PRE - FEASIBILITY REPORT
For
Proposed 90 KLPD Grain Based Distillery
along with 3.0 MW Co-Generation Power Plant
At
Village Ganora, Tehsil Ghatol,
District Banswara (Rajasthan)
Applicant
Express Digital Payment Services Private Limited
Registered office: A-47, Lower Ground Floor, Hauz Khas,
New Delhi – 110016
Email id – [email protected]
i
INDEX
S. NO. CONTENTS PAGE NO.
1. EXECUTIVE SUMMARY 1
I INTRODUCTION 1
1.1 Environment Management Plan 3
2. INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION 5
(i) Identification of Project & Project Proponent 5
(ii) Brief Description of Nature of The Project 5
(iii) Need for The Project & Its Importance to The Country and/ Or Region 5
(iv) Demand-Supply Gap 6
(v) Import vs. Indigenous production 6
(vi) Export Possibility 6
(vii) Domestic / Export Markets 6
(viii) Employment Generation (Direct And Indirect) Due To The Project 6
3. PROJECT DESCRIPTION 7
(i) Type of Project Including Interlinked and Independent Projects, If Any 7
(ii) Location (Map Showing General Location, Specific Location and Project Boundary & Project Site
Layout) with Coordinates
7
(iii) Key Plan 9
(iv) Details of alternative sites consideration and basis of selecting the proposed site, particularly the
environmental considerations gone into should be highlighted.
10
(v) Size or Magnitude of Operation 10
(vi) Project Description with Process Details 10
(vii) Raw material required along with estimated quantity, likely source, marketing area of final
products, mode of transport of raw material and finished product.
15
(viii) Resources optimization/ recycling and reuse envisaged in the project, if any, should be briefly
outlined.
16
(ix) Availability of water it’s source, energy /power requirement and source should be given. 16
(x) Quantity of waste to be generated (liquid and solid) and scheme for their management/disposal 19
4. SITE ANALYSIS 19
(i) Connectivity 19
(ii) Land form, land use and land ownership 19
(iii) Topography 20
(iv)
Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area under
crz), shortest distances from the periphery of the project to periphery of the forests, national
park, wild life sanctuary, eco sensitive areas, water bodies (distance from the hfl of the river), crz.
In case of notified industrial area, a copy of the gazette notification should be given
20
(v) Existing Infrastructure 21
(vi) Soil Classification 21
(vii) Climatic Data From Secondary Sources 21
(viii) Social Infrastructure Available 21
ii
5. PLANNING BRIEF 21
(i) Planning concept (type of industries, facilities, transportation etc.) Town and country planning/
development authority classification.
21
(ii) Population Projection 21
(iii) Assessment of infrastructure demand (physical & social) 21
(iv) Amenities/Facilities 22
6. PROPOSED INFRASTRUCTURE 22
(i) Industrial Area (Processing Area) 22
(ii) Residential Area (Non Processing Area) 22
(iii) Green Belt 22
(iv) Social Infrastructure 22
(v) Connectivity 22
(vi) Industrial Waste Management 22
(vii) Solid Waste Management 22
(viii) Power Requirement & Source 23
7. REHABILITATION AND RESETTLEMENT (R & R) PLAN 23
(i) Policy to be adopted (central/state) in respect of the project affected persons including home
oustees, land oustees and landless labourers (a brief outline to be given)
23
8. PROJECT SCHEDULE & COST ESTIMATES 23
(i) Likely date of start of construction and likely date of completion (time schedule for the project to
be given)
23
(ii) Estimated project cost along with analysis in term of economic viability of the project. 23
9. ANALYSIS OF PROPOSAL 23
(i) Financial and social benefits with special emphasis on the benefit to the local people including tribal population, if any, in the area.
23
iii
LIST OF TABLES
TABLE NO. CONTENTS PAGE NO.
1 Salient Features Of The Project 1
2 Manpower Requirement 6
3 Raw Material Requirement for Grain Based Distillery 15
4 Fuel Requirement 15
5 Total Water Input 16
6 Steam requirement 18
7 Boiler details 18
8 Details Regarding the D.G. Sets 18
9 Environmental Settings of the Area 20
LIST OF FIGURES
FIGURE NO. CONTENTS PAGE NO.
