PRE-FEASIBILITY REPORT€¦ · pre-feasibility report setting up of ligno-cellulosic biomass based...

PRE-FEASIBILITY REPORT

SETTING UP OF LIGNO-CELLULOSIC BIOMASS BASED SECOND GENERATION (2G) ETHANOL BIO-REFINERY WITH CAPACITY OF 100 KLPD AT VILLAGE-SAINJANI, TEHSIL- DATAGANJ, DISTRICT BADAUN (U.P.), BY M/S HPCL


FOR

SETTING UP OF SECOND GENERATION (2G)

ETHANOL BIO-REFINERY AT BADAUN, UTTAR PRADESH

BY

M/S HINDUSTAN PETROLEUM CORPORATION LIMITED

PREPARED BY

Environment Consultant

Vardan Environet (QCI and NABET/EIA/1619/RA 0037)

D-142, Sushant Lok-III, Sector 57 Gurgaon (Haryana)

Contact no.-9810355569 Mail ID: [email protected]

Contact No. 0124-4291036, 09899651342

mailto:[email protected]



TABLE OF CONTENTS

1. EXECUTIVESUMMARY ............................................................................................................... 1-2

2. INTRODUCTION ............................................................................................................................ 3

2.1 Project Proponent………………………………………………………………………………..............3

2.2 Nature of Project ............................................................................................................................ 3

3. SITEINFORMATION.................................................................................................................. 4-9

3.1 EnvironmentalSetting .................................................................................................................... 4

4. PROJECTDESCRIPTION ...................................................................................................... 10-13

4.1 ProcessDescription .......................................................................................................................... 10

4.2 ManufacturingProcess .................................................................................................................... 11

4.3 WaterRequirement .......................................................................................................................... 15

4.4 PowerRequirement ......................................................................................................................... 15

4.5 ManpowerRequirement ................................................................................................................. 16

4.6 WasteManagement .......................................................................................................................... 16

4.7 Domestic Effluent Treatment(STP) ........................................................................................... 16

5. ENVIRONMENTCONTROLMEASURES .................................................................................. 17

6. PROJECT SCHEDULE ANDCOSTESTIMATES .................................................................... ...18

6.1 ProjectSchedule ................................................................................................................................. 18

6.2 ProjectCostEstimates ...................................................................................................................... 18



LIST OF TABLES Table 1.1:Khasra No./ Gata No…………………………………………………………………....................1

Table 3.1:EnvironmentalSetting ..................................................................................................................... 4

Table 4.1: Proposed Product List ................................................................................................................. 14

Table 4.2: Proposed Raw Materials ............................................................................................................ 14

Table 4.3: Proposed Water Requirement ................................................................................................. 15

Table 4.4: Proposed Manpower Requirement ........................................................................................ 16

Table 4.5: Non-Hazardous Solid Waste ..................................................................................................... 16

Table 4.6:HazardousWaste ............................................................................................................................ 16

LIST OF FIGURES

Figure 3.1:Project Location……………………………………………………………………………...6

Figure 3.2: Aerial Image of theProjectSite………………………………………………………...7

Figure 3.3: Google Image of theProjectSite ................................................................................................. 8

Figure 3.4: Environmental Setting Map ....................................................................................................... 9

Figure 4.1:ProcessFlowchart ......................................................................................................................... 11

Figure 4.2: Project Site Layout ...................................................................................................................... 13



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1. EXECUTIVESUMMARY

HPCL is a Government of India Enterprise with a Navratna Status, and a Forbes 2000 and Global Fortune 500 company. It had originally been incorporated as a company under the Indian Companies Act 1913. It is listed on the Bombay Stock exchange (BSE) and National Stock Exchange (NSE), India. HPCL owns & operates 2 major refineries producing a wide variety of petroleum fuels & specialties, one in Mumbai (West Coast) of 6.5 Million Metric Tonnes Per Annum (MMTPA) capacity and the other in Visakhapatnam, (East Coast) with a capacity of 8.3 MMTPA. HPCL also owns and operates the largest Lube Refinery in the country producing Lube Base Oils of international standards, with a capacity of 428 TMT. This Lube Refinery accounts for over 40% of the India's total Lube Base Oil production. Presently HPCL produces over 300+ grades of Lubes, Specialties andGreases.

