Measures Adequate stack height/ Acoustic

(x) Quantity of waste to be generated (liquid and solid) and scheme for their management/disposal

� The project will be based on “Zero Effluent Discharge”.

Molasses Based Distillery

� Spent wash generated during Molasses operation will be concentrated in Multi-effect

evaporator and then used for Bio-composting.

� Process condensate from MEE will be treated and recycled back in the process.

� Record of wastewater returned back to process for utilization in Fermentation/cooling tower

and to gardening will be kept.

� The sewage generated from the sanitary blocks is being/will be treated in septic tanks and

applied on to soak pits and used for irrigation.




� Spent Wash generated during the process will be first treated in Bio-Digester (Bio-

Methanation) and after that will be concentrated in Multi-effect evaporator and concentrate

is used for bio composting.

� Ash from the Boiler will be used in bio-composting & also given to nearby brick manufacturers.

� Yeast sludge & Digesters sludge will be finally disposed as Mixing with Press Mud.

� The company will utilize the spent wash for manufacturing bio-compost within the premises,

with proper labelling and marketing of the finished compost, in sealed bags, bearing the name

and seal of our industry and the composition of the bio-compost.

� The company will not sell compost in open tractors/ trolleys.

Grain Based Distillery

� Grain slops (Spent Wash) will be taken care through Centrifuge Decanters for separation of

Suspended Solids separated as Wet Cake and which goes as cattle feed as it contains high

protein. (Also known as DWG – Distillers Wet Grains).

� Thin slops from the Decanter Centrifuge will be partly recycled back to process (30-35%) and

partly taken to the Thins Slops Evaporation Plant for concentration of remaining solids to form

a Syrup. This Syrup is also mixed into the Wet Cake coming out of Centrifuge and forms a part

of Cattle Feed. (Also known as Soluble – Collectively known as DWGS).

� DWGS Drier – Wet Cake / DWGS will be passed through steam tube bundle drier for drying

with 10-12% moisture (max.) to give higher shelf life. Solid dry cakes will be obtained finally as

DDGS.

� The process condensate will be cooled and collected into a neutralization tank with sufficient

residence time. After neutralization and filtration this process condensate will be recycled into

process use.

� Solid waste from the grain based operations generally comprises of Fibres and proteins in the

form of DDGS, which will be ideally used as Cattle Feed.

� Used oil & grease generated from plant machinery / Gear boxes & D.G. Set is being / will be

partly used in oiling & greasing as lubrication of external parts of machinery & partly is being /

will be sold to the CPCB authorized recycler.

4.0 SITE ANALYSIS

(i) Connectivity

The plant site is located about at Village Hamjheri, Jakhal Road, Patran, District Patiala (Punjab). The

plant site is well connected to NH 71 (Approx 3 km in NE direction from the plant site) & SH 10

(Approx 1 km in East direction from the plant site). Nearest town to the plant site is Patran (~ 3.5 km

in NNE direction). Nearest railway station is Jakhal Railway Station (~ 24.5 km in SW direction) and

nearest airport is Chandigarh Airport, which is ~ 110 km in NE direction from the plant site. The site is

suitably located with respect to availability of raw material, water, road network, skilled/semi




skilled/unskilled and professional manpower etc. All communication facilities such as telephone,

telefax & internet are available in the vicinity of the plant site.

(ii) Land from Land use and Land ownership

Total plant area is 70 acres/ 28.32 ha. Since, the proposed installation of Unit II will be done within

the existing plant premises, thus, no additional land is required. Hence, land ownership will be

considered as Industrial type.

(iii) Topography

The topography of the area is almost flat.

(iv) Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area under

CRZ)), shortest distances from the periphery of the project to periphery of the forests, national

park, wild life sanctuary, eco sensitive areas, water bodies (distance from the HFL of the river),

CRZ. In case of notified industrial area, a copy of the Gazette notification should be given

Environmental Settings of the Area

S. NO. PARTICULARS DETAILS

1. Nearest Village Hamjheri (1.0 km in SE direction)

2. Nearest Town Town - Patran (3.5 km in NNE direction)

3. Nearest National Highway / State Highway

NH - 71 (3.0 km in NE direction)

SH - 10 (1.0 km in East direction)

4. Nearest Railway station Jakhal Railway Station (~ 24.5 km in SW direction)

5. Nearest Airport Chandigarh (~ 110 km in NE direction)

6. National Parks, Wild Life Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors etc. within 10 km radius

No National Park, Wild Life Sanctuary, Biosphere Reserve, Tiger / Elephant Reserve, Wildlife Corridors etc. falls within 10 km radius of the plant site.