1 Location Map 8
2 Key Plan 9
3 Process Flow Chart for Grain Based Distillery 14
4 Water Balance for Grain Based Operation 17
Proposed 90 KLPD Grain Based Distillery along with 3.0 MW Co-Generation Power Plant
At Village Ganora, Tehsil Ghatol, District Banswara (Rajasthan).
Pre - feasibility Report
M/s. Express Digital Payment Services Private Limited 1
PRE - FEASIBILITY REPORT
1.0 EXECUTIVE SUMMARY
(I) Introduction
M/s. Express Digital Payment Services Private Limited is proposing 90 KLPD Grain based
Distillery along with 3.0 MW of Co-Generation Power Plant at Village Ganora, Tehsil Ghatol,
District Banswara (Rajasthan).
Grains such as damaged grain feed stock, broken rice, maize, bajra & sorghum will be used
as raw material which is easily available from the local market.
As per EIA Notification dated 14th Sep., 2006 and as amended from time to time; the
project falls in Category ‘A’, Project or Activity - 5(g)(ii) [Non-molasses based distilleries
>60 KLD].
Table – 1
Salient Features of the Project
S.
NO.
PARTICULARS DETAILS
A. Nature & Size of the Project Proposed 90 KLPD Grain Based Distillery along with 3.0 MW
Co-Generation Power Plant
B. Category of the Project As per EIA Notification dated 14th Sep., 2006 as amended
from time to time; the project falls in Category ‘A’, Project or
Activity - 5(g)
C. Location Details
Village Ganora
Tehsil Ghatol
District Banswara
State Rajasthan
Latitude 23046’21.78’’ N to 23046’37.48’’ N
Longitude 74016’58.94’’ E to 74017’22.85’’ E
Topo sheet No. 46 I/1, 46I/2, 46I/5, 46I/6
D. Area Details
Total Plant Area 20.0 acres (8.10 ha)
Greenbelt / Plantation Area 6.6 acres, i.e. ~33% of the project area will be covered under
green belt/ plantation
E. Environmental Setting Details (with approximate aerial distance & direction from plant site)
1. Nearest Village Dukwara Village (0.7 km in SE direction)
Proposed 90 KLPD Grain Based Distillery along with 3.0 MW Co-Generation Power Plant
At Village Ganora, Tehsil Ghatol, District Banswara (Rajasthan).
Pre - feasibility Report
M/s. Express Digital Payment Services Private Limited 2
2. Nearest Town & City • Nearest Town: Ghatol (~12.5 km in ESE direction)
• District Headquarters: Banswara (~30 km in SSE direction)
3. Nearest National Highway /
State Highway
• SH - 32 (~2.5 Km in WSW direction)
• NH - 113 (~10.5 Km in SE direction)
4. Nearest Railway station Dungarpur (~58 km in West direction)
5. Nearest Airport Maharana Pratap Airport, Udaipur (~ 100 km in NNW
direction)
6. National Parks, Wild Life
Sanctuaries, Biosphere
Reserves, Tiger/ Elephant
Reserves, Wildlife Corridors
etc. within 10 km radius
No National Parks, Wild Life Sanctuaries, Biosphere Reserves,
Tiger/ Elephant Reserves, Wildlife Corridors etc. falls within
10 km radius from the plant site.
7. Reserved Forests (RF) /
Protected Forests (PF) etc.