The company appointed M/s. VardanEnvironet (MoEF&CC recognized and NABL approved), Gurugram to carry out study of the impacts of the project on local environment and for obtaining Environmental Clearance. is an established Consultancy in the field of Environmental Services. The Notification No. S. O. 1533 promulgated on 14th September 2006 has covered this type of industries under its schedule 5(g) “A”. Hence, HPCL intends to approach MoEF&CC for environment clearance for proposed Biorefinery. The prefeasibility report is prepared for forming a frame work for EIA study, scoping and finalizing terms of reference as may be required. Form I, as is prescribed by the said notification is duly filled up and submitted. The Prefeasibility Report is an accompaniment to the same and prepared as per MoEF guideline dated 27/02/2012.

HPCL proposes to setup of 2G Ethanol bio-refinery at Badaun, U.P. HPCL is in the process of acquiring 20 ha (50 Acres) from UPSIDC on a long term lease in the Village Sainjani, Tehsil-Dataganj, District Badaun. Location Total Plot Area of 20 Ha (50 acres approx.) is identified as barren & vacant land and will be taken from UPSIDC on lease basis for the setting up of the bio refinery.

Table 1.1: Khasra No./Gata No. Sr. No. GATA No. Area in Hectares, Ha Area in Acres

1 1009 6.121 15.125



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Sr. No. GATA No. Area in Hectares, Ha Area in Acres 2 1010 1.657 4.094 3 1011 4.161 10.282 4 1013 1.183 2.923 5 1014 5.132 12.681 6 1015 1.746 4.314 Total Area 20.00 49.421

There is no forest land involved in this 20 Ha. of land proposed for the project site.

The geographical location of the proposed bio refinery is Latitude 27°57'24.26"N, Longitude

79°19'37.69"E.

The estimated production capacity of the project is 2G Ethanol – 100 KLD and other By-

products.

The commercial operation date (COD) is envisaged as24 months reckoned from the date of

approval from MoEF&CC.

The total project cost for the Proposed Installation of 2G Ethanol bio-refinery is around Rs.

865crores. This includes the cost of land and land development, on lease from UPSIDC as per

lease rentals/terms & conditions.

PRE FEASIBILITY REPORT


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2. INTRODUCTION

2.1 Project Proponent

Hindustan Petroleum Corporation Limited (HPCL) is a Government of India Enterprise

with a Navratna Status, and a Forbes 2000 and Global Fortune 500 company. HPCL has the

second largest share of product pipelines in India with a pipeline network of more than

3015 kms for transportation of petroleum products and a vast marketing network

consisting of 13 Zonal offices in major cities and 106 Regional Offices facilitated by a Supply

& Distribution infrastructure comprising Terminals, Pipeline networks, Aviation Service

Stations, LPG Bottling Plants, Inland Relay Depots & Retail Outlets, Lube and LPG

Distributorships.

Consistent excellent performance has been made possible by highly motivated workforce

of over 11,000 employees working all over India at its various refining and marketing

locations.

HPCL is committed to achieve the economic, ecological & social responsibility objectives of

sustainable development consistently through varied operations and activities. HPCL’s

focus areas are in the fields of Child Care, Education, Health Care, Skill Development &

Community Development, touching lives of weaker section of society.

2.2 Nature of Project

The technology is suited for both Indian and global needs and it is projected to be capable

of converting all types of agricultural residues like bagasse, rice strawetc. to ethanol with

optimum product yields. The Badaun Bio-refinery will be utilizing agriculture residues for

production of ethanol which may be sufficient to meet the ethanol blending requirement

of the State. The proposed Bio-refinery will generate employment. The project shall also

help in reducing CO2emissions from the paddy straw which currently is being burnt after

harvesting. One of the major outputs of this Bio-refinery shall be Bio-fertilizer which shall

be incorporated into the soil for improving soil fertility and overall productivity of farms in

U.P.



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3. SITEINFORMATION

HPCL proposes to setting up of 2G Ethanol bio-refinery at Badaun, U.P. HPCL is in the

process of acquiring 20 ha (50 Acres) from UPSIDC on a long-term lease in the Village

Sainjani, Tehsil-Dataganj, District Badaun.

