PRE - FEASIBILITY REPORTenvironmentclearance.nic.in/writereaddata/Online/TOR/0_0_21_Dec_2… · Rs. 10 Crores Cost for Environment Management Plan o Capital Cost - Rs. 3.0 Crores

Proposed Capacity Enhancement by Modernization in Existing Grain Based Distillery (100 KLPD to 125 KLPD) & Co-generation Power Plant (3 MW to 3.8 MW) At Village: Chulkhana, Tehsil: Samalkha, District: Panipat (Haryana)

Pre - feasibility Report

M/s. Haryana Organics (A unit of Globus Spirits Ltd.) 1

PRE - FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY

(I) INTRODUCTION

Globus Spirits Ltd is one of the leading players in the alcohol industry in Northern India.

The company has an existing 100 KLPD Grain/ Molasses Based Distillery at Village Chulkhana, Tehsil

Samalkha, District Panipat (Haryana). Now, the company is proposing enhancement in capacity

from 100 to 125 KLPD within the same premises.

The proposed capacity enhancement by modernization is only about 25% of the present operation

capacity i.e. 100 to 125 KLPD; the same will be achieved by adopting improvement in fermentation

& distillation technology.

In addition to above, Vapour Integration Plant with the dryer will be installed for recycling of

water.

No additional land is required for the proposed capacity enhancement project, as the same will be

done within the existing plant premises.

No increase in water, steam, power and manpower requirement. The project is based on “Zero

Effluent Discharge.”

Table - 1

Salient Features of the Project

S. NO. PARTICULARS DETAILS

A. Nature & Size of the Project

Units Existing Capacity

Proposed

Capacity

Enhance

ment

Total Capacity

after

Enhancement

Grain Based

Distillery (KLPD)

100

or 75 KLPD Grain

based + 25 KLPD

Molasses Based

25 125

Co-generation

Power Plant (MW) 3.0 0.8 3.8

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 Chulkhana

Tehsil Samalkha

District Panipat

State Haryana

Latitude 290 12’ 59.64’’ N to 290 13’ 11.74’’ N




Longitude 760 59’ 42.07’’ E to 760 59’ 76.24’’ E

Toposheet No. H43Q16,H43R3 & H43R4

D. Area Details

Total Plant Area

o Existing plant area: 17 acres (6.878 ha).

o No additional land is required for the proposed capacity enhancement, as

the same will be done within the existing plant premises.

Greenbelt / Plantation Area (ha) 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 Chulkhana (1.5 km in SW direction)

2. Nearest Town Samalkha (2.6 km in NNE direction)

3. Nearest City Panipat (20 km in SE direction)

4. Nearest National Highway / State

Highway

NH-1 (2.0 km in East direction)

5. Nearest Railway station Samalkha Railway Station (2.6 km in NNE direction)

6. Nearest Airport New Delhi (74 km in South direction)

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

No Reserved / Protected Forest lies within 10 km radius (Boundary to

boundary distance) of the proposed project site.

9. River / Water Body (within 10 km

radius)

Western Yamuna Canal - New Delhi parallel branch (5.5 km in West direction)

F. Cost Details

Total Cost of the Enhancement

Project

Rs. 10 Crores

Cost for Environment

Management Plan

o Capital Cost - Rs. 3.0 Crores

o Recurring Cost - Rs. 50 Lacs / annum.

G. Basic Requirements for the project Existing

Additional for proposed

capacity enhancement

Total after proposed

capacity enhancement

Water Requirement (KLD) 552 Nil 552

Source: Ground Water

Power Requirement (MW) 3.2 Nil 3.2

Source: Captive Thermal Power Plant, State Electricity Board & D.G Set (for

emergency).

Man Power Requirement 120 Nil 120

Source: Unskilled / Semi-Skilled - Local Area; Skilled - Outside Haryana.

H. Product Rectified Spirit, Extra Neutral Alcohol, Country Liquor & IMFL

I. Working Days 350 Days per Annum




1.1 Environment Management Plan

Particulars Details

Air Management

Emissions � A stack of adequate height equipped with ESP is installed with the boiler to control the

particulate and gaseous emissions.

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

Scrubbers and sold to authorized vendor.

� Grain is being / will be stored in silos.

� All the roads are concreted to control the fugitive dust emissions.

� Proper servicing & maintenance of vehicles is being/will be carried out.

� Greenbelt has already been developed all around the plant boundary and the same will be

further maintained & enhanced.