within 10 Km. radius
• Kundli Dudka Block PF (~3.5 km in ENE direction)
• Bhoyar Borda PF (~4.5 km in ESE direction)
• Loharia Block A PF (~7.0 km in WSW direction)
• Gargiyamarga Block PF (~7.5 km in ENE direction)
• Loharia Block B PF (~8.4 km in West direction)
• Suliya Venka Block PF (~8.5 km in North direction)
8. River / Water Body (within 10
km radius)
• Budanpura Minor (~2.5 km in South direction)
• Mahi River (~5.7 km in NW direction)
• Mahi Canal (~7.2 km in East direction)
• Shakliya Nadi (~8.5 km in ESE direction)
• Som River (~9.0 km in NW direction)
F. Cost Details
Total Cost of the Project Rs. 170.75 Crores
Cost for Environment
Management Plan
Capital Cost: Rs. 20 Crores
Recurring Cost : Rs. 1.5 Crores/annum
G. Basic Requirements for the project
Water Requirement 760 KLPD
Source – Groundwater
Power Requirement 2.1 MW
Source – Co Generation Power Plant of 3.0 MW
Man Power Requirement 100
(Source:- Unskilled / Semi-Skilled - Local Area; Skilled- Local &
Proposed 90 KLPD Grain Based Distillery along with 3.0 MW Co-Generation Power Plant
At Village Ganora, Tehsil Ghatol, District Banswara (Rajasthan).
Pre - feasibility Report
M/s. Express Digital Payment Services Private Limited 3
Outside)
H. Product Mix ENA / RS / IMFL /Ethanol
I. Working Days 350 days/annum
1.1 ENVIRONMENT MANAGEMENT PLAN
Particulars DETAILS
Air Quality Management
Possible
Sources
Boilers, Transportation vehicles, D.G. Sets etc.
Emissions � ESP/Bag Filters will be installed with the proposed boiler.
� Adequate boiler stack height will be provided.
� CO2 produced during the fermentation process will be collected and utilized as
an industrial gas.
� DG Sets will also have adequate stack of height as per CPCB Guidelines.
� Adequate measures for Fugitive Dust Emissions will be taken.
� All the internal roads will be asphalted.
� Development of Green Belt all around the periphery & within the premises of
the plant will help in attenuating the pollutants emitted by the plant.
Monitoring � Online stack monitoring system will be installed.
� Ambient air quality will be regularly monitored.
Water Management
Management � The proposed Grain based distillery will be based on “Zero Effluent Discharge”.
� Fresh water requirement of the project will be met by Ground Water & recycled
water.
� Grain Slops (Spent Wash) will be taken through Centrifuge Decanters for
separation of Suspended Solids separated as Wet Cake.
� Thin Slops from the Decanter Centrifuge are partly recycled back to process (30-
35%) and partly taken to Thins Slops Evaporation Plant for concentration of
remaining solids to form a Syrup. This Syrup is also mixed into the Wet Cake
coming out of Centrifuge and forms part of Cattle Feed. (Also known as Soluble
– Collectively known as DWGS)
� DWGS Drier – Wet cake / DWGS will be passed through steam tube bundle drier
for drying into cake with 10-12% moisture (max.) to give higher shelf life. Solid
Proposed 90 KLPD Grain Based Distillery along with 3.0 MW Co-Generation Power Plant
At Village Ganora, Tehsil Ghatol, District Banswara (Rajasthan).
Pre - feasibility Report
M/s. Express Digital Payment Services Private Limited 4
dry cakes (DDGS) will be obtained finally.
� The Process condensate will be cooled and collected into a neutralization tank
with sufficient residence time. After Neutralization and filtration (UF+RO) this
process condensate will be recycled into process use.
� Rainwater will be collected and recharged into underground resource through
scientifically designed Rainwater Harvesting System.
Noise Management
Management � Proper maintenance, oiling and greasing of machines at regular intervals.
� PPEs like earplugs and earmuffs to the workers exposed to high noise level.
� Development of Green Belt for 33% of the total project area.
� D.G sets will be provided with acoustic enclosures to control the noise level
within the prescribed limit.
Monitoring Regular monitoring of noise levels will be carried out and corrective measures in
concerned machinery will be adapted accordingly to the possible extent.
Solid Waste Management
Management � Solid waste generated would be wet cake, yeast sludge and ash from the boiler.
� Solid waste from the grain based operations generally comprises of fibres and
proteins in the form of DDGS, which will be ideally used as cattle feed.
� Ash from the boiler will be supplied to brick manufacturers & cement plant.
� The Yeast sludge will be added to the Wet Cake.
� Used oil & grease generated from plant machinery/Gear boxes as hazardous
waste will be sold out to the CPCB authorized recycler.
