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PRE-FEASIBILTY REPORT FOR THE EXPANSION AND MODIFICATION OF EXISTING

MOLASSES BASED DISTILLERY PLANT FROM 60 KLPD TO 70 KLPD.

At

Sy. Nos. 49/2B/1 & 2, 57/2D & 2E, 58/1B,

58/1A/3, 66/4D, 85/2, 87, 93/2/3, 95/1 & 107/2,

Siddapur village, Jamkhandi Taluk,

Bagalkot District, Karnataka State.

Submitted by

M/s. Siddapur Distilleries Limited., Siddapur village, Jamkhandi Taluk, Bagalkot District, Karnataka State.

Environmental Consultants

M/s. AQUA TECH ENVIRO ENGINEERS, (Environmental Engineers & Consultants) # 3391, 6th Main, 3rd Cross, RPC Layout,

Vijayanagar II Stage, Bengaluru – 560 040. Tele Phone: 080: 23141679

1

Contents Sl. No. Description Pg. No

CHAPTER 1 EXECUTIVE SUMMARY

1-6

1.1 Introduction 1

1.1.1 Preamble 1

1.1.2 Project at a glance 2

1.1.3 Water requirement and wastewater treatment and discharge

details

3

1.1.4 Quantity of water required and wastewater generated 4

1.1.5 Air pollution details 5

1.1.6 Noise pollution details 6

1.1.7 Solid waste details 6

1.1.8 Environmental Impacts and Management Plan 6

CHAPTER 2 INTRODUCTION OF THE PROJECT/ BACKGROUND

INFORMATION

9-13

2.1 Introduction Of Project Proponent 9

2.2 Brief Description About The Nature Of The Project 10

2.3 Need For The Project And Its Importance To The Country

And/Region

10

2.4 Demand Supply Gap 11

2.5 Export Possibility 12

2.6 Domestic/Export Markets 12

2.7 Employment Generation (direct and indirect) Due To The

Project

13

CHAPTER 3 PROJECT DESCRIPTION

14-48

3.1 Type Of Project 14

3.2 Location Of The Industry 14

3.3 Basis Of Selecting The Proposed Site 16

3.4 Size/Magnitude Of Operation 16

3.5 Products Manufactured 16

3.5.1 Manufacture process technology 16

3.5.2 Process Description-70 KLD based on Molasses 17

3.5.3 Manufacturing Process for Molasses based Ethanol 19

3.5.4 Brief Description of Fed Batch Process 22

2

3.5.5 Major difference b/w continuous & Fed batch Fermentation process

23

3.5.6 Block Diagram of Existing 60 KLPD Plant 25

3.5.7 Block Diagram of Existing 70 KLPD Plant 26

3.6 Raw Materials 27

3.6.1 Storage Facility for Raw Materials and Products 27

3.7 Machinery and Equipment Details 28

3.8 Solid Waste and Hazardous Waste 39

3.8.1 Domestic Solid Waste Re-use 39

3.9 Water, Energy/Power Requirement and Source 40

3.9.1 Water 40

3.9.2 Power 40

3.10 Wastes Generated & Scheme For Their Management/Disposal 40

3.10.1 Water Demand and Wastewater/effluent Discharge 40 3.10.2 Treatment of Effluents and Disposal 41

3.11 Air Pollution Details 47

3.12 Noise Pollution Details 47

3.13 Solid Waste Details 47

3.14 Schematic Representations Of The Feasibility Drawing 48

CHAPTER 4 SITE ANALYSIS

49-55

4.1 Site Connectivity 49

4.2 Land Form, Land Use & Ownership 50

4.3 Topography 50

4.4 Existing Land Use Pattern 51

4.5 Existing Infrastructure 51

4.6 Soil Classification 51

4.7 climatic Data from secondary sources 53

4.7.1 Temperature 54

4.7.2 Relative Humidity 54

4.7.3 Rainfall 54

4.7.4 Atmospheric Pressure 54

4.7.5 Cloud Cover 54

4.7.6 Wind 54

4.8 Social Infrastructure 55

CHAPTER 5

3

PLANNING BRIEF 58-58

5.1 Planning Concept 58

5.2 Population Projection 58

5.3 Land-Use Planning 58

5.4 Assessment Of Infrastructure Demand 58

5.4.1 Water Supply & Sewerage Infrastructure 58

5.5 Amenities/Facilities 58

CHAPTER 6 PROPOSED INFRASTRUCTURE

59-64

6.1 Industrial Area (Processing Area) 59

6.2 Residential Area (Non Processing Area) 59

6.3 Green-Belt 59

6.4 Social Infrastructure 64

6.5 Connectivity 64

6.6 Sewerage System 64

6.7 Industrial Waste Management 64

6.8 Solid Waste Management 64

6.9 Power Requirement & Supply Source 64

CHAPTER 7 REHABILITATION & RESETTLEMENT PLAN

65

CHAPTER 8 PROJECT SCHEDULE & COST ESTIMATES

66-67

8.1 Time Schedule 66

8.2 Estimated Project Cost 66

CHAPTER 9 ANALYSIS OF PROPOSAL

68

4

LIST OF TABLES

Table no. Description Pg. No 1.1 Project at Glance 2

1.2 Water Requirement and Wastewater Treatment and Discharge Details

3

1.3 Water Consumption and Discharge 4

1.4 Sewage/wastewater treatment and discharge 5

1.5 Sources of air pollution, type of fuel used, APC details 5 1.6 Solid Waste Generation during the Operation Phase 6

1.7 EMP during the Operation Phase 6

3.1 Major difference b/w continuous & Fed batch Fermentation process

23

3.2 Raw Materials Requirement 27

3.3 Technical Specifications for 60 KLPD Distillery Plant Continuous Fermentation and Multi pressure Distillations

28

3.4 Solid Waste Generated 39

3.5 Solid Waste Generation During the Operation Phase 39

3.6 Water Consumption and Discharge 40

3.7 Sewage/Effluent Treatment and Discharge 41 3.8 Sources of Air Pollution, Type of Fuel Used, APC Details 47

3.9 Solid Waste Generation during the Operation Phase 47

4.1 Connectivity of Project Site 49

4.2 Existing Land Use Pattern 51 4.3 Meteorological Data of Bagalkot for the Year 2016 53

4.4 List of Infrastructural Facilities in the Surroundings 55

5.1 Land Use Pattern 58

8.1 Project Cost for expansion of Distillery Plant capacity from 60 KLPD to 70 KLPD.

66

5

List of Figures

Fig. no. Description Pg. No 3.1 Google Map Showing Project Site 14

3.2 Map showing the Project Site Location on District Map of Bagalkot

15

3.3 Plant layout plan 15 A

3.4 Flow Chart Of Existing & Proposed Environmental Management Plan (EMP)

44

3.5 Feasibility & environmental assessment process 48

4.1 Google map showing connectivity to Project Site 49 4.2 Topo map 50

4.3 Wind Rose diagrams 56

6.1 Green Belt Photographs 60

List of Annexure

Annexure Description A Land Records

B Environmental Clearance and Compliance Report

C Drawings

M/s Siddapur Distilleries Limited.,

Pre-Feasibility Report Page 1

CHAPTER 1

EXECUTIVE SUMMARY

1.1 INTRODUCTION

1.1.1 Preamble

Amendment of the Environmental Impact Notification No. S.O. 60(E) dated 27.01.1994,

issued by the MoEF, Govt. of India has made mandatory under Schedule-I of EIA notification

for 30 different activities to obtain NOC (No Objection Certificate) from the State Pollution

Control Board and Environmental Clearance from the Ministry of Environment & Forests,

Govt. of India. This amendment to the EIA Notification is effective from 14.09.2006.

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

project falls in Category ‘A’, Project or Activity - 5(g) Molasses based distilleries. The

proposed project is Expansion/Modification of Distillery plant.

The proposed expansion and modifications envisages changing the process technology and

increasing the capacity of distillery plant. There is no additional Water & air pollution is

added.

M/s. Siddapur Distilleries Limited., has proposed to expand and modified its Molasses Based

Distillery Plant from 60 KLPD to 70 KLPD through process modification in its existing

Distillery Plant at Sy. Nos. 49/2B/1 & 2, 57/2D & 2E, 58/1B, 58/1A/3, 66/4D, 85/2, 87,

93/2/3, 95/1 & 107/2, Siddapur village, Jamkhandi Taluk, Bagalkot District, Karnataka State.

The unit has 30 Acres of land in the name of “Siddapur Distilleries Limited., Siddapur village,

Jamkhandi Taluk, Bagalkot District, Karnataka State.

Molasses is used as a raw material which is easily available from our parent sugar factory i.e

Shri Prabhulingeshwar Sugars & Chemicals Limited (SPSCL) and nearby sugar factory.

Distillery plant capacity.

1. Existing :- 60 KLPD

2. Proposed :- 70 KPLPD



1.1.2 Project at Glance

Details are appended in the following table 1.1 below.

Table 1.1:- Project at Glance

Sl.No. Details 1 Project Expansion and modification of Molasses Based Distillery

Plant from 60 KLPD to 70 KLPD through process modification in its existing Distillery Plant – “M/s. Siddapur Distilleries Limited.,”

2 Project developers M/s. Siddapur Distilleries Limited., at Sy. Nos. 49/2B/1 & 2, 57/2D & 2E, 58/1B, 58/1A/3, 66/4D, 85/2, 87, 93/2/3, 95/1 & 107/2, Siddapur village, Jamkhandi Taluk, Bagalkot District, Karnataka State.

3 Location of the site Sy. Nos. 49/2B/1 & 2, 57/2D & 2E, 58/1B, 58/1A/3, 66/4D, 85/2, 87, 93/2/3, 95/ & 107/2,

4 Constitution of the Organization

Public Limited Company

5 Raw materials Sl.No. Particulars Quantity MT/Month

EXISTING 1 Molasses 6720

2 Deformer 3.0

3 Urea 1.3

4 DAP (Di-ammonium Phosphate)

1.2

PROPOSED 1 Molasses 7800

2 Deformer 3.5

3 Urea 1.5

4 DAP (Di-ammonium Phosphate)

1.4

6 Product/s proposed to be manufactured with production capacities? #

Distillery plant capacity.



7 Project cost? Total cost of project is Rs. 1,16,00,000/-

8 Total man power requirement during construction

phase occupancy

phase

Construction phase: No construction activity is envisaged Operational phase: 115 employees (Existing Plant Manpower utilized )

9 Proposed trees to be planted?

Tress planted – 50,000 Nos Around compost yard & Plant Surroundings Trees proposed to be planted- 2,000-3,000 No.s Every year.



10 Species of trees to be planted?

Silver Wood, Teak wood, Coconut, Asoka Trees, Mango trees, Neem , Bheema Bamboo, Cassia fistula, Alstonia scholaris, and several native species

11 Groundwater recharging pits details?

Storm water recharge pits are provided

12 Elevation of the project site with respect to MSL?

618 m above MSL; Latitude: 16°26'17.03"N ; Longitude: 75°16'16.77"E

13 Total area of the project?

1,21,541.84 SQM (about 30 Acres)

14 Ground water quality?

Portability of water is tested and can be used for drinking.

15 Noise levels? Noise levels are within the standard limits. 16 Facilities provided

for the workers during construction phase at site?

No construction activity is envisaged, The proposed expansion and modifications envisages changing the process technology and thereby increasing the capacity of distillery plant.

1.1.3 Water Requirement and Wastewater Treatment and Discharge Details Water requirement and waste water generation details are appended in the following table 1.2 below.