Monitoring Ambient air quality and stack emission is being / will be regularly monitored to ensure that ambient

air quality standards are being met all the time.

Water Management

Management � The project is being /will be based on “Zero Effluent Discharge”.

� Grain Slops (Spent Wash) is being / will be taken 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 is being/will be partly recycled back to process (30-

35%) and partly taken to 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

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

� DWGS Drier - Wet cake / DWGS is being / will be passed through steam tube bundle drier for

drying into cake with 10 - 12% moisture (max.) to give higher shelf life. Solid dry cakes are being

/ will be obtained finally.

� The Process condensate is being / will be cooled and collected into a neutralization tank with

sufficient residence time. After Neutralization and filtration (UF+RO) this process condensate

will be recycled into process use.

Noise Management

Management � Personal Protective Equipment like earplugs and earmuffs is being / will be provided to the

workers exposed to high noise level.

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

prescribed limit.

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

to reduce generation of noise.

� Green Belt of appropriate width inside the plant premises and at the plant boundary has been

developed.

Monitoring Regular monitoring of noise level is being / will be carried out and corrective measures in

concerned machinery are being/will be adapted accordingly to the possible extent.




Solid & Hazardous Waste Management

� Solid waste from the Grain based operations generally comprises of Fibres and proteins in the form of DDGS, which

are being / will be ideally used as Cattle Feed.

� Ash from the Boiler is being / will be sold to Brick manufacturers.

� Used oil & grease generated from plant machinery/Gear boxes as hazardous waste are being / will be sold out to the

CPCB authorized recycler.

Green Belt Development / Plantation

� Out of the total plant area (i.e. 6.878 ha), ~ 33% area has already been developed under green belt/ plantation. The

same will be maintained & further enhanced.

� Green belt development along with the road & plant boundary will attenuate noise level arrest dust and improve the

environment in surrounding.

� Native plant species has been planted in consultation with local horticulturist.

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of Project and Project Proponent

Applicant : M/s Globus Spirits Limited

Registered Address : F-0, Ground Floor, The Mira Corporate Suites, Plot No. 1 & 2, Ishwar Nagar,

Mathura Road, New Delhi.

Globus Spirits Limited has enjoyed a good track record in the business of manufacture, marketing

and sale of Indian Made Foreign Liquor (IMFL), Industrial Alcohol comprising Rectified Spirit &

Extra –Neutral Alcohol and Country Liquor.

With headquarter in Delhi, the company markets its own IMFL brands in North Indian states of

Rajasthan, Haryana and Uttar Pradesh and also in union territory of Chandigarh. Company also

proposes to launch IMFL brands in three more states in North India. In South India it is already

selling in Kerala, Andhra Pradesh and Karnataka. The company also has an extensive brand

portfolio of its own brands in the country liquor segment.

Globus Spirits Limited (GSL) is having an existing 100 KLPD Grain Based Distillery or 75 KLPD Grain

Based & 25 KLPD Molasses Based Distillery at Village Chulkhana, Tehsil Samalkha, District Panipat

(Haryana). Environmental Clearance for the same has been obtained from MoEF, New Delhi vide

Letter No. J-11011/714/2009- 1A II (I) dated 28th Feb., 2011.

(ii) Brief description of nature of the project

Globus Spirits Limited is proposing capacity enhancement by modernization of grain based

distillery (100 KLPD to 125 KLPD) and Co-generation Power Plant (3 MW to 3.8 MW) at Village

Chulkhana, Tehsil Samalkha, District Panipat (Haryana).

The additional capacity of 25 KLPD will be grain based alcohol using grain as raw material which

are abundantly available in the state. The Project is based on zero effluent discharge. The distillery

has put up the most modern technology for treatment of distillery spent wash which ensures Zero




discharge of distillery effluents. The distillery unit generates its own electricity by its co-generation

power plant.

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. It has a potential as fuel in

the form of power alcohol for blending with petrol in the ratio of 20:80. The use of alcohol for the

purpose of potable liquor is as high as its use for industrial purposes. The Country Liquor is mainly

used by the common masses.

According to analysts, the Indian alcoholic beverages industry is expected to witness accelerating

growth in coming years with the consumer base likely to expand amidst rising disposable income.

The domestic alcoholic drinks market is estimated around $13 billion and has been growing at a

compounded annual growth rate in excess of 10% in the past few years. The growth rate is higher

than other major Asian markets like China and South Korea, etc.