3.1 Environmental Setting

The Environmental Setting in 10 km radius of project site is presented in Table 3.1

Table 3.1: Environmental Setting

Sr.No. Particulars Details

1. Plant location GATA No: 1009 (6.121 ha), 1010 (1.657), 1011(4.161),

1013(1.183), 1014(5.132), 1015(1.746) =total of

Approx. 20 Ha,

is government land

2. Approx. site Centre point

Coordinates

Latitude 27°57'24.26"N,

Longitude 79°19'37.69"E

3. Maximum temperature in

Summer

40.5°C.

4. Minimum temperature 8.6°C

5. Annual rainfall (total) 639.8 mm

6. Relative humidity Then mean monthly morning relative humidity is 69%

and mean monthly evening humidity is 51%.The mean

wind speed is 5.1 Kmph

7. Plant site elevation above MSL 175 m

8. Present land use at the site Barren Land(Banjar)

9. Nearest highway NH-93 = 8.9 km (SW) SH-43 = 8.7 km(SW) SH-33 = 22 km(WNW) MDR-25W = 2.6 km(SE) MDR-74W = 7.9 km(NNW)



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10. Nearest railway station Badaun Railway station 20 km(NW)

11. Nearest Airport Lucknow Airport:202Km (SE)

12. Nearest major water bodies Aril Nadi at 3.5 km in North-East direction,

Ram Ganga is about 9.1 km in ESE direction

Seasonal Nala (Kadwara) is nearby to project site

13. Nearest village Village Sainjani which is sparsely populated

14. Archaeologically important

places

Not Applicable

15. Protected areas as per Wildlife

Protection Act, 1972 (Tiger

reserve,Elephant reserve,

Biospheres, National parks,

Wildlife sanctuaries,

communityreservesand

conservation reserves)

Not Applicable

16. Reserved / Protected Forests RF patches =(near Bhagonda), 700 m in North

Direction

RF patches =(near Kundajajkaran), 1.2 km in South-East

Direction

17. Defense Installations Nil

18. Seismicity The proposed project is located in Seismic Zone IV

as per IS: 1893 and all designs will be as per IS Codes

The location map of the project site is as depicted in Figure 3.1, Connectivity Map is shown inFigure 3.2 and Google Image is as shown in Figure 3.3.



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Figure 3.1: Project Location



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Figure 3.2: Aerial Image of the Project Site



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Figure 3.3: Google Image of the Project Site



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Figure 3.4: Environmental Setting Map of the Project Site



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4.1 ProcessDescription

4. PROJECTDESCRIPTION

M/s HPCL proposes to set up Second generation (2G) ethanol Bio-refinery of 100 KLPD fuel grade ethanol (specification: - IS 15464:2004) production in Badaun, Uttar Pradesh by adopting the 2G ethanol technology using multi-feedstock ligno-celluloses biomass (i.e. Rice straw etc.), based on indigenous technologies

Feed Specification:

The feed for ethanol bio refinery will be ligno-celluloses biomass (i.e. Rice straw etc.) The total requirement of the raw material (dry basis) is estimated to be 457 TPD (approx.) for the production of 100 KLPD of fuel grade Ethanol.

Manufacturing Technologies:

The technology is feedstock agnostic and has been successfully used with various agricultural feedstock such as rice straw, wheat straw, sugarcane bagasse etc.

The typical process for conversion of ligno-cellulosic biomass to ethanol route is based on enzymatic hydrolysis and comprises four main steps as given below:

a). Pre-treatment-

Physical or chemical pre-treatment of the bio refinery fibers to expose the cellulose and

reduce its crystallinity,

b). Hydrolysis-

Hydrolysis of the cellulose polymer, with enzymes or acids, to convert it into simple

sugar,

c). Fermentation-

Microbial fermentation of these simple sugars to ethanol,

d). Distillation-

Distillation and dehydration to produce 99.5% pure alcohol

.



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4.2 ManufacturingProcess

In this process by products is also utilized as fuel for the boiler section generated such as lignin & concentrated syrup along with the ethanol, which will be utilized as fuel for the boiler section

Figure 4.1: Basic Process

Process Units:

The following are the major sections in the 100 KLPD 2G ethanol bio refinery.