Table 1.2:-Water Requirement and Wastewater Treatment and Discharge Details Sl. No. Particulars Details

A Water, wastewater details

1 Water supply sources Krishna River water supply

2 Total water requirement The total fresh water requirement for molasses based process is 940 KLD

3 Total wastewater generated The waste water generated from the industry is 593.2 KLD

4 Treatment/Disposal details Existing Effluent Treatment Plant

B Air pollution details

1 Sources of air pollution DG set 2 Air pollution control units

provided * DG set stack height as per the stack height calculation for 1000 KVA - 1 no. is 31 m AGL.

C Solid/Hazardous wastes

1 Source of solid waste Domestic sources and industrial effluent.

2 Total quantity of solid waste generated

Domestic solid waste – 23 kg/day Hazardous solid waste

Sl. no

Hazardous waste Existing Proposed

1 Fermenter Sludge 20 TPD 26 TPD

2 Waste oil generation from DG set

300 LPA

300 LPA



3 Treatment/Disposal of solid wastes

* The domestic wastes are segregated at source and collected in bins. The organic portion of the solid wastes will be composted and recyclable portion will be disposed to the recycler for scientific recycling.

1.1.4 Quantity of Water Required and Wastewater Generated The total quantity of water requirement for the industry is about 770 KLD. The break-up of the consumption of water is as presented in Table 1.3.

Table 1.3 Water Consumption and Discharge Sl. No

Particulars Existing water Consumption in KL / Day(60KLPD)

Particulars After Expansion water

Consumption in KL / Day(70KLPD)

1 Water consumption details

a Fresh water for molasses dilution

423.0 Fresh water for molasses dilution

253.0

b Cooling Tower Make Water

432.0 Cooling Tower Make Water

432.0

c Domestic 4.5 Domestic 4.5

d Gardening 70.0 Gardening 70

e Others 5.5 Others 5.5

f Floor washing 5.0 Floor washing 5.0 Total 940.0 Total 770.0

2 Waste Water generation details a Spent Wash (ZLD,

Bio-methanation followed by Composting )

420.0 Spent Wash (ZLD, Bio-methanation followed by Composting)

420.0

b Spent Leese (Treated effluent used for irrigation or greenbelt development )

80.0 Spent Leese (Re-use in Process or cooling Tower make up)

70.0

c Process Condensate water(Treated effluent used for irrigation or greenbelt development )

80.0 Process Condensate water(Re-use in Process or cooling Tower make up)

100.0

d Sewage Domestic ( Septic Tank Followed Soak fit)

3.2 Sewage Domestic ( Septic Tank Followed Soak fit

3.2

Total 583.2 Total 593.2



Note: - 1) Sanctioned raw water quantity is 940 KLD from irrigation department Govt. of Karnataka & MoEF , New Delhi . 2) Maximum fresh water requirement for molasses based process is 770 KLD (For Proposed Expansion).

WASTEWATER TREATMENT AND DISPOSAL DETAILS

The treatment methods and the final disposal of each type of wastewater generated is

appended in the table 1.4

Table 1.4 Sewage/wastewater treatment and discharge

Sewage/effluent generated from

Treatment provided Final disposal point

(a) Domestic Sewage is treated septic tank Disposed in Soak pit

(b) Industrial RSW is treated with Full-fledged ETP with collection tanks are provided.

RSW is treated with Bio-methanation followed by Bio-Composting To archived ZLD Concept

(c) Industrial Spent Leese Spent leese is treated with the phyiso-chemical treatment and re-use in cooling tower make up or process dilution purpose

1.1.5 Air Pollution Details

The major air pollution sources from the industry are DG set. These sources are provided with stacks of adequate height so as to disperse the emanating flue gases containing SPM, oxides of sulfur and nitrogen without affecting the ground level concentrations.

The sources of air pollution, type of fuel used, fuel consumption and chimney heights for each of the air pollution sources of the proposed project are indicated in the following table 1.5.

Table 1.5 Sources of air pollution, type of fuel used, APC details

SI. no.

Stack attached to

Fuel used Fuel consumption

Number of stacks

Stack/s height

Air pollution control unit

Predicted emissions

1 D.G. set – 1000 KVA – 1 No.

HSD 58.75 L/hr

1

31 m AGL

Stack SOx, NOx, SPM



1.1.8 Noise pollution details The major source of noise pollution in the industry is the DG set for which acoustic enclosure is provided. Also ambient noise levels will be ensured within the ambient standards by inbuilt design of mechanical equipment and building apart from vegetation (tree plantations) along the periphery and at various locations within the industry premises. 1.1.9 Solid waste details The quantity of solid waste generated from the proposed industry is detailed in the following table 1.6.

Table: 1.6 Solid Waste Generation during the Operation Phase

Total no. of employees 115 Assuming per capita solid waste generation rate as 0.20 kg/capita/day

Quantity of solid waste generated 23 kg/day

Organic solid waste : 60 % of the total waste 14 kg/day

Inorganic solid waste : 40 % of the total waste 9 kg/day

Disposal of domestic solid waste The domestic wastes are segregated at source, collected in bins and composted.

1.2 ENVIRONMENTAL MANAGEMENT PLAN (EMP) The environmental management plan is detailed in below table 1.7.

Table: 1.7 EMP during the Operation Phase

Particulars

DETAILS

Air Quality Management

Possible Sources Existing D.G. Sets, Transportation Vehicles etc.

Emissions and Existing

Control measures

➢ Oxides of Sulphur, Nitrogen and Particulate matter

➢ Existing DG Set (1000 KVA) also have adequate stack of height as

per CPCB Guidelines.

➢ Adequate measures for Fugitive Dust Emissions are being taken.

➢ All the internal roads are asphalted.

➢ Existing Green Belt (25 Acres) developed around the periphery &

internal areas within the premises of the plant will help in

attenuating the pollutants emitted by the plant.

Monitoring Ambient air quality emissions are being monitored regularly to

ensure that ambient air quality standards are met.



Water Management

Management ➢ The project is based on “Zero Effluent Discharge”.(ZLD)

➢ Fresh water requirement of the project is being met by Krishna

River.

➢ Water & recycled water. Efforts are being made to conserve as

much water as possible by recycling and reuse.

➢ Record of wastewater returned back to process for utilization in

Fermentation/cooling tower and to gardening is being

maintained

➢ Spent lees generation from distillation column is being recycled

partly to the columns for dilution and balance is being used for

cooling tower makeup.

➢ Domestic waste water generated from the plant is being treated

in Septic Tank and Soak pit.

➢ Effluent Treatment Plant (ETP) has been installed and treated

water from ETP is being recycled back to the process and

remaining is being used for green belt development.

Noise Management

Management ➢ Proper maintenance, oiling and greasing of machines at regular

intervals is adopted

➢ PPEs like ear plugs and ear muffs to the workers exposed to high

noise level.

➢ Development of Green Belt for 33% of the total project area.

➢ Regular monitoring of noise level.

➢ D.G set is provided with acoustic enclosures to control the noise

level within the prescribed limit.

Monitoring

➢ Regular monitoring of noise levels is being carried out and

corrective measures in concerned machinery is adapted

accordingly as and when required.

Solid Waste Management

Management ➢ Solid waste from the Molasses based operations generally

comprises of yeast sludge separated by mechanical using

decanter machine and collected in tractor troll which is being

composted and used as manure.

➢ Used oil & grease generated from plant machinery/Gear boxes

are hazardous wastes is being used as lubricant for chains for

Compost yard Aero-Tiller Machines within premises.

Green belt Development/ Plantation

Management ➢ 33% of total project area has been developed under green

belt/plantation with diverse species.

➢ All the barren areas are vegetated.



➢ Native plant species is planted in consultation with local

horticulturist.

➢ Green belt development along with the road & plant boundary

will attenuate noise level arrest dust and improve the

environment in surrounding.

Odor Management

Management ➢ Odor is the primarily controlled at source by good operational

practices, including physical management control measures.

➢ Better housekeeping is being maintained with good hygiene

condition by regular steaming of all fermentation equipment.



CHAPTER 2

INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

2.1 INTRODUCTION OF PROJECT PROPONENT Siddapur Distilleries Limited is a Public Limited Company registered under the Company’s

Act 1956 in the year 2003 bearing Registration No.08/32213 dated 07/07/2003 having its

Registered Office at 2nd Block, 1st Floor, “Sukrut” Building, Opp:K.C.Park Main Gate, P.B.

Road, Dharwad and plant site at Siddapur Village, JamkhandiTaluk, Bagalkot District.

Siddapur Distilleries Limited has installed 60 KLPD Distillery Plant in the year 2004-05.

Distillery plant is based on continuous fermentation and multi-pressure vacuum distillation

technology to produce good quality potable grade Rectified Spirit, Extra Neutral Alcohol and

Fuel Alcohol to meet the requirements of Potable Alcohol Consumers, Pharmaceuticals

Industries and Oil Companies for blending with petrol. Distillery Plant was supplied by Mojj

Engineering System Ltd., Pune and started its trial and Commercial production on 05th

November, 2004.

Siddapur Distilleries Limited is a sister concern of Shri Prabhulingeshwar Sugars & Chemicals

Limited, having 12,000 TCD Sugar Plant at Siddapur Village, Tq.Jamkhandi, Dist.Bagalkot

having its Registered Office at 1st Floor, “Sukrut” Building, Opp.K.C.Park Main Gate,

P.B.Road, Dharwad.

Shri Prabhulingeshwar Sugars & Chemicals Limited is a Public Limited Company consisting

about 14,000 members holding Equity & Preference shares. The Company owns about 200

acres of land near Siddapur village, Tq.Jamkhandi, Dist.Bagalkot. The Company has

established its factory in the said area with all the infrastructure facilities like Staff Quarters,

Guest House, Workers Quarters, Canteen, School, Medical and Bus facility etc. The initial

crushing capacity was 2500 TCD. The capacity was expanded from 2500 TCD to 8000 TCD

during the year 2009 -2010, 8000 to 10000 TCD during the year 2010-11 and finally to 12000

TCD in the year 2015-2016 with a view to crush all the available sugarcane in the area of

operation.



2.2 BRIEF DESCRIPTION ABOUT THE NATURE OF THE PROJECT

M/s. Siddapur Distilleries Limited., has proposed to expand and modified its Molasses Based




The unit has 30 Acres of land in the name of “Siddapur Distilleries Limited., Siddapur village,

Jamkhandi Taluk, Bagalkot District, Karnataka State.

Molasses is used as a raw material which is easily available from our parent sugar factory i.e

Shri Prabhulingeshwar Sugars & Chemicals Limited (SPSCL) and nearby sugar factory.



2.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND/REGION

India is the largest producer of sugarcane as well as sugar in the world. The sugar industry

occupies a pride of place in rural economy. Most of the sugar industries are located in rural

areas providing employment to rural masses.

The molasses is used mainly for production of ethyl alcohol. There are more than 350

distilleries in the country with annual installed capacity 4.295 billion liters of alcohol

production and licensed capacity 4.527 billion liters. The alcohol production in the year

2007 was 2.3 billion liters. At present the state of Karnataka is having 35 distilleries.

Molasses is considered as one of the valuable by-products of sugar industry. The total

molasses availability in the country was around 85.49 lac MT in 2005-06 and increased up to

131.11 Lac MT in 2006-07 and to 113.11 Lac MT in 2007-08. However, molasses produced in

the country in the year 2008-09 was 65.42 Lac MT. In the ensuing crushing season, the

crushing of cane and molasses will be highest and the required quantity will be available to

all the distilleries in the state.