Green belt Development/ Plantation
Management � Out of the total plant area ~ 33% of total project area will be developed under
green belt/plantation.
� Plantation will be done as per Central Pollution Control Board (CPCB) Norms.
� Greenbelt will be developed all along the plant boundary and plantation will be
done all along the roads which attenuates noise level, arrest dust and improves
the surrounding environment.
� Native species will be given priority for plantation in consultation with local
horticulturist.
� The plantation would start along with the start of the construction activities of
the proposed unit.
Odour Management
Proposed 90 KLPD Grain Based Distillery along with 3.0 MW Co-Generation Power Plant
At Village Ganora, Tehsil Ghatol, District Banswara (Rajasthan).
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M/s. Express Digital Payment Services Private Limited 5
Management � Adequate greenbelt all around the periphery of the plant.
� Efficient CO2 scrubbing to avoid carry over of alcohol vapours & other fumes.
� DWGS Dryer will be installed for complete drying of solids.
� Better housekeeping will maintain good hygiene condition by regular steaming
of all fermentation equipment.
� Longer storages of any product/by-products will be avoided & use of efficient
biocides to control bacterial contamination.
� Regular use of bleaching powder/formalin in the drains to avoid generation of
putrefying micro-organisms.
2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION
(i) Identification of Project and Project Proponent
M/s Express Digital Payment Services Private Limited (EDPSPL) is a company promoted by
Mrs. Anita Gupta and family. The promoters of EDPSPL have diversified interests in liquor,
edible oils, real estate, financial services etc. The promoters have the financial and
managerial capability to set up and manage large industrial projects.
Now, EDPSPL is proposing Project comprising of Grain Based Distillery, IMFL & Country
Liquor Bottling, Brewery and Co-Generation Power Plant at Village Ganora, Tehsil Ghatol,
District Banswara (Rajasthan). It would be an eco-friendly project. We shall adopt zero
discharge concepts.
(ii) Brief description of nature of the project
M/s Express Digital Payment Services Private Limited is proposing to set up Extra Neutral
Alcohol/ Rectified Sprites / Ethanol/Industrial Alcohol/Total Alcohol etc. manufacturing
facility with an installed capacity of 90 KLD & 3 MW Co-generation Power Palnt along with
CO2 & Distillers Dried Grains & Solubles (DDGS) for Cattle/Poultry/Fish or Prawn feed as by-
products. For the purpose of setting up the unit, the site is located at Village Ganora,
Tehsil Ghatol, District Banswara (Rajasthan). The company will manufacture ENA through
grain based process. The proposed site is chosen because of its proximity to the
agriculture field surrounding the area & easy availability of food grains like Maize, Bajra,
Sorghum & broken rice to the distillery for producing alcohol.
(iii) Need for the project and its importance to the country and or region
With hundreds of kind of alcoholic beverages being made and consumed in India, the
industry can be categorised into four broad groups’ viz. Indian Made Foreign Liquor
(IMFL), Country Liquor (CL), illicit liquor & Beer.
IMFL products contain about 42.85% of alcohol. The consumption of CL is slowly on the
Proposed 90 KLPD Grain Based Distillery along with 3.0 MW Co-Generation Power Plant
At Village Ganora, Tehsil Ghatol, District Banswara (Rajasthan).
Pre - feasibility Report
M/s. Express Digital Payment Services Private Limited 6
decreasing trend as some cheap IMFL is available. In spite of this, the CL industry is
growing at around 8%. However, government is taking necessary steps to restrict the illicit
liquor as it causes loss of revenue and spoils the health of the people, also bad quality may
lead to death of consumer. The major consumption of alcohol as of now is for alcoholic
beverages. Ethyl alcohol has the potential to become the fuel of the future relegating
gasoline to a secondary place.
The ethanol produced from the grains is superior in quality as compared with that from
molasses. It is estimated that IMFL market will require around 3000 million litres in the
year 2014 and expected to grow more than 50% in next 3 years. As Government declares
5% mandatory mixing of fuel ethanol in the gasoline thus there is great potential for new
distillery establishment.
(iv) Demand- Supply Gap
Not required in this Project. This depends on excise Department.