In the path of company’s growth and development this 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 ENA production is concerned, Indian market play a vital role at both domestic &

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

(vi) Export Possibility

There will be possibility of export of alcohol to African, European & Asian countries.

(vii) Domestic / Export Markets

Market depends on excise department.

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

The total manpower requirement after the proposed capacity enhancement project will remain

same as existing i.e. around 120 persons.




3.0 PROJECT DESCRIPTION

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

There are no interlinked projects related to this capacity enhancement by modernization project.

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

layout) with coordinates

Figure - 1: Location Map




(ii) Key Plan

Figure 3: Key Plan




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

environmental considerations gone into should be highlighted.

Since the proposed capacity enhancement 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

Globus Spirits Limited is proposing capacity enhancement by modernization of grain Based

distillery (100 KLPD to 125 KLPD) & Co-generation Power Plant (3 MW to 3.8 MW) at Village

Chulkhana, Tehsil Samalkha, District Panipat (Haryana).

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).

(vi) Project Description with Process Details

Project Description

Units Existing Capacity Proposed Capacity

Enhancement

Total Capacity after

Enhancement

Grain Based Distillery 100 25 125

Co-generation Power Plant (MW) 3.0 0.8 3.8

Process Description

Distillery Unit - Production from Grain:

• Grain storage

• Grain cleaning, milling and flour handling

• Slurry preparation & liquefaction

• Multi pressure distillation

• Alcohol (ENA & IA) daily receivers & bulk storage

• MEE & Dryer

MAIN PLANT & MACHINERY

1. Grain Storage :

Grains are procured from various sources, such as FCI Storage godowns through agencies and are

unloaded into large Storage Silos after Pre-Cleaning. Storage Silos are specially designed to keep

the Grains in good condition for longer durations and also avoid its deterioration and theft, etc. It

is being proposed to have 30 – 45 days of Grain Storage facility in the Distillery.

2. Grain Cleaning, Milling and Flour Handling :

The grain is lifted in bucket elevators, screened followed by removal of stones and iron matter.

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. The




flour addition is metered through the Batch Tipping Machine with load cell arrangement, before

transferring the flour to the Slurry Tank through another Screw Conveyor (pre-masher) for slurry

preparation process. It is being proposed to have 2 x 8 TPH (+ 1 Standby option) as milling

paraphernalia for this Distillery.

3. Slurry Preparation & Liquefaction :

Grain flour and process water is fed at controlled rate to Initial Liquefaction tank. Mixed slurry is

taken to the Initial Liquefaction Tank where additional quantity of water is added as per

requirement. Viscosity reduction Enzyme and stabilizing chemicals and a portion of liquefying

enzyme are also added at this stage. This slurry is then “cooked” in the jet cooker.

The slurry is continuously pumped to a steam jet cooker where high-pressure steam rapidly raises

the slurry temperature. The mixture of slurry and steam is then passed through the Retention

Vessel. The retention vessel has sufficient capacity to provide the desired retention time at a given

flow rate. The cooked mash is discharged to a Flash Tank.

The cooking process, accomplished in the above manner, converts the slurry into a hydrated,

sterilized suspension and is therefore susceptible to enzyme attack for liquefaction.

The gelatinized mash from the Flash Tank is liquefied in the Final Liquefaction Tank where

liquefying enzyme (alpha-amylase) is added. The liquefied mash is cooled in Mash Cooler and

transferred to Saccharification cum fermentation section. This process initiates the formation of

sugar.

The gelatinized mash from the Flash Tank is liquefied in the Final Liquefaction Tank where

liquefying enzyme (alpha-amylase) is added. The liquefied mash is cooled in Mash Cooler and

transferred to Saccharification cum Fermentation section.

4. Hiferm-Nm Saccharification and Instantaneous Fermentation:

Yeast Activation:

Yeast seed material is prepared in water-cooled Yeast Activation Vessel by inoculating sterilized

mash with Active Dry Yeast. Optimum temperature is maintained by cooling water. The contents

of the Yeast Activation Vessel are then transferred to Fermenter.

Saccharification & Instantaneous Fermentation:

The Liquefied starch slurry comprising Dextrins is partly taken for Yeast development in Yeast

Activation vessel and majorly transferred into the Fermenter. Amyloglucozydase and other

nutrient Enzymes are first added to Saccharify the Starch Slurry causing formation of Sugars.