CAPACITY OF DISTILLERY:

Normally distilleries are expected to work for 270 days in a year and most of the distilleries

in India have adopted seasonal working of their distilleries in view of the fact that they can

receive surplus steam and power from their sugar factories. It is an important consideration

to keep the cost of production low. Some factories have installed independent boiler and

turbo-alternator to run the Distillery unit during off season. This will help the distilleries to

use all available molasses.



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

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

distillery.

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

mild steel.

3) As per the latest norms of CPCB, all distilleries are required to achieve “Zero Liquid

Discharge” (ZLD) of spent wash. Therefore, necessary measures should be taken by the

management to achieve Zero Liquid Discharge (ZLD) and prevent any kind of pollution in

surrounding area.

Molasses is risk as it has a property of auto – combustion and its BOD is as high as

9, 00,000 mg/lit. Thus, even a small escape can result in large scale fish kill. Bagasse if not

baled can become air-borne fugitive with high SPM nuisance. We shall attempt to minimize

this by using some fraction of molasses and bagasse.

This is precisely the main objective of this project, which will be supported by low or no

discards and conservation of resources. This type of plant is likely to be more viable in view

of present situation, when the Organic Chemicals have demand in the particular market and

Global inflow of money is permissible. This has a foreign-exchange saving/ earning potential.

Ethanol has assumed a very important place in the economy of the country. It is used as a

raw material for number of organic chemicals, as a potential fuel in the form of power

alcohol when blended with petrol and as an ingredient in beverages. Use of ethanol as a

main ingredient in beverages is well known. Further, it is a major source of revenue by way

of excise duty to the State Governments. The economic and social significance of alcohol

production has of late assumed considerable importance all over the world. The importance

and utility of ethanol as an industrial raw material for manufacture of variety of organic

chemicals is now being increasingly appreciated all over the world. This is partly due to the

escalating costs of these chemicals produced through petrochemical route consequent and

abnormal increase in crude oil prices. Crude oil which was sold at 2 dollars per barrel in 1969

is now around 135 dollars. The price is predicted to increase rise further depending upon

International situation and with depletion/exhaustion of petroleum resources of the world.

Hence the proponents have proposed to expand and modified its Molasses Based Distillery

Plant from 60 KLPD to 70 KLPD through process modification in its existing Distillery.

2.4 DEMANDS‐SUPPLY GAP

Molasses is a very important by-product of the sugar industry. The profit earned by

conversion of molasses to alcohol shall be much higher than the value released by sale of

molasses. There is a good demand for alcohol in the country as production and consumption

of alcohol in India is quite balanced. The target of alcohol demand as projected in the

perspective plan for chemical industry, prepared by government of India, Ministry of



Industry, Department of chemical and petrochemicals is 2400 million liters per annum by

year 2000. In addition, now days, there is a good potential to export alcohol out of country.

Alcohol has assumed a very important place in the economy of the country. The importance and utility of alcohol is well known as an industrial raw material for manufacture of a variety of organic chemicals including pharmaceuticals, cosmetics, potable alcohol etc. This is partly due to high costs of products produced through petroleum route, consequent to the phenomenal increase in petroleum price. Further, it is a potential fuel in the form of power alcohol when blended with petrol. Alcohol is a substitute to the imported petroleum. Being produced from renewable source it is an environmental friendly product. Large demand is also anticipated for its use as fuel. Use of alcohol as an ingredient in beverages is well known. It is a major source of revenue by way of excise duty for the State Governments. It follows that the supply of industrial alcohol to chemical and drugs units in the country will

remain below normal for some more time.

In order to maintain proper rate of growth of Industries, production of alcohol must

increase. Denatured spirits are rectified spirit made unfit for drinking by addition of

chemicals, which have strong disagreeable odor and which cannot be easily separated from

spirit. The Denatured Spirits are taxed at a nominal rate so that their use in industry

becomes economical.

Ethanol has a potentiality as fuel in the form of “power alcohol” for blending with petrol.

This trend is continuing and will continue in view of the fact that potable liquor has larger

revenue generating potential for the Governments. The demand for alcohol will always be

there for industrial purposes. Further the use of alcohol in automobile fuel will enhance the

demand for alcohol. Other than the above mentioned major requirement, alcohol is also

being used in the production of many downstream chemicals including drugs, polymers,

plastic, etc.

2.5 EXPORT POSSIBILITY The possibility of alcohol export is very good. So Indian industries export alcohol in

African, Europe & Asian countries which is very profitable now days. After setup of this

type of alcohol industries government can collect more revenue.

2.6 DOMESTIC/EXPORT MARKETS Presently the big Indian players in alcohol production and bottling are United Spirits Ltd,

ABD Pvt Ltd, Radico, khaitan Ltd, Globus Spirits Ltd etc. So they try to fulfill the current

requirement of alcohol in domestic as well as export market.



2.7 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO PROJECT. M/s. Siddapur Distilleries Limited will give direct employment to local people based on qualification and requirement. In addition to direct employment, indirect employment shall generate ancillary business to some extent for the local population.



CHAPTER 3

PROJECT DESCRIPTION 3.1 TYPE OF PROJECT The proposed project is expansion and modification of Molasses Based Distillery Plant from

60 KLPD to 70 KLPD through process modification in its existing Distillery Plant.

3.2 LOCATION OF THE INDUSTRY M/s. Siddapur Distilleries Limited., is established at Sy. Nos. 49/2B/1 & 2, 57/2D & 2E,

58/1B, 58/1A/3, 66/4D, 85/2, 87, 93/2/3, 95/1 & 107/2, Siddapur village, Jamkhandi Taluk,

Bagalkot District, Karnataka State. Google Map Showing Project Site is shown in Fig 3.1

Fig 3.1 Google Map Showing Project Site

618 m above MSL; Latitude: 16°26'17.03"N ; Longitude: 75°16'16.77"E

PROJECT SITE



Fig 3.2 Map showing the Project Site Location on District Map of Bagalkot

LOCATION MAP

LOCATION

MAP OF THE

PROJECT SITE


Pre-Feasibility Report Page 15 A

Fig 3.3 Plant Layout Plan



3.3 BASIS OF SELECTING THE SITE

The efficient functioning of any industry mainly depends on the availability of its basic requirements viz. raw materials, fuel, power, water, manpower etc. The industry is established in Siddapur village, Jamkhandi Taluk, Bagalkot District, Karnataka State. The choice of the land confers several advantages, which are summarized below.

1. The site is well connected by roadways. 2. Water will be supplied from Krishna River. 3. Power will be supplied from M/s Shri Prabhulingeshwar Sugars & Chemicals Limited (SPSCL). 4. No incidence of cyclones, earthquake, floods or landslides in the region.

3.4 SIZE/MAGNITUDE OF OPERATION The industry “M/s. Siddapur Distilleries Limited.,” is a large scale industrial unit with a total capital investment of the Expansion project is Rs.1.16 crores. The total production capacity proposed is 70 KLPD. 3.5 PRODUCTS MANUFACTURED

3.5.1 MANUFACTURING PROCESS TECHNOLOGY

Rectified Spirit production is based on Fed Batch Fermentation Technology with yeast

recycle using yeast separators for production of ENA and RS. Yeast strain used has property

to form flocks and settle faster than sludge present in the medium. Thus separation and

recycle of sludge is avoided employing the special strain of yeast. The yeast cream obtained

by settling is subjected to centrifugal yeast separation, acidified and then reactivated in the

dilute molasses medium. The reactivation stage brings back the yeast to normal stage and

performs better compared to recycling yeast without reactivation stage. Yeast separation

employing yeast separators ensures separation of maximum yeast bio-mass and

maintenance of required Yeast concentration in the medium leading to higher fermentation

efficiency, higher productivity and generation of less quantity of spent wash.

Adequate space has been provided for foaming to minimize the requirement of antifoam

compound.

Effective wash cooling and monitoring of parameters viz fermentation temperatures, pH,

YCS, contamination level, residual sugars and alcohol concentration will ensure highest

fermentation efficiency and better yield per MT of molasses.



3.5.2 PROCESS DESCRIPTION – 70 KLD BASED ON MOLASSES

Rectified Spirit production in the plant is based on Fed Batch Fermentation Technology.

Production of Rectified spirit is mainly carried under the following three steps.

1. Dilution - Preparation of molasses for fermentation

2. Fermentation - Production of alcohol from fermentable sugars in molasses soln.

3. Distillation - Product Recovery

Each of the above steps of production are detailed below:

Dilution

Molasses available from sugar mills (Our parent company Shri Prabhulingeshwar Sugars &

Chemicals Ltd.) contains solid content between 76-90 % and sugar content varies between

45 and 50 %

The main dilution operation occurs in a diluter where the solid concentration is brought

down to 20 – 25o Brix. The bulk of this diluted molasses is fed to the fermentation tank while

a small quantity is further diluted to 10 – 15o Brix and used for preparation of the final yeast

inoculum. Propagation of yeast for the final inoculation is done in successive stages in

volumes of 10, 100, 1000 and 10,000 liters where in each stage 10 parts of diluted molasses

is inoculated with 1 part yeast culture.

Fermentation

Fermentation in the fermentation tank continues for about 15 to 20 hours after the final

inoculum is added to it. The basic reaction in the fermentation process is

C6H12O6 ----- 2 C2H5OH + 2 CO2 + 26 calories

Glucose Ethyl Alcohol + Carbon dioxide + Energy

Yeast seed material is prepared in water-cooled yeast vessels by inoculating molasses with

yeast. The contents of the yeast vessel are then transferred to the yeast activation vessel.

The purpose of aerated yeast activation vessel is to allow time for the yeast cell

multiplication.

Fermentation:

The purpose of fermentation is to convert the fermentable sugars into alcohol. During

Fermentation, sugars are broken down into alcohol and Carbon dioxide. Significant heat

release takes place during Fermentation. Fermentation temperature is maintained at

optimum level by forced recirculation heat exchangers.

Fermentation process on Fed batch mode which is very feasible for the molasses having

higher valve of volatile acids by using culture yeast .Which offers you the flexibility of



running the process in Fed batch. Inoculation of yeast culture is 20% filling of molasses is

13 hours ,total fermentation period 24 -28 hours and residuals sugars is controlling at >

1.60% and achieved the average Alcohol is 10-11% then finally total spirit yield will be 270-

280 MT of molasses.

In this Fed batch fermentation to increase in the alcohol in wash. The plant capacity will be

increased by 10-15%. However the steam consumption will be remain same and the

generation of Spent wash will be reduced by 3-4% by this process optimum efficiency can be

achieved.

Distillation:

Fermented wash is preheated in fermented wash preheater and fed to the analyzer column.

The dilute alcohol water vapors from the analyzer top are fed to the Pre-Rectification

column. An impure spirit draw of 3 % is drawn from this column. Bottom liquid from Pre-

Rectified column is fed to the IS purification column. Draw from IS purification column is fed

to purified column.

The purification column is operated under atmospheric pressure and is heated by using

steam. The bottom of this column is maintained at 20%v/v alcohol and is fed to the

rectification/ Exhaust column. A small draw from the top of the column is fed to the IS

Purification column.

The purified rectified spirit is removed from the bottom of the purified column.

The Lees from the Exhaust column bottom is used to pre heat the heat from the purified

bottom to the Rectifier/ Dilution water.

Lower side draws streams are taken from Rectified column to avoid fusel oil build up in the

column. These streams are then taken to the IS Purification column.

The total spent wash generation from the process is estimated to be about 6 kl/ kl of RS

produced.

The total waste water generation from the plant is about 593.2 m3/day.