(v) Import vs. Indigenous Production
Indian market could not meet present alcohol demand. So they import alcohol 5-7% of
total demand. As far as ethanol production is concerned, Indian market play a vital role at
both domestic & international level. So they require produce the more alcohol to meet the
demand.
(vi) Export Possibility
Export of Alcohol is currently governed by Govt. policy.
(vii) Domestic / Export Markets
Sales and Marketing division has always been a key focus area for our company. Over the years
we have reached a number of key customers through our initiatives. We have a thrust on
institutional Buyers which is a paradigm shift from the tradition of selling to wholesale market.
(viii) Employment Generation (Direct and Indirect) due to the project
For smooth functioning of the plant, the company needs a team of 100 persons. These
persons are responsible towards their respective department such as Process Plant, Boiler
Operating Plant and administrative block. Here is the detail description of the manpower
requirement of the company.
Table 2
Manpower Requirement
S. No. Units Requirement
1. Process Plant 18
2. Raw material and Product handling 19
3. Boiler House Plant 8
Proposed 90 KLPD Grain Based Distillery along with 3.0 MW Co-Generation Power Plant
At Village Ganora, Tehsil Ghatol, District Banswara (Rajasthan).
Pre - feasibility Report
M/s. Express Digital Payment Services Private Limited 7
4. Administrative Plant 15
5. Others 40
Total 100
3.0 PROJECT DESCRIPTION
(i) Type of Project including interlinked and independent projects, if any.
There are no interlinked projects related to this proposed project.
(ii) Location (map showing general location, specific location, and project boundary &
project site layout) with coordinates
Proposed 90 KLPD Grain Based Distillery along with 3.0 MW Co-Generation Power Plant
At Village Ganora, Tehsil Ghatol, District Banswara (Rajasthan).
Pre - feasibility Report
M/s. Express Digital Payment Services Private Limited 8
Figure - 1: Location Map
Proposed 90 KLPD Grain Based Distillery along with 3.0 MW Co-Generation Power Plant
At Village Ganora, Tehsil Ghatol, District Banswara (Rajasthan).
Pre - feasibility Report
M/s. Express Digital Payment Services Private Limited 9
(ii) Key Plan
Figure - 2: Key Plan
Proposed 90 KLPD Grain Based Distillery along with 3.0 MW Co-Generation Power Plant
At Village Ganora, Tehsil Ghatol, District Banswara (Rajasthan).
Pre - feasibility Report
M/s. Express Digital Payment Services Private Limited 10
(iv) Details of alternative sites consideration and basis of selecting the proposed site,
particularly the environmental considerations gone into should be highlighted.
No alternative site has been taken into consideration as the proposed site has been
acquired by the company keeping in mind following mentioned factors:
� Grant of state excise permissions (LOI) for setting up distillery in the district/state.
� The proposed site falls in the safe groundwater zone.
� Raw material availability & markets for both products & by-products within the
state.
� Nearness to SH-32 (~ 2.5 km in WSW direction) & NH 113 (~10.5 Km in SE direction)
makes it easier to transport raw materials & final product to market.
(v) Size or magnitude of operation
The total proposed capacity of Grain Based Distillery is 90 KLPD & Co-generation Power
Plant is 3.0 MW.
The process includes basic raw material requirement, sizing of equipment, utilities &
services, infrastructure facilities & sources of waste generation, their quantity, treatment
& safe disposal of the waste.
S. No. Units Capacity
1. Distillery (ENA / RS / IMFL /Ethanol) 90 KLPD
2. Co-Generation Power Plant 3.0 MW
(vi) Project Description with Process Details
Process Description of Grain Based Operation
A) Grain Storage Silos, Cleaning, Handling and Milling Section:
Grain is received from various sources and is pre-cleaned off stones, husk, etc. and then
stored in specially designed storage silos. Grains are continuously lifted from the bottom
of the silos and screened followed by removal of stones in de-stoner and iron matters in
magnetic separators. Cleaned Grains are then milled using dry milling process in Hammer
Mills. The flour is fed through the bucket elevator and conveyed to the Batch Tipping
Machine through a Screw Conveyor.