1. Biomass handling and size reduction section 2. Biomass wet washing section 3. Biomass pretreatment section 4. Enzymatic hydrolysis section 5. Co-Fermentation section 6. Ethanol Distillation section 7. Ethanol dehydration section 8. Solid/ Liquid separation section 9. Evaporation section 10. Process condensate treatment section.



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The lignin-hemicellulose-cellulose complex forms stringent seals around cellulose. The first

step in the overall process of ligno-cellulosic fermentation is breaking this barrier. This is the

most important and rate limiting step in the overall process. Further steps involve isolation

and hydrolysis of cellulose and hemicellulose to generate emendable sugars

(saccharification) followed by fermentation and distillation as shown in Fig 4.1. The pre-

treatment processes involve the use of acids, alkalis, steam and/or organic solvents. The aim

of this process is to separate lignin, cellulose, hemicellulose from ligno-cellulosic biomass.

Post pre-treatment, the recalcitrant ligno-cellulosic biomass becomes susceptible to acid

and/or enzymatic hydrolysis as the cellulosic microfibrils are exposed and/or accessible to

hydrolysing agents.

In the pre-treatment process, small amounts of cellulose and most of hemicellulose is

hydrolysed to sugar monomers. The pre-treated biomass is then subjected to filtration to

separate liquids (hemicellulose hydrolysate) and solid (lignin & cellulose). The liquid is sent

to a xylose (pentose) fermentation column for ethanol production. Solids are subjected to

hydrolysis (also called second stage hydrolysis). This process is mainly accomplished by

enzymatic methods using cellulases. Mild acid hydrolysis using sulfuric and hydrochloric

acids is an alternative procedure. The hydrolysed sugars such as can be readily fermented to

ethanol using various strains of yeast.

The Site layout of the proposed project is as shown in Figure 4.2



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Figure 4.2: Project Site Layout



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The plant is designed for the products as listed in the Table 4.1. The plant and Machinery have been designed with required specification considering volume of reaction, material of construction and are located at appropriate positions. Adequate ventilation, air conditioning and Air Filtration systems have been planned to prevent environmental hazards. The raw materials required for the proposed production is listed in Table 4.2.

Table 4.1: Proposed Product List

Products Rice Straw (TPD) Ethanol 80.00 Raw CO2 76.00

Technical Alcohol 1.6 Fusel Oil 0.20

Total 157.8

Table 4.2: Proposed Raw Materials

Raw Materials Rice Straw (TPD) A. BIOMASS

Biomass (dry basis) 457.00 Chemicalcharacteristics Lignocelluloses (with 15% w/w moisture) Physical characteristics Supplied as 15-25 kg rectangular bales

B. CHEMICALS Sulphuric Acid (98% w/w) 6.4 Sodium Hydroxide (40-50 w/waqueouslye) 19.5

Phosphoric Acid(85%w/w) 3 Sodium Sulphite (85%w/w) 9.4 Nitric Acid 2 Others Chemicals 22.5

Enzymes (liquid proteinsolution with stabilizers)

2.3

C.FUEL Biomass 200.00

D.OTHERS Salts 0.8

Total 722.9



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The main features of the plant automation are enumerated below: • The plant is fully automated and DCScontrolled with suitable interlocks for Process and

Safety • The plant is supported by an equipped QC/QAlaboratory • Sugars produced are fermented using specific yeast strains • Enzyme and chemicals required to be procured from recommendedsuppliers • The plant does not produce and create liquideffluent

The following are the expected Plant Performance figures: • Ethanol Production per day: 0.5L/kg totalsugars • Overall maximum possible yield of ethanol on dry biomass: 218L/tonbiomass

4.3 WaterRequirement The total water requirement for the proposed project will be approximately3200m3/day; Table 4.3 shows the distribution of the water requirement

Table 4.3: Proposed Water Requirement

S. No. Water Requirement TPD 1 Process water 420 2 Cooling water 2000 3 Boiler 576 4 Drinking water 6 5 Domestic water Blow down water will be used for domestic purpose 6 Green Belt 288 (Blow down water will be used) 7 Floor Washing Blow down water will be used for floor washing

4.4 PowerRequirement Total power requirement (connected load and maximum demand) and source, power exported during season and off-season will be 14 MW. Emergency power required for boiler, distillation system, cooling water circulation, membrane system and water pump for reactor flushing is 2.5 MW. Thus, the capacity of the DG set will be 2.5 MW.