3.5.3 MANUFACTURING PROCESS FOR MOLASSES BASED ETHANOL

The manufacture of ethanol through molasses consists of following operations and process.

A typical flow chart for manufacture of ethanol based on molasses is given in Figure.

i. Substrate (Feed) Preparation

Molasses stored in a storage tank is first weighed in a tank with load cells so that accurate

quantity can be fed to the fermentation section. The weighed molasses then transferred

from tank to the diluter in fermentation section where it is diluted with water and fed to the

Fermenter.

ii. Yeast Propagation and Fed Batch Fermentation

In this process the culture containing highly efficient yeast strain ( Hi firm XP ) from Praj ind

Pune is propagated in yeast culture vessel under aseptic conditions,

The ready yeast seed is then transferred from culture vessel number 2 and 3 transferred to

Fermenter. Because of fresh yeast culture and good retention time we will get average

alcohol of 11% in 30 hr retention. The glucose in media gets converted to alcohol and CO2

The gas liberated during reaction is contaminated with traces of alcohol vapors. It is sent to

CO2 scrubber for recovery of ethanol and vented to atmosphere.

After fermentation the sludge containing spent yeast is separated from the wash in a settler

cum decanter tank. Then passes through decanter and disposed as solid waste.

iii. Multi-Pressure Distillation

The fermentation wash containing Alcohol, non-fermentable solids and water is supplied to

distillation to separate the alcohol and other impurities, as a continuous flow. The

distillation system is designed for quality ethanol. The system details are as below.

The system consists of 8 columns, namely CO2 stripper, analyzer column, Pre-rectifier

column, Extraction column, Rectification Column, Refining Column, Fusel Oil column & HCC

Column.

Wash is fed to de-gasifier cum analyzer column. CO2 and other non-condensable gases are

removed at the de-gasifier unit. Distillate containing 40 % alcohol from analyzer column

along with additional fresh water as lees water is sent to R.S. column. RS as distillate and

spent lees as bottoms are taken out from RS column. In case of ENA production, the RS

along with lees or dilution water is sent to extraction column. Most of the high boiling

impurities are removed from top of this column and from bottom aqueous alcohol is

obtained. The latter is taken to rectification column, and from where 95 % alcohol and spent

lees water are obtained as distillate and bottoms, respectively. 95 % alcohol is further



distilled in refining column to remove low boiling impurities (mainly methanol) Extra Neutral

alcohol from is sent to storage tanks.

The impure spirit from top of RS column, extraction column, rectifier column and refining

column are taken to purification column. Impure spirit is recovered from purification

column and balance alcohol is recycled to RS column. The alcohol containing fusel oil from

pre-rectifier and rectifier column is fed to fusel oil column. The FOC column inputs are so

adjusted to get 15 kl /day RS with required concentration at the top.

The top vapors from analyzer column, extraction column and fusel oil column are

condensed in evaporator for spent wash concentration. The rectifier column, fusel oil

column and pre-rectifier column get heat from fresh stream at 3.5 kg/cm2.

Rectification column works under positive pressure. The top vapors from rectifier column

are condensed in analyzer column for giving heat to stripper re-boiler. Most of the other

columns work under vacuum.

IV. Dehydration of RS to Anhydrous/fuel grade ethanol

Rectified spirit at Azeotropic concentration is pumped by a feed pump to the dehydration

plant. The rectified spirit containing 95 % alcohol and 5 % water will first pass through feed

economizer, then through a vaporizer cum super heater which will convert the rectified

spirit feed to superheated vapors. The superheated vapor will pass through a sieve column,

which is already regenerated and pressurized to working pressure. All the water vapors

present in vapor mixture are adsorbed in the column. Along with alcohol traces of alcohol

are also adsorbed in the column. The Anhydrous alcohol vapors free from water vapors

exhausted from the column are duly condensed in the re-boiler at the recovery column and

is further passed through feed economizer to preheat the incoming feed and then to a final

product cooler. After saturation of sieve column with water, the flow will be shifted to the

next sieve column, which is already regenerated and pressurized. After completion of

dehydration cycle, the sieve column saturated with water is regenerated by evacuation of

adsorbed water and alcohol. The evacuated vapors are condensed. The condensed mixture

of alcohol and water is then fed to a recovery column, which enriches the stream back to

azeotropic composition. This sequence of adsorption and regeneration of sieve column

continues.



PROCESS FLOW CHART FOR DISTILLERY

Molasses Arrives

Molasses Weighed & Diluted

Yeast propagated with Molasses in Sterilized Separate vessels

Fermentation

Clarified Wash Tank

Analyzer column

Pre-Rectifier column if required

Rectifier Column

Exhaust column

Reboiler

Fused oil separated and Alcohol Returned

Rectified Spirit

Molecular Sieve Dehydration Bed

Absolute Alcohol / Ethanol



3.5.4 Brief description of Fed Batch Process

1. The Fermentation plant consists of 4 fermenters operating independently and also convertible as series by connecting them for continuous operation. The fermenters are connected with accessories like, plate heat exchanger for cooling, air spargers, broth mixer

and air blower etc. Each has capacity to produce 700 m3/hour fermented wash with 11% v/v alcohol to feed 70 KLPD distillery plant. So, 4 fermenters are used. The fresh yeast culture is used every time to improve fermentation process yield to achieve 11% v/v alcohol instead of 8% v/v alcohol in normal fermentation process. Due to higher percentage of alcohol in the fermented wash, the yeast from these fermenters cannot be used. 2. Fed Batch fermentation process is used for fermentation process, where 11% v/v alcohol concentration in fermented wash is achieved and fresh yeast is used for every batch. It has extra fermenters, they can increase capacity by 30% to the existing.

3. Yield and quality of product are of high standard.

4. To convert the existing “Continuous Fermentation System” into “Fed Batch System” to

increase Alcohol content in Fermented Wash from 10.5 % to 11% v/v

5. It consumes less quantity of steam and operates efficiently.

6. Yield and quality of product are of high standard.

7. High Brix fermentation & more Alcohol % in wash i.e 10% to 11% v/v, when compared

to Continuous Process 8% to 9% v/v.

8. For every batch fresh culture is to be added. This will avoid bacterial contamination.

9. Changing process parameter for every batch depending on the Molasses characteristic.

10. Minimize the acid formation in Fermentation Media for getting good quality of

Alcohol & to increase the yield.

11. Due to increase in the Alcohol % in wash, the plant capacity will be increased by 15

to 20%. However the steam requirement remains same.

12. The generation of spent wash will be reduced by 3 to 4%.

13. The term fed signifies that fed is provided at a required rate to fermentation

system

Without getting accumulated.

14. Simple to operate.

15. Proper control on operating parameters.

16. Optimum efficiency can be achieved.



3.5.5 Major difference b/w continuous & Fed batch Fermentation process

The Major difference b/w continuous & Fed batch Fermentation process is stated in table

3.1

Table 3.1 Major difference b/w continuous & Fed batch Fermentation process

Sl. No.

Description Continuous Fed batch

1 Alcohol yield in % 10.5 % 11 %

2 Yeast generation Less More 3 Spent wash Based on

Molasses : 420 KLD

Based on molasses 420

KLD

4 Spent lees Based on Molasses: 80

KLD

Based on Molasses : 70

KLD

5 Water consumption

940 KLD 770 KLD

General difference between continuously fermented processes to Fed Batch fermented

process.

Batch process

The molasses obtained from the sugar industry is first diluted to bring down the

concentration of sugar from 40- 45% to 18 to 20%. Using a portion of the diluted molasses a

yeast culture is developed from an inoculum. After 4-6 hours, when the culture has

developed fully, the remaining molasses is mixed and allowed to ferment 30hours. The pH is

maintained around 4-4.5 by addition of sulphuric acid. As the reaction is exothermic, the

contents of the fermentation tank are kept at 32 to 330C by circulating through plat sheet

exchanger. Due to increased retention, higher sugar cane and fresh yeast will get higher

alcohol (Average 11% )in fermenter.

After fermentation is complete the yeast sludge is removed from the bottom and the

fermenter wash is pumped to the analyser column for distillation using steam. The mixture

of alcohol vapours and steam is collected at the top of the column and alcohol free spent

wash is discharged from the bottom. The alcohol and the steam stream are fed to

rectification column where water and alcohol vapours condense at different levels and

rectified spirit is withdrawn. The bottom water from this stage is called spent lees and forms

another waste stream.



Continuous Process

In this process yeast is recycled. Fermentation and distillation is coupled to get a continuous

supply of fermented mass for the distillation column. The advantage of the process is that a

highly active yeast cell initiates the fermentation rapidly but the quality of molasses affects

immediately.

Bio-still process is one of the continuous processes, which is a trade name in which molasses

is fed to the fermenter at a constant flow rate. The flow rate of molasses is controlled to

maintain the sugar and alcohol concentrations in the wash at 0.2% or lower and 6-7%

respectively.

The waste streams comprise spent wash which is the main source of wastewater, spent lees

and yeast sludge. The yeast sludge is disposed separately after drying. In addition

wastewater may be generated from the bottling, fermentation tank cooling and washing

and utility sections of the plant, which is used as a diluent for the treated spent wash.



3.5.6 BLOCK DIAGRAM of EXISTING 60 KLPD PLANT Steam 216 MT CO2 49 MT Process Water 416 KL

Molasses Fermented 224 MT Wash 640

Alc + Water Vap Spent Wash Spent Leese 80 KL

Biogas to Boiler Spent Leese 80 KL

420 KL Conc. Spent Wash

Process Condensate 80 KL

TRSW 420 KL

Treated Water Used for Gardening & Plantation.

Aerobic Treatment Plant

160 KL

Distillation

Fermentation

Evaporator

Biogas Plant

RS/ ENA / Ethanol

Bio-Composting Processing



3.5.7 BLOCK DIAGRAM of 70 KLPD PROPOSED PLANT

Steam 216 MT

CO2 54 MT

Process Fresh

Water 230 KL

Molasses Fermented

260 MT Wash 660 KL

Alc + Water Vap

Biogas to Boiler Spent Leese 70 KL

Spent Wash

520 KL Spent Wash

Process Condensate Water 100 KL

TRSW 420 KL

Treated Water Used for Process (170 KL)

Fermentation

RS /ENA / Ethanol

Bio-Gas Plant Evaporator

Bio-Composting Processing

Treated with Physiochemical

treatment

Distillation



3.6 RAW MATERIALS

Molasses is the main raw materials. A detail of the raw material used in the plant is stated in below table. 3.2

Table -3.2 Raw Materials Requirement

Sr No Particulars Quantity MT/Month

EXISTING

1 Molasses 6720

2 Deformer 3.0

3 Urea 1.3

4 DAP 1.2 PROPOSED

1 Molasses 7800

2 Deformer 3.5

3 Urea 1.5

4 DAP 1.4

3.6.1 STORAGE FACILITY FOR RAW MATERIALS AND PRODUCTS Adequate storage facility for Raw materials such as Molasses, Press mud is provided in an

area of 4.0 Acres.

SDL has 3 Nos (three) molasses storage tanks of capacity 6500 MT the storage tanks have

been provided with necessary dyke walls & cooling arrangements as per excise

department’s guidelines.

Storage facility for molasses (6500 MT x 02 Nos.) is also provided by our parent company

M/s. Shri Prabhulingeshwar Sugars & Chemicals Limited (SPSCL).

SDL shall use the existing storage tanks Total capacity of 7500KL (i.e. RS-1183KL, ENA-2725,

FA-3200 & IS-380 respectively) for storage of RS, ENA & Ethanol.