B) Liquefaction Section
Grain flour mixed with recycle streams and water in Pre-masher and slurry has been fed to
Liquefaction tank. Required temperature has been maintained by applying steam through
steam sparger in liquefaction tank. The cooking process, accomplished in the above
manner, converts the slurry into a hydrated, sterilized suspension (as starch molecule is
solubilized) and is therefore susceptible to enzyme attack for liquefaction. The liquefied
Proposed 90 KLPD Grain Based Distillery along with 3.0 MW Co-Generation Power Plant
At Village Ganora, Tehsil Ghatol, District Banswara (Rajasthan).
Pre - feasibility Report
M/s. Express Digital Payment Services Private Limited 11
mash is cooled in slurry cooler and transferred to Fermentation section.
C) Fermentation Section
The purpose of fermentation is to convert the fermentable substrate into alcohol. To
prepare the mash for fermentation, it is diluted with water. Yeast is added in sufficient
quantity to complete fermentation to produce alcohol.
At the start of the cycle, the Fermenter is charged with mash and contents of the Yeast
Activation Vessel (Pre-fermenter). Significant heat release takes place during
fermentation. This is removed by passing the mash through heat exchangers to maintain
an optimum temperature. The recirculation pumps also serve to empty the Fermenters
into Beer Well. CO2 evolved during fermentation carries along with it some entrained
alcohol. This CO2 is taken to a CO2 scrubber where it is washed with water to remove the
entrained alcohol. The scrubbed CO2 can then be taken to CO2 plant or vented out. After
emptying of Fermenter, it is cleaned with CIP using cleaning nozzles. After CIP Fermenter
is ready for next batch to be filled.
D) MPR Distillation Wash to ENA:
Multi-Pressure Distillation system has eight Distillation columns operating at various
pressure conditions. Heat energy from columns operating under high pressure is utilized
for columns operating under low pressure to optimize the operation for energy
consumption. Following Columns will be under operation
� Analyser Column
� Degasifying Column
� Pre-Rectifier Column cum
� Exhaust Column
� Extractive Distillation Column
� Rectifier cum Exhaust Column
� Recovery Column
� Simmering Column
Pre-heated fermented wash is fed at the top of the Degasifying column. Analyser Column
is provided with Reboiler. Top vapors of Analyser column containing all the alcohol in the
wash are sent to Pre-Rectifier column. Rest of the fermented wash flows down the
Analyser column and is taken out as thick slops from Analyser column bottom. Low boiling
impurities are concentrated in the Pre-Rectifier column. A draw of impure alcohol is taken
out from the top of the Pre-Rectifier column. RS draw is taken from the top of Pre rectifier
column, which further is sent to Extractive Distillation column. Dilution water is fed to this
Proposed 90 KLPD Grain Based Distillery along with 3.0 MW Co-Generation Power Plant
At Village Ganora, Tehsil Ghatol, District Banswara (Rajasthan).
Pre - feasibility Report
M/s. Express Digital Payment Services Private Limited 12
column. The Extractive Column operates on the principle of inversion of relative volatility.
Low boiling impurities are separated in the Extractive Distillation Column & bottom is sent
to Rectifier cum Exhaust column. The Rectifier/Exhaust column concentrates the alcohol
to 96% v/v. The spirit is drawn from the upper trays of the Rectification Column. Fusel oil
build up is avoided in the Rectifier cum exhaust column by withdrawing side streams
(fusel oils). ED condensates, fusel oil draw from R/E column are sent to Recovery column
where these fusel oils are concentrated and then sent to decanter where these streams
are diluted with water and fusel oil rich layer is separated. Washings are sent back to the
column to recover alcohol. The spirit Draw from the Rectifier column is sent to the
Simmering column where methanol is separated in the form of a cut from the top and
ENA is taken out from the bottom. ENA drawn from the Simmering Column is taken to the
receiver after cooling in ENA cooler.