Immediately, the Active Yeast is introduced in the system for simultaneous Fermentation. The

process of fermentation is to convert the fermentable substrate into alcohol. To prepare the mash

for fermentation, it may have to be diluted with water. The pH of the mash is adjusted by the

addition of acid. Yeast is available in sufficient quantity to initiate fermentation rapidly and

complete it within the cycle time.




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 fermenters into Beer Well. After the fermenters are

emptied, they are cleaned with water and caustic solutions and sterilized for the next batch. The

carbon dioxide evolved during the process is vented to atmosphere after recovery of alcohol in a

scrubber.

5. Multi Pressure Distillation :

This process utilizes following columns namely the Analyser, Degassifier, Pre-Rectifier Column,

Stripper, Rectifier cum Exhaust, Extractive Distillation (ED) Column, Recovery Column and

Simmering Column in ideal heat integration in order to reduce the energy consumption.

The Analyzer & Degassifier Columns are operated under Vacuum whereas the Simmering, the

Recovery Columns are operated under Atmospheric condition. The Pre-Rectifier, Rectifier-cum-

Exhaust Columns are operated under Pressure.

The energy requirement for Analyser, Degassifier Column is met by Rectifier Column top vapours.

The Rectifier Column top vapours are condensed in a thermo-siphon reboilers connected to a flash

tank and then flash vapours are injected into Analyser Column.

The energy requirement of the Simmering Column is met by the top vapours of Pre-Rectifier

Column while that of the Recovery Column is through direct steam. The overall Technical Alcohol /

Impure Spirit Cut will be maintained at 7% max. The Distillation Plant shall be designed for use of

Grain starch route only.

6. Alcohol (ENA & TA) Daily Receivers & Bulk Storage :

The Extra Neutral Alcohol & Technical Alcohol (Impure Spirit) is first taken to Daily receiver

storage tanks, which is based on the State Excise laws, storage for three days considering the

weekly holidays of two days. Thereafter, the alcohol is transferred to Bulk Storage Tanks after

taking the daily receiver Dip. This is transferred using flameproof pumps. Final dispatch of alcohol

is metered and again is carried out using special flameproof pumps. The Bulk Spirit Storage is

proposed to be set up for 30 days.

EFFLUENT HANDLING SECTION

1. Decantation Section:

Decantation section comprises of Centrifuge Decanters, operating at high rpm which are used for

separation of suspended solids from Spent Slops coming out of Distillation section. The Wet cake

thus separated has 30-35% w/w solids, as removed from bottom of Decanters. This is directly

loaded on the trolleys parked below. Thin slops coming out of Decanter are collected in a tank and

are transferred for part recycle & further for Evaporation into thick syrup.

2. Integrated Evaporation Section:




The suggested treatment scheme is a 2 FF + Finisher Evaporation Plant for Thin Slops Evaporation.

The following points will elucidate the basic working principle:

� Shell & Tube type Evaporators with highly efficient liquid distributor working on the

principle of Falling Film Evaporation have been used, with Plate type Preheaters for

preheating of FEED stream which serves the purpose of energy conservation.

� Analyzer vapour is fed to the first effect evaporator shell side at the given pressure and

temperature as the heating medium.

� The Feed from the Feed balance tank is taken to the PHCOND to make the best heat

recovery.

� The Feed after getting heated to the predetermined temperature in preheater is fed from

the first effect evaporator which is Falling Film Evaporator -1

� The flow path is given below.

INLET FEED - pH cond – E1 – E2 – OUTLET PRODUCT

� Vapours generated in 1st effect VLS (Vapour Liquid Separator) are used as heat source in

the 2nd effect.

� The product at the desired concentration of TS is obtained at the outlet of the second

effect, which is a Falling Film evaporator.

� A Shell & tube type Multi-pass Surface condenser is employed for condensing the shell side

vapours.

� The Pure and the process condensate are collected in receiving vessels.

� Highly efficient operating pumps will be provided for pumping the required fluid.

� The operation of the plant will be under vacuum. Vacuum is created with the help of a

water ring vacuum pump.

� The plant will have high level of automation to get consistent output at required

concentration.

� The system operates under vacuum. Water-ring vacuum pumps are used to maintain a

desired vacuum.

� Cooling water from cooling tower is used in the surface condensers for condensing the

vapours.