SDL has adopted the following method for treatment of spent wash :

The industry is treating the effluent (Spent wash) in anaerobic digester followed by bio

composting. The area of the compost yard is 31 acres including storage area. Compost yard

provided is as per the MOEF / CPCB guidelines. SDL has provided necessary storage facilities

for the storage of spent wash generated over a period of 30 day.



3.7 MACHINERY & EQUIPMENT DETAILS The detailed list of machinery & equipments in the industry are appended in the tables 3.3 below

TABLES 3.3: TECHNICAL SPECIFICATIONS FOR 60 KLPD DISTILLERY PLANT CONTINUOUS FERMENTATION AND MULTI PLRESSURE DISTILLATIONS

Sr. No.

Particulars Remarks

1 A B

Molasses Day Storage Tank 1 No. Capacity Material Size Raw molasses pump, Gear type with gear box, drive motors (day storage to weighing section)

550 m3

M.S. 9700 mm Dia x 8224 mm Height. Capacity – 15MT/hr. Drive HP – 10 HP, RPM 1450 Nos. - 1+1

2 Fermentation: Molasses weighing section:

i) Automatic molasses weighing system with duplex stirrer and with receiving tank.

ii) Weighed molasses tank: iii) Capacity:

Material iv) Check weighment with suitable system

approved by weights and measures department.

v) Weighed molasses pump: Gear box & motor, C.I. body with CI wetted parts (Weighing section to diluter) Make – PSP Gear type

Capacity – 20MT/hr. (2 MT/Tip) Volume – 4 m3

20 MT M.S. 20MT/hr. 10 HP, 1450 RPM 1+1 No. Capacity – 22MT/hr. (2 MT/Tip)



3

Fermentation Section:

i) Yeast vessels with sterilizing & cooling arrangement ( Min.3 mm thick) with filtered & moisture free air & other fitting. MOC

ii) Tank for antifoam agent Volume Material Quantity

YV-I-300 lits. YV-II-3000 lts. Pre – Fermenter - I Cap 50000 Liters Pre – Fermenter - II Cap 60000 Liters SS 304 1 M3

SS 304 1 No.

iii) Cleaning in place tank Volume Material Quantity

10 M3 SS 304 1 No

4 Fermenters: (Gross capacity) with mountings for antifoam dosing air Spurger, sight and light glass, manholes, level indicators, pressure relief device and accessories. MOC

350 M3 each SS 304 4 Nos. with stiffeners sparger and all fittings in contact with wash made. SS 304

5 Plate type heat exchangers HTA m2 (Total) MOC

6 Nos. 156 m2 For fermenter cooling plate SS 316

6 Clarified wash tank Capacity Material

60 m3 SS 304 Clarified wash holding tank (on ground floor)

7 Air blower twin lobe type with motor with air purifier (Bacteria proof)

700 m3/hr. 40 HP, 1 No. CI body with motor twin lobe type

8 Air filters (Bacteria proof) Corrugated HEPA type, 1 No.

9 CO2 Scrubber

0.625 mm diameter. SS 304 Sieve tray type 1 No.

10 Pumps with motor: 1. Antifoam pumps. 2. Process water pump 3. Fermented wash recirculation pump 4. Fermentation Cooling Tower Pumps 5. Pre-fermenter to fermenter pump 6. Yeast vessel transfer pump YV2 & YV3 7. Clarified wash pump (F.W to Distillation) 8. C.I.P. Pump 9. Sludge transfer to Decenter

Capacity / MOC/ Quantity: 0.250 m3/hr. SS304, 1+1 Nos. 50 m3/hr. CI, 1+1 Nos. 240 m3/hr. SS316, 1+1 Nos. 300 m3/hr. SS316, 700 m3/ hr, CI 1+1 Nos. 20 m3/hr. SS316, 1+1 Nos. 3 m3/hr. SS316, 1+1 Nos. 35 m3/hr. SS316, 1+1 Nos. 10 m3/hr. SS316, 1+1 Nos. 10 m3/hr. C.S. 1 No.



11 Piping: Molasses Fermented wash Fermented wash recirculation Process and cooling water CO2 / Air Antifoam agent

MS-“C” class SS304 Sch - 10 SS304 MS Class “C” MS Class “C” MS Class “C”

12 Valves: Fermented wash Process and cooling water CO2 / Air Antifoam agent

CS/ SS304 CI with Neoprene SS304 internals MS

13 Instruments

Instruments as per process requirements.

1 Distillation: CO2 stripping column

a. Diameter b. MOC c. No. of plates d. Type of plates e. Plate spacing f. Thickness: Shell/Plate/Cap.

1000 mm SS 316 8 Nos. Bubble cap Suitable (500 mm) nominal 4/2/1.6 mm

2 Stripping column: a. Diameter b. MOC c. No. of plates d. Type of plates e. Plate spacing f. Thickness: Shell/Plate/Cap.

2200 mm SS 316 Suitable ( 22 ) Bubble cap Suitable (750 mm) nominal 4/2/1.6 mm

3 Pre -Rectifier column: a. Diameter b. MOC c. No. of plates d. Type of plates e. Thickness: Shell/Plate/Cap.

1700 mm Deoxidized copper/ SS 304 Suitable (72) Bubble cap (300 mm) nominal 5/2/1.6 mm

4 Extraction column: a. Diameter b. MOC c. No. of plates d. Type of plates e. Plate spacing f. Thickness: Shell/Plate/Cap.

2000 mm Deoxidized copper Suitable (44) Bubble cap Suitable (300 mm) nominal 5/2/1.6 mm



5 Rectifier column: a. Diameter b. MOC c. No. of plates d. Type of plates e. Plate spacing f. Thickness: Shell/Plate/Cap.

1475 mm Deoxidized copper Suitable (72) Bubble cap Suitable ( 225 mm) nominal 4/2/1.6 mm

6

Refining column: g. Diameter h. MOC i. No. of plates j. Type of plates k. Plate spacing l. Thickness: Shell/Plate/Cap.

1100 mm Deoxidized copper Suitable (45) Bubble cap Suitable ( 300 mm) nominal 5/2/1.6 mm

7 Fusel Oil column: a. Diameter b. MOC c. No. of plates d. Type of plates e. Thickness: Shell/Plate/Cap.

675 mm SS 316 Suitable (50) Bubble cap ( 250 mm) nominal 3/2/1.6 mm

8 Head Concentration Column a. Diameter b. MOC c. No. of plates d. Type of plates e. Plate spacing f. Thickness: Shell/Plate/Cap.

900 mm SS 304 Suitable (50) Bubble cap (250 mm) nominal (250 mm) 3/2/1.6 mm

9 Aldehyde column (Alcohol scrubber): a. Diameter

b. MOC c. No. of plates d. Type of plates e. Plate spacing f. Thickness: Shell/Plate/Cap.

735 mm SS 316 Suitable (10) Sieve (250 mm) nominal 2.5/2/1.6 mm

10 Re - boiler for stripping column a. HTA b. MOC

275 m2 nominal SS 304/ MS

11 1ST Re -boiler for extraction column a. HTA b. MOC

15 m2 nominal Deoxidized copper / SS304

12 2nd Re - boiler for extraction column a. HTA b. MOC

85 m2 nominal Deoxidized copper/SS 304

13 Re - boiler for rectifier column a. HTA b. MOC

280 m2 nominal Tubes – Deoxidised copper Shell MS with SS contact parts



14 Re - boiler for fusel oil column a. HTA b. MOC

8 m2 nominal SS304/MS

15 Re - boiler for refining column a. HTA b. MOC

65 m2 nominal SS 304

16

H C C Re - boiler a. HTA b. MOC

25 m2 nominal SS 304 / MS

17 Principle condenser with vapour bottle / evaporator body. a. HTA b. MOC

See evaporator 1st stage

18 Beer heater with vapour bottle /evaporator body a. HTA b. MOC

See evaporator 2nd stage SS316

19 Vapour condenser with vapour bottle a. HTA b. MOC

40 m2 Deoxidized copper / MS

20 Impure spirit cooler a. HTA b. MOC


21 ENA cooler a. HTA b. MOC


22 R.S. Cooler a. HTA b. MOC


23 Fusel Oil cooler a. HTA b. MOC

10 m2 SS 316 / MS

24 Fusel oil de-canter MOC

SS 316

25 Plate heat exchangers a. MOC b. Qty. c. HTA m2

Plate – SS 316, Frame-MS with Anticorrosive coating 4 Nos. 13 + 6 + 4 + 1

26 Steam chest with fittings a. Size b. Accessories

600 mm, 1000 mm long Safety valve, drain, inlet/ Outlet steam valve etc., (1 No.)

27 Cold water tank a. Capacity b. MOC

36 m3 Mild steel



28 Hot water tank a. Capacity b. MOC

2 m3 Mild steel

29 Piping – MOC a. Fermented wash b. Water, steam c. R.S/ENA d. Impure spirit e. Fusel oil

SS 304 MS Copper / SS 304 Copper / SS 304 SS 304

30 Valve – MOC a. Fermented wash b. Water, steam c. Rectified spirit d. Impure spirit e. Fusel oil

SS with SS 304 internals CI SS with SS 304 internals SS with SS 304 internals SS with SS 304 internals SS with SS 304 internals

31 Instrumentation and controls Flow meters & Rota meters Temperature indicators Pressure gauges Other instruments

1 Set

32 Control panel 1 Set As per process Requirements

33 PLC panel 1 No.

34 Distillation pumps with flame proof motor Type MOC Quantity

Centrifugal SS 316 for contract parts 18 + 18 Nos.

35 Vacuum pump MO Quantity

CI body CI internals 1 + 1

36 Condensate transfer pump SS304

Included in Evaporator section.

37 DCS/PLC Modules and Rack, software and communication cable.

1 Lot

38 PC Pentium III with 15” Monitor and Printer 1 Lot.

39 Software package for SCADA 1 Lot. 40 Instrumentation and control 1 Lot.

41 Energy (power) meter 1 No.

42 Vent condenser for rectifier 5 m2, SS 304



SPENT WASH CONCENTRATION SYSTEM SPECIFICATION OF EQUIPMENTS FOR SPENT WASH CONCENTRATION SYSTEM (EVAPORATION)

Sr. No. Particulars Specifications

1 Stripper Bottom Spent Wash Feed to evaporator 1st Body Pump Capacity MOC Type

35 m3/hr SS304 . Centrifugal

2 Three effect evaporator calendria Type HTA m2

MOC Shell Tubes

EV-1 S & T 216 SS

SS 316

EV-2 S & T 170 SS

SS 316

EV-3 S & T 176 SS

SS 316

3 Vapour separator Capacity MOC

Suitable SS 316

4 Product transfer pump Capacity MOC Type

25 m3/hr. SS 304 for contract parts Centrifugal

5 Condensate pump Capacity MOC Type

13 m3/hr. SS 304 for contract parts Centrifugal 1 + 1

6 Vapor duct MOC

SS 304

7 Piping & valves for steam, product condensate, non-condensate etc.

SS 316 / 304 / mild steel

8 Barometeric condenser HTA MOC Type

265 sq mtrs SS 304 Shell & tube / spray

9 Vacuum pump Capacity MOC Type

160 m3/hr. 1 + 1 Qty. SS 304 Water ring vacuum

10 Control panel Included in distillation.

11 Instruments & controls 1 set

12 Circulation transfer pump: 1. Axial flow pump - Capacity 2. Axial flow pump - Capacity 3. Axial flow pump - Capacity 3. Spent wash transfer pump - Capacity

SS 316 for contact parts 1026 m3/hr. 800 m3/hr. 800 m3/hr. 36 m3/hr.