E) Decantation Section Excluding Decanter Centrifuges
Decantation section comprises of a Centrifuge Decanters (Client scope) for separation of
suspended solids from Thick slop coming out of Grain Distillation Plant. Wet cake is
removed from bottom of Decanter. Thin slops coming out of Decanter are collected in a
tank and partly recycled into the process & Evaporation for further concentration. The
concentrated thin slops called as Syrup is mixed with Wet cake and sold in wet form as
cattle feed (DWGS) or the entire mixture can be dried in a DWGS Dryer and then sold in
dry form as Cattle feed (DDGS).
F) Integrated Evaporation
The suggested treatment scheme is a Multi Effect Evaporation Plant for Thin Slop
Evaporation. Shell & Tube type Evaporators with highly efficient liquid distributor working
on the principle of Falling Film and Forced circulation Evaporation has been used.
The product at the desired concentration of 40%w/w Total Solid is obtained at the outlet
of the final effect. Each effect is provided with recirculation cum transfer pumps. The
condensate from surface condensers is collected in a common condensate pot. The
condensate is transferred for further treatment / drain by using centrifugal pump. The
system operates under vacuum. Water-ring vacuum pumps are used to maintain a desired
vacuum. Cooling water from cooling tower is used in the surface condensers for
condensing the vapours.
G) DWGS Dryer Section
Wet distiller’s grains shall be fed into the dryer housing at controlled rate through a
suitable feeding system. The Rotary Bundle is enclosed in an insulated dryer housing and
Proposed 90 KLPD Grain Based Distillery along with 3.0 MW Co-Generation Power Plant
At Village Ganora, Tehsil Ghatol, District Banswara (Rajasthan).
Pre - feasibility Report
M/s. Express Digital Payment Services Private Limited 13
on its outer flights are fixed. Dry, saturated steam is to be supplied to the bundle through
rotary joint at one end & the condensate is discharged through rotary joint mounted of
another end. During the course of rotation, these flights pick up the material and shower
them on to the tube bundles. The heat transfer is primarily by conduction. The water
vapors are exhausted through an Exhaust Blower & passed through a cyclone separator
for separating fines. Dry product partially recycled back to feed conditioner for feed
conditioning through Product Screw & Recycle Conveyor. Entire operation of the Dryer is
controlled through Local Indication cum Control panel.
G) Process Condensate Treatment Section
The process condensate from the evaporation section is treated in this unit and this
treated condensate is then recycled back to process thus reducing the fresh water
consumption.
Proposed 90 KLPD Grain Based Distillery along with 3.0 MW Co-Generation Power Plant
At Village Ganora, Tehsil Ghatol, District Banswara (Rajasthan).
Pre - feasibility Report
M/s. Express Digital Payment Services Private Limited 14
Fig. 3: Process flow chart For Grain Based Distillery
Proposed 90 KLPD Grain Based Distillery along with 3.0 MW Co-Generation Power Plant
At Village Ganora, Tehsil Ghatol, District Banswara (Rajasthan).
Pre - feasibility Report
M/s. Express Digital Payment Services Private Limited 15
(vii) Raw material required along with estimated quantity, likely source, marketing area
of final products, mode of transport of raw material and finished product.
(a) Raw Material Requirement
List of raw materials & Chemical required, their source along with mode of transportation
are given below:
Table 3
Raw Material Requirement for Grain Based Distillery
S.
No.
Name of Raw Material Requirement Storage Source & Mode of
Transportation
1 Grains 208 TPD Silo & Godowns Through vendors / By
road
2 CHEMICALS
Sodium Hydroxide
(Caustic)
300 -350 Kgs Solid form packing in 50 kg
bags & Stored Godown
Nearby areas via road
Nutrients 200 Kgs Solid form packing in bags
& Stored Godown
Enzymes 200 Kgs Liquid form packed in cane
& Stored Godown
Antifoam Agent 100 Kgs Semi Solid form packing in
drum & Stored Godown
Yeast (Active Dry
Yeast/Distiller’s Yeast)
90 Kgs Solid form packing in bags
& Stored Godown
(b) Fuel Requirement
Rice husk or Indian coal or pet coke will be used for the proposed boiler of 30 TPH. Details
regarding fuel requirements are given below.