7. Reserved Forests (RF) / Protected Forests (PF) etc. within 10 Km. radius

Nil

8. River / Water Body (within 10 km radius)

River

• Ghagghar River (9.0 km in SE direction)

Nala/Drain

• Choa Nala (1.0 km in NW direction)

• Kalbhanu Drain (1.0 km in South direction)

• Main Drain n0 1 (9.0 km WNW direction)

Agricultural canal

• Alan Branch (0.5 km in East direction)

• Hariau Branch (4.0 km WSW direction)

• Bhakra Canal (6 km in ESE direction)

• Ladbanjara Distributary (7.5 km in WNW direction)

9. Soil Type Tropical arid brown and arid brown

10. Seismic Zone Zone - III [as per IS 1893 (Part-I): 2002]




(v) Existing Infrastructure

Total plant area is about 70 Acres/28.3 ha. Proposed installation of Unit II will be done within the

existing plant premises.

(vi) Soil classification

The district area is occupied by Indo-Gangetic alluvial plain and consists of three types of region viz.

the Upland plain, the Cho-infested Foothill Plain and the Floodplain of the Ghaggar River. The

elevation of land ranges from 240 to 278 m amsl. Due to arid climate, the soils are light coloured.

Tropical arid brown soils exist in the major parts of the district. Here soils are deficient in nitrogen,

phosphorus and potassium. In Patran and Samana blocks, soils are arid brown soils occur. These are

calcareous in nature and in most cases kankar layers occur.

(vii) Climatic data from secondary sources

The climate of Patiala district can be classified as tropical steppe, Semi-arid and hot which is mainly

dry with very hot summer and cold winter except during monsoon. There are four seasons in a year.

The hot weather season starts from mid March to last week of the June followed by the south west

monsoon which lasts upto September. The transition period from September to October forms the

post monsoon season. The winter season starts late in November and remains upto first week of

March. The normal monsoon and annual rainfall of the district is 547 mm and 677 mm, respectively

which is unevenly distributed over the area 29 days. The south west monsoon sets in from last week

of June and withdraws in end of September, contributing about 81% of annual rainfall. July and

August are the wettest months. Rest 19% rainfall is received during non-monsoon period in the wake

of western disturbances and thunderstorms. Generally rainfall in the district increases from

southwest to northeast. The mean minimum and maximum temperature in the area ranges from 7.1o

C to 40.4o C during January and May or June respectively.

(viii) Social Infrastructure available

Nearest habitation is at Hamjheri village. The nearest town is Patran, which is approx. 3.5 km

distance from the plant site. At Patran Town schools, Hospital, dispensaries, colleges, places of

worship, Railway station, Markets & other facility etc are available. Electrical power supply in most of

surrounding villages is available.

Telephone, Medical facilities are available in the nearby towns. Almost all the villages in the buffer

zone are electrified. L.T. power is being supplied for drawing water from a large number of tube

wells sunk around the important village of the buffer zone, for irrigation purpose. Most of the tanks

and ponds as well as the river water are being utilized for irrigation.




5.0 PLANNING BRIEF

(i) Planning Concept (type of industries, facilities, transportation etc.) Town and country Planning/

Development authority classification.

The existing unit is Distillery industry. Transportation of raw material and final product is being / will

be done via existing road and cement concrete road has been developed within the existing plant

premises.

(ii) Population Projection

M/s Piccadily Sugar & Allied Industry Limited has also organised various activities in nearby villages

under corporate social responsibility (CSR) programme which leads to better living standards of

villagers.

(iii) Land use planning (breakup along with green belt etc)

Total Plant area is 70 Acres/28.3 ha. This project is for proposed installation of Unit II which will be

done within the existing plant premises. No additional land will be required. About 33 % of the total

project area is being/will be covered under green belt & plantation in order to reduce dust & noise

pollution levels & to increase aesthetic beauty of the area.