CONCLUSION

The thick syrup thus obtained is mixed with the Wet Cake obtained from Decanter Centrifuges

using specially designed Ribbon type mixer and this enriches the protein content in the fibrous

suspended solids separated earlier in Decanter. This Protein & Fibre rich DWGS is directly sellable

as Cattle / Poultry Feed. However, the DWGS By-Product has less shelf-life and needs to be

consumed within 2-3 days.

In order to increase the shelf life of such by-product, it is necessary to dry the product, with

minimum possible moisture content.




SYSTEM DESCRIPTION FOR DWGS DRYER

Wet distiller’s grains shall be fed into the dryer housing at controlled rate through a suitable

feeding system. The Rotary Tube Bundle is enclosed in an insulated dryer housing and on its outer

flights are fixed. Dry saturated steam is to be supplied to the tube bundle through rotary joint at

one end & the condensate is discharged through rotary joint mounted at other end.

During the course of rotation, these flights pick up the material and shower them on to the tube

bundles. The heat transfer is primarily by conduction. The water vapours are exhausted through

an Exhaust Blower & passed through a cyclone separator for separating fines.

Dry product partially recycled back to Feed conditioner for feed conditioning through Product

Screw & Recycle Conveyor.

Entire operation of the Dryer is controlled through Control panel.

SYSTEM DESCRIPTION FOR COOLING & CONVEYING

� DWGS below product screw is discharged into charging hopper of pneumatic conveying

system.

� Rotary feeder feeds it into the conveying line.

� Ambient air is used for conveying.

� The material gets conveyed to product collector & discharged from rotary discharge

valve.

� Exhaust air is vented to atmosphere.

� The conveying system is lean phase suction type, using centrifugal blower as prime

mover. The conveying air quantity is designed considering cooling requirement & to cool

the product before discharge.

Figure - 3: Process flow chart For Grain Based Distillery




(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 based distillery can be broadly categorized as follows:

• Grain

• Enzymes & Chemicals

• Steam

• Fuel

• Power, etc.

The basic raw material for the manufacturing of ENA/RS will be Grain. In the present scenario,

grains with different starch content are used like broken Rice, sorghum, baira, maize etc. The

process requires the above grains to be milled into specific flour size. Small quantity of sulphuric

acid is sometimes required. The raw material for the boiler fuel will be Coal/Rice Husk.

S. No. Particular

Total Requirement after

proposed Capacity

Enhancement

Source & Mode of Transportation

1 Grain 265 MT/day Through vendors / By road

2

Chemicals

Near-by Markets / By road

Sodium Hydroxide (Caustic) 250 - 300 Kg / day

NH2-CO- NH2 (Nutrients) 300 Kg / day

Enzymes 200 Kg / day

Antifoam Agent 25 Kg / day

Yeast (Active Dry

Yeast/Distiller’s Yeast) 80 Kg / day

(b) Fuel Requirement

Name of Raw Material Total Quantity after Proposed Capacity

Enhancement (MT per day) Source & Mode of Transportation

Rice Husk 180 From Authorized Dealer / By Road

Note: Auxiliary Fuel will be used such as Coal, Petcoke etc.

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

outlined.

The waste water generated from the industry is being /will be properly treated through most

modern technology i.e. Decantation followed by Vapour Integration Plant with the Dryer; and the




condensate water is being / will be recycled back in the process & also, reused for greenbelt

development/plantation, which is being / will be results in ‘’Zero- Discharge’’.

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

(a) Water Requirement and Source

Existing water requirement for 100 KLPD grain based distillery is 552 KLPD.

Vapour Integration Plant with the dryer will be installed for recycling of water due to which there

will be no increase in water requirement after the proposed Capacity Enhancement. Thus, no

additional fresh water will be required for the proposed Capacity Enhancement.

Source of Water: Ground Water.

TABLE - A

WATER REQUIREMENT FOR GRAIN BASED OPERATION

S. No. DESCRIPTION WATER

CONSUMPTION (KLD)

1 PROCESS WATER IN LIQN & FERMENTATION 622

2 DM WATER FOR BOILER FEED 740

3 DM WATER FOR RS DILUTION 180

4 BLENDING 120

5 MISC. BOTTLE WASHINGS 30

6 COOLING TOWER MAKE UP SOFT WATER 351

TOTAL WATER REQUIREMENT (A) 2043

TABLE - B

TOTAL WATER OUTPUT

S. No. DESCRIPTION WATER CONSUMPTION

(KLD)