13

Distillation Cooling Tower Pumps

Capacity / MOC/ Quantity: 1100 m3 /hrs, CI 1+1 Nos



EQUIPMENT LIST FOR INTEGRATED MOLECULAR SIEVE BASED 55.2 KLPD FUEL/ANHYDROUS ALCOHOL PLANT

Sr. No.

Particulars Qty. Remarks

1

Absorber bed with molecular sieve a) Material of construction. b) Overall dimensions (shell + dish end +

skirt support)

3

-- AISI 304 1200 mm Dia x 6000 mm Ht.

2 Feed Sieve Vaporizer Heater a) Material of construction shell b) Tubes

1

(AISI 304 Wetted Parts)MS AISI 304

3 Feed Economizer – Plate heat exchanger type a) Heat transfer area b) Product Control Part – PHE c) Frame material PHE

1 1.7 m2 SS 316

4 Regeneration Cooler – Plate Heat Exchanger Type

a) Heat transfer area b) Product Contact Part PHE

1 22 m2 SS 316

5 Product Cooler –Plate Heat Exchanger Type a) Heat transfer area b) Product Contact Parts material PHE

1 1.2 m2 SS 316

6

Regeneration Condenser - Plate Heat Exchanger Type

a) Heat transfer area b) Product Contact Parts material PHE

1 22 m2 SS 316

7 Regeneration Tank: a) Capacity b) Material of construction

1

1.4 m3 AISI SS 304

8 Feed Pump with flame-proof motors Capacity Head MOC

2 2.4 m2/hr. 55 mtrs (AISI 304)

9 Flame -proof motors with Pump /starter / push button) Capacity Head MOC

2 2.4 m3/hr. 15 mtrs (AISI 304)

10 Regeneration pumps with flame proof motors Capacity Head MOC

2 20 m3/hr. 65 mtrs (AISI 304)



11 Product storage pumps with flame proof motors/ starter/push button Capacity Head MOC

2 40 m3/hr. 25 mtrs (AISI 304)

12 Pumping valves & Instrumentation Piping Alcohol Water Steam Valves Alcohol Water Steam

SS 304 Sch 10 M.S “C” Class M.S “C” Class C. S. IBR SS 304 C.I C.S. IBR

13 Instrumentation & Control: a) Temperature indicator b) Pressure indicator c) Temperature transmitter d) Pressure transfer e) Flow indicators f) Flow transmitter g) Flow indicating controllers h) Control valves i) On Off valve j) Ball Valves k) Globe valves l) Pressure setting valve m) Other local indicators as per the

process requirement

1 Lot

14 Supply of electrical material such as cables, starters, push button, electrical motors: Kirloskar Cromption Greaves Siemens make.

1 Lot

15 Motor control Centre (MCC + PLC Panel) Included in distillation 16 Chilling Plant 2 No. 2 TR + 4TR

17 Chilled water circulation pump Capacity Head MOC

2 Nos. 2.5 m3/hr. 6 mtrs C I

18 Compressor with air dryer Capacity

2 Nos. 1 No

7.5 m3/hr. @ 6 Bar (g) 8 m3/hr. @ 8 Bar (g)

19 PLC modules and rack, software & communication cables.

Included in distillation

20 PLC Pentium III with 15” monitor & printer, Software and SCADA

Included in distillation



21 Recovery Column Capacity MOC

1 No.

720 mm Dia 18 Trays, Bubble Caps SS 304

22 Flow meter with totalizer Capacity 1 No. 40 m3/hr.

RECEIVERS & STORAGE FOR RECTIFIED SPIRIT / IMPURE SPIRIT 1 Rectified Spirit Receivers Tanks

Capacity Number

70 m3 3

2 Rectified Spirit Bulk Storage Tank Capacity Number

950 m3 1

3 Impure Spirit Receivers Capacity Number

20 m3 3

4

Receivers (Technical Grade) Capacity Number

20 m3 3

5

Impure Spirit storage tank with a suitable vent condenser & flame arrester. Capacity Number

100 m3 & 150 m3

2

6 Denatured Spirit tank Capacity Number

70 m3 2

7 Flow Meters: Flow meters with totalizer

2 Nos.

8 Alcohol Pumps: Capacity Numbers Material Motors/Starter

20 m3/hr., 40m3/hr. 4 Nos. (2+2), 2 Nos.(1+1) SS 316 Flame proof

RECEIVING & STORAGE TANKS FOR ENA:

1 ENA Receivers Capacity Number

60 m3 3

2 ENA Storage tanks Capacity Number

950 m3 – 03 Nos and 250 m3- 01No & 190 m3 - 2 Nos 6

3 Flow Meter with totalizer Number

1 No.

4 Issue pump set Number

1 + 1



Capacity Head MOC

40 m3 20 m C.S. body with SS 316 Shaft & impeller with Single mechanical seal

ABSOLUTE ALCOHOL RECEIVERS AND BULK STORAGE TANKS

1 Absolute Alcohol Receivers Capacity Number

60 m3 3 Nos.

2 Absolute Alcohol Storage tanks Capacity Number

850 m3 - 01 Nos. 950 m3 - 02 Nos 3 Nos..

Flame arrestors / level gauge / nozzle for dip / nozzle for overflow, feed, outlet, suction, Vent condenser for open installation spirit tanks

MOLASSES STORAGE TANKS

1 Molasses Day Storage Tank Capacity Number

800 M T 01 Nos.

2

Molasses Storage Tanks Capacity Number

6500 M T 0 3 Nos.

3 Molasses Unloading Masonry Pit Capacity Number

1100 MT 1 Nos..



3.8 SOLID WASTE & HAZARDOUS WASTE

Solid waste generated from the industry is as follows:

Table 3.4 : Solid Waste generated

Sl.

No.

Type Quantity Storage Utilization/disposal

Molasses based

Existing Proposed

1 Fermenter Sludge

20 TPD

26 TPD

Separated by

Decanter machine

&collected in

Tractor Trolley

Mixed with Press Mud converting into organic manure

Hazardous Waste

2 Waste oil

300 LPA

300 LPA

Sealed Carboys

Used as lubricant for

Compost yard Aero

tiller & Composting

Machinery within the

premises.

3.8.1 DOMESTIC SOLID WASTE RE-USE

The quantity of solid waste generated from the proposed industry is detailed in the following table 3.5.


Total no. of employees 115

Assuming per capita solid waste generation rate as 0.20 kg/capita/day



Inorganic solid waste : 40 % of the total waste 9 kg/day

Disposal of domestic solid waste The domestic wastes are segregated at source, collected in bins and composted.



3.9 WATER, ENERGY/POWER REQUIREMENT & SOURCE

3.9.1 Water

The water demand is met from Krishna River water supply. The requirement of water for the

unit is for domestic, industrial purposes. Details are appended in section 3.11.1 later in the

report.

3.9.2 Power

The Proposed power requirement of the Distillery plant is 800 KW/Hr, Distillery has given on lease a 2.50 MW TG set to our parent sugar plant i.e. SPSCL. The required power is available. During off season it shall depend on 1000KVA DG Set only.

3.10 WASTES GENERATED & SCHEME FOR THEIR MANAGEMENT/DISPOSAL

3.10.1 Water demand and wastewater/effluent discharge

The total quantity of water requirement for the industry is about 770 KLD. The break-up of the consumption of water is as presented in Table 3.6.

Table 3.6 Water Consumption and Discharge

Sl No

Particulars Existing water Consumption in KL / Day(60KLPD)

Particulars Expansion water Consumption in

KL / Day(70KLPD)

1 Water Consumption details

a Fresh water for molasses dilution

423.0 Fresh water for molasses dilution

253.0

b Cooling Tower Make Water

432.0 Cooling Tower Make Water

432.0

c Domestic 4.5 Domestic 4.5

d Gardening 70.0 Gardening 70

e Others 5.5 Others 5.5

f Floor washing 5.0 Floor washing 5.0

Total 940.0 Total 770.0

2 Waste water generation details

a

Spent Wash (ZLD, Bio-methanzation followed by Composting )

420.0 Spent Wash (ZLD, Bio-methanzation followed by Composting)

420.0

b

Spent Leese (Treated effluent used for irrigation or greenbelt development )

80.0 Spent Leese (Re-use in Process or cooling Tower make up)

70.0



c

Process Condensate water(Treated effluent used for irrigation or greenbelt development )

80.0 Process Condensate

water(Re-use in Process or cooling Tower make up)

100.0


3.2 Sewage Domestic ( Septic Tank Followed

Soak fit 3.2

Total 583.2

Total 593.2

Note: - 1) Sanctioned raw water quantity is 940 KLD from irrigation department Govt. of Karnataka. 2) Maximum fresh water requirement for molasses based process is 770 KLD.

The treatment methods and the final disposal of each type of wastewater generated is

appended in the table 3.7 below

Table 3.7: Sewage/effluent treatment and discharge

Sewage/effluent generated from

Treatment provided Final disposal point

(a) Domestic Sewage is treated septic tank Disposed in Soak pit

(b) Industrial RSW is treated with Full-fledged ETP with collection tanks are provided.

RSW is treated with Bio-Methanisation followed by Bio-Composting To archived ZLD Concept

(c) Industrial Spent leese Spent leese is treated with the phyiso-chemical treatment and re-use in cooling tower make up or process dilution purpose

3.10.2 TREATMENT OF EFFLUENTS AND DISPOSAL

The unit generates liquid, solids and air effluents. The mitigation measures for these

effluents are as follows:

Treatment of Distillery Spent Wash

The existing Distillery plant capacity is 60KLPD and the spent wash generated per

liter of alcohol is maximum 7.0-7.5 liters. However with the changes / optimization made in

our fermentation & Evaporation plant we are generating about 6.0 liter of spent wash per

liter of Alcohol.



We have changed the Continuous fermentation process to Fed Batch system where the

spent wash generation is reduced, further to this we are concentrating the Biomethanated

spent wash in distillation column re-boiler so there will be further reduction in the spent

wash generation. The process condensate generated will be treated through Physio

Chemical treatment and recycled back to process plant.

We propose to increase the Distillery capacity from 60 KLPD to 70 KLPD and we have

adequate spent wash treatment facility in existing Effluent treatment Plant.

The spent wash is anaerobically treated in the digester. During this anaerobic

degradation, the organic matters are converted into Bio-gas (55% contains methane) which

brings down the BOD value to 7000 – 8000 mg/lit, from the original level of about 45000 –

50000 mg/lit. The generated Bio-gas is used as fuel in the boiler of our parent sugar factory.

Further, the concentrated spent wash is utilized for Bio-composting using sugar

factory press mud, boiler ash and other waste bagasse to produce useful organic manure.

Bio-composting Process:-

In the Bio-composting system, the process is carried out on a concrete floor yard by

aerobic windrow technology using special aerobic microbial culture. The sugar industry

press mud, boiler ash, waste bagasse and yeast sludge from the distillery are mixed suitably

and bio-activated on the concrete floor. The reaction is an exothermic one which helps to

evaporate the water content and gasses. The necessary windrow moisture for the process

is maintained by spraying of concentrated treated RSW through tanker on the windrows

uniformly and aero tiller machine is used to turn the material, the composting process is

aerobic condition. The Bio-composting process would take about 60 days for completion

and the ready Bio-compost manure is enriched and distributed to the farmers.

Thus, the entire spent wash generation during the alcohol production will be converted into

valuable Bio-compost manure. This environmental management plan is of “ZLD” (Zero

Liquid Discharge) Environmental concept of Pollution Control Boards.