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4.5 ManpowerRequirement The estimated manpower requirement during operation phase will be around 120 personnel’s. The details of the same are provided in Table 4.4.

Table 4.4: Proposed Manpower Requirement 1. Persons for operation of bio refinery in 3 rotating shifts 45 2. Persons for maintenance of the bio refinery 45 3. Persons for lab-chemist, microbiologist 25 4. Managers 5

Totals 120

4.6 WasteManagement

The details of the Non-Hazardous Solid Waste are as provided in Table 4.5 and Hazardous Waste is as provided in Table4.6.

Table 4.5: Non-Hazardous Solid Waste

Feed stock Total Solid waste – Ash (TPD) Rice Straw 144 Mud generation during process 9

Table 4.6: Hazardous Waste

Cat. Type of waste Source Qty. Method of Disposal 34.3 Sch – I ETP Sludge ETP 8 MTPD CHWTSDF

5.1 Sch – I UsedLubricants Plant &Machineries

0.5 MTM CHWTSDF

33.3 Sch – I Used Containers (Metal&Plastic)

Raw Material Storage

1200(Nos.) Decontamination Re-use or sell Scrap vendors

& to

HDPE/LDTE/Gunny Bags

Raw Material Storage

2000(Nos.) Decontamination Re-use orsell

Scrap vendors

& to

4.7 Domestic Effluent Treatment (STP):

MBR (Membrane Bio-reactor) based Sewage Treatment Bio refinery (STP) is envisaged. The design capacity of STP shall be 10 KLD (10 m3/day). The scheme consists of the following stages:



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• Screen chamber with bar screen & debris retaining grid, and oil & grease trap in the STP

inlet channel.

• Sewage Collection Sump (RCC construction) with an effective capacity of 10 m3 and

submersible MBR Feed Pumps (capacity 1.5 m3/hr each pump) (1 working + 1 standby).

• Package Membrane Bio-Reactor Unit (including anoxic tank, aeration tank, permeate

transfer and backwashing pump system, air scouring blowers and air diffuser system, and

associated cleaning and chemical dosing facilities as required as per MBR system

supplier’s recommendations) to provide treated sewage of the required quantity and

quality.

• The MBR permeate water shall be stored in Treated Sewage Tank/Sump of RCC

construction (effective capacity of 10 m3) and sent for use in horticulture via permeate

water transfer pumps (capacity 5 m3/hr each pump) (1 working + 1 standby)

• The bio-sludge generated from the STP shall be dewatered employing Bag Filters and the

filtered effluent water shall be recycled back to the Sewage Collection Sump.

• NaOCl dosing shall be provided at for the disinfection of the treated sewage water.



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5. ENVIRONMENT CONTROLMEASURES

During construction phase there will be fugitive emissions due to movement of equipment at site, dust emitted during the levelling, grading, earthworks, foundation works and other construction related activities. These impacts will however, be marginal and temporary innature.

The DG sets shall be acoustically insulated resulting in reduction of noise as per

limits prescribed by State Pollution Control Board. The exhaust pipe from DG sets shall be taken above the building as per State Pollution Controlnorms

All conditions & pre-requisites of water and air consents together with certificate to

handle hazardous products issued by State Pollution Control Board shall be strictly adheredto.

During operation phase, there shall be air emission being generated due to the Boiler.



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6. PROJECT SCHEDULE AND COSTESTIMATES

6.1 ProjectSchedule The construction of the project shall commence soon after receipt of Environment

Clearance from MoEF&CC and CTE from UP PCB. The project execution schedule shall be

another 18 months after getting project clearance/ environment clearance.

The commercial operation date (COD) is envisaged in 24 months reckoned after taking

requisite clearances from MoEF&CC.

6.2 Project CostEstimates

The total project cost for the Proposed Installation of 2G Ethanol bio-refinery is

around Rs. 865 crores. This includes the cost of Land and land development, on

lease from UPSIDC as per lease rentals/terms & condition.

PRE-FEASIBILITY REPORT€¦ · pre-feasibility report setting up of ligno-cellulosic biomass based...

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