1 STEAM CONDENSATE 586

2 COOLING TOWER EVAPORATION LOSS 351

3 SPENT LEES (ENA) 180

4 SPENT LEES (RS) 150

5 WATER IN PRODUCT 120

6 MISC. WASHING 30

7 THIN SLOP 499

8 BOILER BLOW DOWN & DRIP LOSSES 40

9 WATER IN WET CAKE (DWGS) 87

TOTAL (B) 2043




TABLE - C RECYCLING & UTILIZATION STREAM

S. No. RECYLCE & UTILIZATION STREAMS WATER CONSUMPTION

(KLD)

1 STEAM CONDENSATE 586

2 SPENT LEES (ENA) - COOLING TOWER MAKEUP 180

3 PROCESS CONDENSATE RECYCLED TO PROCESS 711

4 MISC.BOTTLE WATER 14

Total Recycling /Re-utilizations of water per day (C) 1491

TOTAL FRESH WATER INPUT (A-C) 552

Hence, Fresh Water Requirement is 552 KLD

* Water requirement for first run would be 2043 KLD




Figure - 4: Water Balance chart For Grain Based Distillery




(b) Power Requirement and Source

Existing power requirement is 3.2 MW and no additional power will be required for proposed

capacity enhancement project. Thus, the total power requirement after proposed capacity

enhancement project will remain same as existing.

Source: Co-generation Power Plant, Haryana State Electricity Board & D.G Sets (for emergency).

(c) Steam Requirement

Existing steam requirement is 31.0 TPH and there will be no additional steam requirement for the

proposed Capacity Enhancement project.

Source: Boiler - 2 in nos. (25 & 14 TPH).

STEAM REQUIREMENT

S. No. Purpose Requirement after Proposed Capacity

Enhancement (TPH)

1. Cooking & Liquefaction 3.3

2. Multi-pressure Distillation 17.7

3. Evaporation (Integrated) & DWGS Drier

(DDGS) 7

4. Boiler De-aeration 3

Total 31.0

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

o The proposed Capacity Enhancement project is being/will be based on “ZERO EFFLUENT

DISCHARGE”.

o Grain Slops (Spent Wash) will be taken through Centrifuge Decanters for separation of

Suspended Solids separated as Wet Cake.

o Thin Slops from the Decanter Centrifuge are partly recycled back to process (30-35%) and

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

Syrup. This Syrup is mixed with the Wet Cake coming out of Decanter Centrifuge and forms

part of Cattle Feed. (Also known as Distillers Wet Grain Solubles - Collectively known as

DWGS)

o DWGS is taken to a dryer operating on steam and is dried to make it DDGS – Distillers Dried

Grain Solubles.

o The process condensate is cooled and collected into a neutralization tank with sufficient

residence time. After Neutralization, this process condensate will be recycled into process and

is used for green belt development within the complex.

o Two streams of low BOD lees (White Effluent) comes out is partly used as fermenter washing

and then sent for Cooling, treatment and utilized for RS dilution. The second part requires

only cooling and can be used as Cooling Tower water makes up directly.




o Solid waste from the Grain based operations generally comprises of Fibres and proteins in the

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

o Ash from the Boiler is being / will be sold to Brick manufacturers.

o 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 is located at 4 Kms, Chulkhana Road, Village Chulkhana, Tehsil Samalkha, District

Panipat, Haryana. The capacity enhancement of the existing plant will be undertaken within plant

premises; hence no new land will be required. NH-1 (Delhi-Amritsar), approx. 2.0 km in E direction

from the proposed project site and nearest Samlakha Railway Station (2.6 Km NNE) from the

proposed project site have resulted in excellent connectivity of the village.

It has an easy access to raw material availability and other infrastructural facilities e.g. land,

power, water, transport and communication, approach through road & access distances from the

nearest highway, railway station etc. The site is well connected with communication facilities like

telephone, fax, wireless and telex and as such, no constraints are envisaged in this aspect also.

(ii) Land from Land use and Land ownership

Total plant area is 17 acres (6.878 ha). Since, the proposed capacity enhancement will be done

within the existing plant premises, thus, no additional land is required for the proposed capacity

enhancement project.