(iv) Assessment of infrastructure demand (Physical & Social)

Piccadily Sugar & Allied Industry Limited has assessed the demand of infrastructure (Physical &

Social) in nearby area of the plant site and development activities are being undertaken under

corporate social responsibilities program for rural development initiatives for the upliftment of the

nearby communities from time to time.

(v) Amenities/Facilities

Piccadily Sugar & Allied Industry Limited has developed and will further develop the

Amenities/Facilities in nearby area of the Plant site as per requirement of local people of the nearby

area under corporate social responsibilities programs.

6.0 PROPOSED INFRASTRUCTURE

(i) Industrial Area (Processing Area)

No additional infrastructure will be required for the project as the project is of proposed installation

of Unit II 60 KLPD Ethanol Plant and is already set up in the existing plant premises.

(ii) Residential area (Non Processing area)

No residential area is envisaged. The local labor will be preferred to provide employment

opportunities.

(iii) Green Belt

Out of the total plant area i.e. 70 Acres/28.3 ha, 23 acres/9.3 ha (~33%) has already been developed

under greenbelt / plantation area. The same will be maintained in order to reduce dust & noise

pollution levels & to increase aesthetic beauty of the area.

(iv) Social Infrastructure




The project has resulted in growth of the surrounding areas by increased direct and indirect

employment opportunities in the region including ancillary development and supporting

infrastructure.

(v) Connectivity

The site is well connected with communication facilities like telephone, fax, and wireless as such, no

constraints are envisaged in this aspect as the Tehsil and District headquarters are near to the site.

(vi) Drinking Water

5 m3/ day water will be required for drinking purpose which will be sourced from Ground Water.

(vii) Sewage Treatment System

The sewage generated from the sanitary blocks will be treated via soak pit. Treated water will be

utilized in process, greenbelt development & dust suppression.

(viii) Industrial Waste management

The Molasses based Ethanol Plant will be based on “ZERO DISCHARGE”.

(ix) Solid Waste Management

� Solid waste from the grain based operations generally comprises of Fibres and proteins in the

form of DDGS, which will be ideally used as Cattle Feed.

� Spent Wash generated during the process, will be first treated in Bio-Digester (Bio-

Methanation) and after that will be concentrated in Multi-effect evaporator and concentrate

is used for bio composting.

� Ash from the Boiler will be used in bio-composting & also given to nearby brick manufacturers.

� Yeast sludge & Digesters sludge is being/will be finally disposed as Mixing with Press Mud.

(x) Power requirement and source

The total power requirement of the plant will be 1.2 MW which will be sourced from proposed 2.0

MW Co-Generation Power Plant & & D.G Sets (for emergency).

7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

(i) 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).

The proposal is for installation of Unit II – 60 KLPD Grain /Molasses based Ethanol Plant which will be

done within the existing plant premises. No additional land is required. Therefore there will not be

displacement of people and hence Rehabilitation & Resettlement is not applicable.

8.0 PROJECT SCHEDULE AND COST ESTIMATES

(i) Likely date of start of construction and likely date of completion (time schedule for the project to

be given).

The project will start only after obtaining Environmental Clearance and all other required clearance

and will complete within 3 years of commencement.




(ii) Estimated project cost along with analysis in term of economic viability of the project.

� Total cost of the Project: Rs. 47.0 Crores

� Cost for Environment Protection Measures:

� Capital Cost: Rs. 10 Crores

� Recurring Cost/annum: Rs. 1.0 Crores/annum

9.0 ANALYSIS OF PROPOSAL

(i) Financial and social benefits with special emphasis on the benefit to the local people including

tribal population, if any, in the area.

Proposed project will result in growth of the surrounding areas by increasing direct and indirect

employment opportunities in the region including ancillary development and supporting

infrastructure. Special emphasis on Financial and Social benefits will be given to the local people

including tribal population, if any, in the area.

Development of social amenities will be in the form of medical facilities, education to

underprivileged and creation of self help groups.

Punjab state will get revenues in terms of taxes and local people will get direct & indirect

employment. Business opportunities for local community will be available like transport of alcohol to

market, fly ash transport to Brick manufactures, maintenance & house-keeping contract work etc.

Documents

PRE - FEASIBILITY REPORTenvironmentclearance.nic.in/writereaddata/Online/TOR/01...dependent on fuel within the country, M/s. Piccadily Sugar & Allied Industries Ltd (PSAIL) has planned