Spent Lees & Process Condensate Water Treatment Plant System

Spent lees and the process condensate water is generated in the range of 170

m3/day we are treating this effluent through the most advanced treatment technique i.e

physio-chemical treatment and treated water is reused in the process plant.



Waste Water Generation From Existing & Proposed Distillery

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

Sl No

Particulars

Existing water Consumption in KL / Day(60KLPD)

Particulars Expansion water

Consumption in KL / Day(70KLPD)

1 Waste Water Side

a

Spent Wash (ZLD, Bio-methanation followed by Composting )

420.0 Spent Wash (ZLD, Bio-methanation

followed by Composting)

420.0

b

Spent Leese (Treated effluent used for irrigation or greenbelt development )

80.0 Spent Leese (Re-use in Process or

cooling Tower make up)

70.0

c

Process Condensate water(Treated effluent used for irrigation or greenbelt development )

80.0 Process Condensate

water(Re-use in Process or cooling Tower make up)

100.0


3.2 Sewage Domestic ( Septic Tank

Followed Soak fit 3.2

Total 583.2

Total 593.2

Solid Waste Generation from the Existing & Proposed Distillery

Sl. No.

Solid Waste in MT Mode of Disposal Existing 60 KLPD Proposed 70 KLPD

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



Fig :- 3.4 FLOW CHART OF EXISTING & PROPOSED ENVIRONMENTAL MANAGEMENT PLAN (EMP)

Treatment plant unit list The wastewater treatment plant consist of the following unit operations and unit processes.

Aeration fountain: Ø4.1mtr, MOC: RCC lined

Open Channel: 45m X0.75 mtr (2Nos), MOC: RCC lined

Feed Tank:10 X10 X 15 M , Capacity : 150 M3, MOC: RCC lined

Buffer Tank: 12.50 X 8.00 X 3.00 mtr , Capacity : 600 M3 , MOC: RCC lined

Lars Enviro Structured Media Anaerobic Tank (LESMAT): Ø 32.5mtr X 10.5 mtr Height

Capacity -600 M3/day & Tank MOC – Mild Steel

Pre-Aeration Tank (PAT): 4.40 X 3.50 mtr, Capacity: 50 M3 ,MOC: RCC lined

Clarifier: 7.10X3.20 mtr, Capacity: 100 M3 MOC: RCC lined

Bio-Methanated Overflow Tank: 5.50 X 5.50X 2.00 mtr, Capacity: 50 M3 MOC: RCC

lined

5 Days RSW Storage Tank: Size- 36 x 25 x 3.5mtr capacity – 2500 M3

24 Days RSW Storage Tank: Size- 115.5 x 36 x 3.5mtr capacity – 12500 M3

Compost Yard Details: Press mud storage Area – 6.0Acre, Composting Area –18.0

Acre & Finished Compost Storage Area - 4.0 Acre



Typical composition of spent wash

s Parameter Description

1 pH 4.0-4.5

2 BOD, mg/l 45,000-50,000

3 COD, mg/l 1,10,000-1,40000

4 Total Solids, mg/l 95,000 -105,000

5 Volatile solids , mg/l 12,000-30,000

6 Total Nitrogen, mg/l 4,500-5,000

7 Chloride, mg/l 3,500-4,500

8 Potassium as K, mg/l, 8,200-9,500

9 Sodium, mg/l 260-290

10 Sulphate, mg/l 2,500-3,200

11 Phosphorous as P2O5 1,050-1,200

12 Ash, mg/l 45-165



ETP FLOW DIAGRAM

Raw Spent Wash

Anaerobic Digester

Storage Lagoon

Treated Physio Chemical system

Re-Boiler/Evaporation

Concentrated Spent Wash

Process Condensate

Reused in Process Section

Press Mud from Sugar Factory

Bio-Composting Process

Compost Manure to Farmers



3.11 AIR POLLUTION DETAILS The major air pollution sources from the industry are DG set. These sources are provided with stacks of adequate height so as to disperse the emanating flue gases containing SPM, oxides of sulfur and nitrogen without affecting the ground level concentrations.

The sources of air pollution, type of fuel used, fuel consumption and chimney heights for each of the air pollution sources of the proposed project are indicated in the following table 3.8 .

Table 3.8 Sources of air pollution, type of fuel used, APC details

SI. no.

Stack attached to

Fuel used Fuel consumption

Number of stacks

Stack/s height

Air pollution control unit

Predicted emissions

1 D.G. set – 1000 KVA – 1 No.

HSD 58.75 L/hr

1

31 m AGL

Stack SOx, NOx, SPM

3.12 Noise pollution details The major source of noise pollution in the industry is the DG set for which acoustic enclosure is provided. Also ambient noise levels will be ensured within the ambient standards by inbuilt design of mechanical equipment and building apart from vegetation (tree plantations) along the periphery and at various locations within the industry premises. 3.13 Solid waste details The quantity of solid waste generated from the proposed industry is detailed in the following table 3.9 .


Total no. of employees 115

Assuming per capita solid waste generation rate as 0.20 kg/capita/day



Inorganic solid waste : 40 % of the total waste 9 kg/day Disposal of domestic solid waste The domestic wastes are segregated

at source, collected in bins and composted.

M/s Siddapur Distilleries Ltd.,


3.14 SCHEMATIC REPRESENTATIONS OF THE FEASIBILITY DRAWING

A schematic representation of the overall feasibility and environmental assessment process is shown in Figure 3.5.

Fig 3.5 Feasibility & environmental assessment process

Significant

Not

Economic

Feasibility study conducted for newly proposed industry

Statement of intent by proponent

Guidelines for EIA by SEAC/MoEF

Abandon project

Determine the coverage of the EIA - scoping

Describe the environment – baseline study

Describe the project

Identify the impacts

Evaluate the impacts

Mitigation

Preventive measures

Prepare draft EIS

FINAL EIA REPORT

CONSIDER ALL PHASES OF PROJECT –

CONSTRUCTION, DEVELOPMENT, INSTALLATION &

FINAL OPERATION/ PRODUCTION

SO

CIO

-ECO

NO

MIC

ISSU

ES

MO

NIT

OR R

EVIE

W



4.1 SITE CONNECTIVITY

Table-4.1 Connectivity to Project Site Sl. No.

Road Distance from the project site (km)

Direction w.r.t. project site

1 SH-34 1.07 East

2 NH-218 44.39 East

3 Bagalakot Railway station 54.35 South East 4 Jamkhandi 6.5google North

5 Gokak Airport 58.99 South West

6 Belgaum 95.13 South West

Note: All distances mentioned are aerial.

Fig- 4.1 Google Map Showing Connectivity to Project Site

CHAPTER 4 SITE ANALYSIS



4.2 LAND FORM, LAND USE & OWNERSHIP M/s. Siddapur Distilleries Limited., is Molasses Based Distillery Plant already established at

Sy. Nos. 49/2B/1 & 2, 57/2D & 2E, 58/1B, 58/1A/3, 66/4D, 85/2, 87, 93/2/3, 95/1 & 107/2,

Siddapur village, Jamkhandi Taluk, Bagalkot District, Karnataka State. Now the proponents

intend to expand the Molasses Based Distillery Plant from 60 KLPD to 70 KLPD through

process modification in the existing facility.

4.3 TOPOGRAPHY

M/s. SDL, is located at latitude of 16°26'17.03"N & longitude 75°16'16.77"E at an elevation

of 618 m above MSL. The topo map showing the location of the project site is appended as

fig 4.2.

Fig-4.2 Topo Map



4.4 EXISTING LAND USE PATTERN

Table 4.2 Existing Land Use Pattern Sl. No.

Particulars Details Distance from the project site

(km)

Direction w.r.t. project site

1 Agriculture Major activities - scattered Beyond industrial area

-

1 Reserve Forest Jamakhandi 6.1 North 2 Hunasi Katte 5.7 North East

3 Siddapur adjacent -

4 Banahathi 5.2 North West

5 Hulyal 2.9 North East

6 Mantur 7.8 East, South East

1 Water bodies Krishna River 14.3 km North

2 Ghataphrabha left bank canal

1.3 South

3 Jamakhandi lake 5.6 North

Note: a) All distances mentioned are aerial.

4.5 EXISTING INFRASTRUCTURE

The list of existing infrastructure at the project site is 1. Water supply from Krishna River 2. Power supply will be from 800 KW/Hr, Distillery has given on lease a 2.50 MW TG set to

our parent sugar plant i.e. SPSCL. 3. Storm water drainage system is provided

4.6 SOIL CLASSIFICATION As a consequence of growing Demographic pressure, it is planned to increase food

production with an estimated average of 4 tons per hectare from the present 1.5 tons per

hectare to meet the growing demand in the country. Due to the great dependence and

pressure on land and water resources, obviously, there will be an effect on soil quality and

crop productivity. As per some estimates, the soils have been degrading at the rate of one

million hectares per year and 57% of geographical area is affected by various forms of

degradation viz., water and wind erosion, physical and chemical deterioration. The state

department of Agriculture has estimated that about 10% of irrigated (1.27 lakh ha)

command area are affected by problems such as water logging, salinity and alkalinity.



Similarly a depletion of ground water levels has also been noticed at an alarming rate in recent times through the rapid depletion of the ground water resources. In this context, it is a great challenge to the scientific community, to evolve and develop appropriate strategies, to increase food production on a sustainable basis.

Nutrients and soil loss is a major problem where excessive leaching of soil occurs, besides

in continuous cropping, without adequate input of fertilizers and organic manure. It is

more rampant in areas where agriculture is practiced in poor or moderately fertile soils

without application of sufficient fertilizer or manure, which certainly leads to decrease in

agricultural production. Loss of soil organic matter, following clearing the natural

vegetation is also another way of nutrient loss. Plant nutrients are also depleted from soil

through crop removal, run off and soil erosion.

The loss of nitrogen by erosion is probably more serious than loss of any other nutrient,

since most of the nitrogen being lost is combined with soil organic matter, which is under

threat of erosion. Actual nutrient status of tank silt was not found to be much different

from that of the soil in the catchment area in studies carried out by the scientists of the Dry

land Agriculture project of the University of Agricultural Sciences, Bangalore and also by

the Department of Agriculture (1997). All such soils need different management and

reclamation measures. Their sustained use depends more on the economic concerns and

identification of sustainable alternative uses rather than agricultural production.