(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

(with approximate aerial distance & direction from plant site)

1. Nearest Village Chulkhana (1.5 km in SW direction)

2. Nearest Town Samalkha (2.6 km in NNE direction)

3. Nearest City Panipat (20 km in SE direction)

4. Nearest National Highway / State

Highway

NH-1 (2.0 km in East direction)

5. Nearest Railway station Samalkha Railway Station (2.6 km in NNE direction)




6. Nearest Airport New Delhi ( 74 km in South direction)

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

No Reserved / Protected Forest lies within 10 km radius

(Boundary to boundary distance) of the proposed project

site.

9. River / Water Body (within 10 km

radius)

Western Yamuna Canal - New Delhi parallel branch (5.5 km in

West direction)

(v) Existing Infrastructure

Total plant area is about 17 acres (6.878 ha). Proposed capacity enhancement will be done within

the existing plant premises by adopting improvement in Fermentation & Distillation Technology.

Existing infrastructure will suffice the requirement of proposed capacity enhancement project.

(vi) Soil classification

The district has two types of soils viz-tropical arid brown and arid brown soils (solemnized). The

arid brown soils are found in major parts of the district whereas tropical arid brown soils are found

in north eastern part of the district especially in parts of Bapoli and Panipat blocks.

(vii) Climatic data from secondary sources

The district has a sub - tropical continental monsoon climate where we find seasonal rhythm, hot

summer, cool winter, unreliable rainfall and great variation in temperature. The rainfall

distribution is relatively satisfactory in relation to western parts of Haryana and it is mostly

restricted to rainy season. The district also gets occasional winter rains from cyclones. Air is

generally humid dry during the greater part of the year. Dust storms mostly occur during April to

June. Fog sometime happens dense in the winter season.

(viii) Social Infrastructure available

Nearest habitation are at Chulkhana village. The nearest town is Samalkha, which is approx. 2.6

km distance from the plant site. The nearest major city is Panipat about 20 km respectively from

the plant site.

At Samalkha town schools, dispensaries, small hospitals, places of worship 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 and proposed capacity enhancement will be done within the

existing plant premises by adopting improvement in Fermentation & Distillation Technology.

Facilities required for the proposed capacity enhancement project will be provided as per

requirement. Transportation of raw material and final product is being / will be done by road.

(ii) Population Projection

No influx of people will be there as the proposed capacity enhancement will be done by adopting

improvement in Fermentation & Distillation Technology.

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

Total Plant area is 17 acres (6.878 ha). Proposed capacity enhancement project will be set up in

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)

Globus Spirits Ltd. 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

Globus Spirits Ltd has developed and will further develop the Amenities/Facilities in nearby area

of the proposed capacity enhancement 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 proposed capacity enhancement project as

the proposed project will be set up in the existing plant premises.

(ii) Residential area (Non Processing area)

No residential area is envisaged.

(iii) Green Belt

Out of the total plant area (6.878 ha), 33% has been developed under greenbelt / plantation area.

The same will be maintained & further enhanced for proposed capacity enhancement project, in

order to reduce dust & noise pollution levels & to increase aesthetic beauty of the area.

(iv) Social Infrastructure

Proposed capacity enhancement project will result in growth of the surrounding areas by ancillary

development and supporting infrastructure in the region.




(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 KLPD water is being / will be required for drinking purpose and other use, which will be sourced

from Ground Water.

(vii) Sewage Treatment System

The waste water generated from the sanitary blocks is being/will be disposed off in soak pit via

septic tank.

(viii) Industrial Waste management

The grain based distillery project is being / will be based on “ZERO DISCHARGE”.

(ix) Solid Waste Management

o Solid waste from the Grain based operations generally comprises of Fibres and proteins in the

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

o Ash from the Boiler is being / will be sold to Brick manufacturers.

(x) Power requirement and source

Existing power requirement is 3.2 MW and no additional power will be required for proposed

capacity enhancement project. Thus, the total power requirement after proposed Capacity

Enhancement project will remain same as existing.

Source: Co-generation Power Plant, Haryana State Electricity Board & 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).

Proposed capacity enhancement will be done within the existing plant premises. No additional

land is required for proposed capacity enhancement project. 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 other statutory

permissions. Project will be completed in 12 months period after getting all the regulatory

approvals.

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

� Total cost of the Project: Rs. 10 Crores




� Cost for Environment Protection Measues:

� Capital Cost: Rs. 3.0 Crores

� Recurring Cost/annum: Rs. 50 Lacs / 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 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.

Haryana state will get revenues in terms of taxes. 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/0_0_21_Dec_2… · Rs. 10 Crores Cost for Environment Management Plan o Capital Cost - Rs. 3.0 Crores