4.7 CLIMATIC DATA FROM SECONDARY SOURCES

Table 4.3: Meteorological Data of Bagalkot for the Year 2016

Month Temperature (0C)

Mean Dew Point Temperature in (0C)

Mean RH % Rainfall (mm) Mean Station level pressure in hPa

Total Amount of Cloud in Octa(1/8 sky)

Mean of Av. Wind speed for

Mean Max

Mean Min. 0830hrs 1730hrs. 0830hrs. 1730hrs. Total Heaviest 0830hrs. 1730hrs. 0830hrs. 1730hrs. 24

hrs.(kmph) Jan 31.8 16.2 17.6 12.3 82 34 0.0 0.0 941.8 938.8 0.6 1.2 5.2

Feb 33.1 18.1 18.4 13.6 80 34 0.0 0.0 940.9 937.4 1.5 2.5 6.2

Mar 35.8 20.1 19.0 9.8 70 24 6.6 6.5 940.9 937.4 2.2 4.1 6.0

Apr 37.7 20.8 20.1 7.7 74 18 67.2 49.0 938.0 933.6 1.3 3.2 7.7

May 36.5 20.9 22.4 14.1 82 33 103.2 44.5 936.3 932.4 4.0 4.8 10.0 Jun 29.6 19.5 21.4 20.2 88 68 102.4 56.4 933.9 932.1 6.9 6.9 12.9

Jul 27.7 21.0 21.0 20.2 90 76 36.4 4.5 933.8 932.1 7.4 7.5 17.9

Aug 28.6 20.5 20.2 18.2 87 62 30.6 10.7 935.9 934.3 6.5 6.9 16.4

Sep 28.9 20.8 20.5 19.1 88 67 170.4 30.3 936.5 933.4 6.9 7.0 12.0 Oct 29.6 20.4 20.0 15.4 84 55 88.1 31.8 938.3 935.2 6.0 6.4 9.7

Nov 29.2 17.6 17.9 11.4 79 39 0.0 0.0 940.6 937.4 3.6 4.7 5.6

Dec 28.9 14.7 15.4 10.4 77 34 0.0 0.0 940.8 937.5 1.5 2.2 6.2



4.7.1 Temperature The mean maximum temperature is observed at (37.7°C) in the month of April and the

mean minimum temperature at (14.7°C) is observed in the month of December. In the

summer season the mean minimum temperature is observed during the month of March

(20.1°C). During the monsoon the mean maximum temperature is observed to be 29.6°C in

the month of June with the mean minimum temperature at 19.5°C during June. The values

are presented in table 4.3.

4.7.2 Relative Humidity

Minimum and maximum values of relative humidity have been recorded. The minimum

humidity is observed to be at 18 % in the month of April and the maximum is 90 % in the

month of July. The mean minimum values of humidity during summer, monsoon, post-

monsoon and winter seasons are 18 %, 62 %, 39% & 34% during the months of April,

August, November and February respectively. Similarly the maximum values are 82 %, 90%,

88%, 82% in the months of May, July, September & January during the summer, monsoon

and post monsoon & winter seasons. The values are presented in table 4.3.

4.7.3 Rainfall

The monsoon in this region usually occurs twice in a year i.e. from June to September and

from October to November. The maximum annual rate of precipitation over this region

ranges between 170.4 mm.

4.7.4 Atmospheric Pressure

The maximum and the minimum atmospheric pressures are recorded during all seasons. In

the summer season, the mean maximum and minimum pressure values are observed to be

940.9 mb in the month of March and 932.4 mb in the month of May respectively. During

monsoon season, the maximum pressure is 935.9 mb and minimum 932.1 mb. The

maximum pressure during the post-monsoon season is observed to be 940.6 mb in

November and minimum pressure is 933.4 mb in the month of September. During the

winter season the minimum atmospheric pressure is 937.5 mb in December and the

maximum is 941.8 mb in the month of January. The values are presented in table 4.3.

4.7.5 Cloud cover

The minimum cover measured in the unit of tenths is 1.2 and the maximum observed cloud

cover is 7.4.

4.7.6 Wind

The data on wind patterns are pictorially represented by means of wind rose diagrams for the entire year as figure 4.3 (for different seasons).



Predominant wind directions

Season Period Wind direction Summer March to May North West

Monsoon June to September East

Post monsoon October to November South West

Winter December to February North West

4.8 SOCIAL INFRASTRUCTURE

Infrastructure is the basic physical and organizational structures needed for the operation of

a society or enterprise or the services and facilities necessary for an economy to function.

The term typically refers to the technical structures that support a society, such as roads,

water supply, sewers, electrical grids, telecommunications and so forth and can be defined

as "the physical components of interrelated systems providing commodities and services

essential to enable, sustain or enhance societal living conditions”.

Viewed functionally, infrastructure facilitates the production of goods and services and also

the distribution of finished products to markets, as well as basic social services such as

schools and hospitals; for example, roads enable the transport of raw materials to a factory.

Table -4.4 List of Infrastructural Facilities in the Surroundings

Sl. No.

Hospital Distance from the industry

Direction w.r.t. the industry

1 Gurukrupa Hospital 8.14 North

2 Sanadi Hospital 8.04 North

3 Poojari Hospital 18.24 North West

4 Sharan Hospital 18.5 South West

5 Venkatesh Hospital 17.88 South West

6 Sai Aadhar Hospital 12.7 South 7 B.L.D.E Association law college 7.83 North

8 Konnur Science PU college 13.04 North West

9 Bagalakote Railway station 54.35 South East

Note: All distances mentioned are aerial.



Fig 4.3: Wind Rose Diagrams

1. March to May (summer season)

2. June to September (monsoon season)



3. October to November (post monsoon season)

4. December to February (winter season)



CHAPTER 5

PLANNING BRIEF

5.1 PLANNING CONCEPT M/s. Siddapur Distilleries Limited., has proposed to expand and modified its Molasses Based




5.2 POPULATION PROJECTION The expansion and modification will be done in existing facility no construction activity is envisaged. Total no. of people employed during operation phase: 115 people. 5.3 LAND-USE PLANNING The land use planning is given in Table 5.1

Table 5.1: Land-Use Pattern

Sl. No. Particulars Area (SQM) In % 1 Total plot area 1,21,541.84 100%

2 Hard paved area 10,117.15 08.32%

3 Landscape/Green-belt area 1,00,807.41 82.94% 4 Ground Coverage Area 10,617.28 8.73%

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND The Company is assess the demand of infrastructure (Physical & Social) in nearby area of

the proposed site and is developed in under corporate social responsibilities programs.

5.4.1 Water supply & sewerage infrastructure Water demand for the industry is from Krishna River. The domestic sewage generated is treated in septic tank and sent to soak pit. The industrial wastewater is treated in existing Effluent treatment Plant (ETP) for treatment and reuse. 5.5 AMENITIES/FACILITIES Proper site services such as with Drinking water, safety equipments & first Aid is provided to

the workers.



CHAPTER 6

PROPOSED INFRASTRUCTURE

6.1 INDUSTRIAL AREA (PROCESSING AREA) M/s. Siddapur Distilleries Limited., has proposed to expand and modified its Molasses Based




6.2 RESIDENTIAL AREA (NON PROCESSING AREA) The non-processing area is green belt and open area.

6.3 GREEN-BELT

The industry has developed green belt of 25 acres around the premises and is

constantly making efforts for further development. The philosophy behind the green

belt development is to improve the ecology and environment of the surrounding of the

plant by extensive afforestation. The landscape development photos is shown in fig 6.1.

Below.

Trees particularly having compact branching closely arranged leaves of simple elliptical

and hairy structure, shiny or waxy leaves and hairy twigs are efficient filters of dust.

Native tree species have been planted for development of green belt.

Green belt is a set of rows of trees planted in such a fashion, to create effective barrier

between the plant and surroundings. The green belt helps to capture the fugitive

emissions, attenuate the noise levels in the plant and simultaneously improving

aesthetics of the plant site. The greenbelt around the factory compound wall and in the

reserve site is developed in keeping view of the following objectives.

1. Planting of trees in each row is in staggered pattern.

2. The short trees are being planted in the first two rows and the tall trees in the outer

rows around the pure view of the project site.

3. Since the trunks of the trees are generally devoid of foliage, it is useful to have shrubs in

front of the tress so as to give coverage to this portion.

4. Sufficient spacing is maintained between the trees to facilitate effective height of the

green belt.

5. Plants of native origin, fast growing type with canopy and large leaf index is preferred.



Fig 6.1. GREEN BELT PHOTOGRAPHS



6.4 SOCIAL INFRASTRUCTURE Details Given in Chapter- 4, section 4.8 6.5 CONNECTIVITY The site is well connected with roadways. NH-218 & SH-34 which is about 44.39 km & 1.07

km respectively.

6.6 SEWERAGE SYSTEM Sewage pipes are laid in entire company for the removal and disposal of mainly non-harmful

liquid wastes from the offices and domestic waste, these liquid wastes are sent to septic

tank & soak pit.

6.7 INDUSTRIAL WASTE MANAGEMENT The industrial wastewater is treated in existing Effluent Treatment Plant for treatment reuse. 6.8 SOLID WASTE MANAGEMENT The domestic garbage is composted within the industry premises & the product will be used as manure for green-belt/landscape development. Used oil & grease generated from plant machinery/Gear boxes are hazardous wastes is being used as lubricant for chains / conveyer belts within premises. 6.9 POWER REQUIREMENT & SUPPLY SOURCE

The Proposed power requirement of the Distillery plant is 800 KW/Hr, Distillery has given on

lease a 2.50 MW TG set to our parent sugar plant i.e. SPSCL. The required power is available.

During off season it shall depend on 1000 KVA DG Set only.



CHAPTER 7 REHABILITATION & RESETTLEMENT PLAN

M/s. Siddapur Distilleries Limited., is an existing industry. The expansion and modification

will be done in the existing facility. No home outsets/land outsets are expected & hence no

rehabilitation plan is envisaged.



CHAPTER 8

PROJECT SCHEDULE & COST ESTIMATES 8.1 TIME SCHEDULE The time schedule for completion of the proposed project is given in the following table

Particulars Time schedule

Start of construction activity Existing plant Completion Existing facility

8.2 ESTIMATED PROJECT COST Total capital investment on the proposed Project is detailed in table 8.1 as under.

Table 8.1:- Project Cost for expansion of Distillery Plant capacity from 60 KLPD to

70 KLPD.

1) Fermentation House Expansion Work

Sl

No Description

Approx Value

of Project Cost

(Rs.)

1 SS 304 Fermenter Tank Capacity -350 m³ 22,20,000.00

2 Fermenter tank Centrifugal Pumps with Motor

Model: 150/26N (2 Nos) 3,10,000.00

3 Fermenter & Pre - Fermenter Plate Heat Exchanger 10,00,000.00

4 Magnetic Flow Meter for F3, F4 & pre - Fermenter tank 3,15,000.00

5 Digital Variable Area Flow Meter for pre -Fermenter Tank 30,000.00

6 Consumable Materials including Welding Rod & Gas 1,60,000.00

7 Pipe & Pipe Fittings including Butterfly Valves & Ball

Valves 6,00,000.00

8 SS 304 Ejector 1,80,000.00

9 SS 304 Pre-Fermenter Tank Capacity -60 m³ 3,25,000.00

10 Pre - Fermenter Tank Pump with Motor 3,50,000.00

Total- A 54,90,000.00



2) Distillation Plant Expansion Work

Sl

No Description

Approx Value of

Project Cost (`)

1 Stripper Main Condenser 80 m2 7,80,000.00

2 Refining Re-Boiler 65 m2 9,00,000.00

3 Distillation Cooling Tower pump with motor 15,00,000.00

4 Electrical Cables & Accessories 3,60,000.00

5 New ENA Bulk Storage Tank of Capacity 950 m³ 25,70,000.00

Total -B 61,10,000.00

Total (A+B) 1,16,00,000.00



CHAPTER – 9

ANALYSIS OF PROPOSAL

Observing the demographic pattern of the study area it can be inferred that occupational pattern is a mixture more of agriculture rather industrial. The proposed project will increase the employment potential by creating direct and in-direct employment opportunities and thus be beneficial for the local and nearby populace The management of the industry gives preference to local people with both direct and indirect employment. The techno –commercial viability of the proposed distillery is proved as the following factors significantly favor setting up the unit. Establishment of Plant & Machinery to handle either molasses to

manufacture all or any of the three finished products i.e. RS/ENA/Ethanol

Viability of the project is established beyond doubt with Molasses as input

raw materials.

Capital cost considered slow compared to the general trend in the market.

The proposed process and plant and machinery makes the project

environmental friendly.

To the extent of its installed capacity, production of fuel ethanol improves

energy security & self-sufficiency and saving of foreign exchange for the country.

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