Table 4
Fuel Requirement
Name of Raw Material Quantity (MT per day) Source Of Materials
Rice Husk or 180 Through Local vendors / By road
Indian Coal 130 From Authorized Dealers By road
Pet coke 80 Nearby Refinery by road
Proposed 90 KLPD Grain Based Distillery along with 3.0 MW Co-Generation Power Plant
At Village Ganora, Tehsil Ghatol, District Banswara (Rajasthan).
Pre - feasibility Report
M/s. Express Digital Payment Services Private Limited 16
(viii) Resources optimization/ recycling and reuse envisaged in the project, if any, should
be briefly outlined.
Water as a resource will be recycled at each possible step of the process and latest
technology and methodology will be adopted to conserve and reuse the resources.
(ix) Availability of water it’s source, energy /power requirement and source should be
given.
(a) Water Requirement and Source
Total water requirement for the proposed project will be 760 KLPD (746 KLPD for Plant
Process and 14 KLPD Domestic & Others).
Description Water consumption (KLPD)
Distillery Plant 746 KLPD (8.29 KL/KL)
Domestic use & others 14 KLPD
Total 760 KLPD
Source – Ground water
Water Requirement for Grain Based Operation
The total water requirement for the Grain based is estimated 746 KLPD, worked out as per
details given below:
Table - 5
Total Water Break-up
Water Type Total Water
first run Input
Total water
recycling
Total Fresh water
requirement after recycling
Process Water 562 440 122
Soft Water 702 348 354
DM Water 699 429 270
Total 1963 1217 746
KL/KL 8.29
Proposed 90 KLPD Grain Based Distillery along with 3.0 MW Co-Generation Power Plant
At Village Ganora, Tehsil Ghatol, District Banswara (Rajasthan).
Pre - feasibility Report
M/s. Express Digital Payment Services Private Limited 17
Figure 4: Water balance for Grain based Operation
Proposed 90 KLPD Grain Based Distillery along with 3.0 MW Co-Generation Power Plant
At Village Ganora, Tehsil Ghatol, District Banswara (Rajasthan).
Pre - feasibility Report
M/s. Express Digital Payment Services Private Limited 18
(b) Power Requirement and Source
The power requirement is 2.1 MW, which will be sourced from proposed 3.0 MW Co-
Generation Power Plant via a straight back pressure turbine.
(c) Steam Requirement
Steam consumption for the process and boiler de-aeration is 21.70 TPH, which will be
sourced from Boiler (30 TPH).
Table 6 Steam requirement
S. No. Purpose Steam Requirement TPH
1. Cooking & Liquefaction 3.17
2. Multi-pressure Distillation & Evaporation (Integrated) 10.66
3. DWGS Drier 5.91
4. Boiler De-aeration 1.96
Total 21.70
Boiler Details
A Boiler of 30 TPH capacity with ESP as APCE is sufficient to meet the requirements.
Others details regarding this are mentioned in the table given below:
Table – 7 Boiler details
S. No. Details
1. Type of Fuel Rice Husk/ Indian Coal/ Pet
coke
2. Capacity of Boiler 30 TPH
3. Stack Height Adequate stack height
4. Pollution Control Equipment Measures ESP/Bag Filter
Details regarding the D.G. Sets
2 Number of D.G. sets of 1000 KVA & 500 KVA will be installed for the power backup.
Details regarding the D.G. Sets are mentioned in the table given below:
Table – 8 Details Regarding the D.G. Sets
S. No. Details
1. Type of Fuel HSD
2. Capacity 1000 KVA & 500 KVA
3. Stack Height (above roof level) As per CPCB/SPCB norms
4. Pollution Control Equipment Measures Adequate stack height/ Acoustic
Proposed 90 KLPD Grain Based Distillery along with 3.0 MW Co-Generation Power Plant
At Village Ganora, Tehsil Ghatol, District Banswara (Rajasthan).
Pre - feasibility Report
M/s. Express Digital Payment Services Private Limited 19
(x) Quantity of waste to be generated (liquid and solid) and scheme for their
management/disposal
� The proposed project is based on “ZERO EFFLUENT DISCHARGE”.
� Grain Slops (Spent Wash) will be taken through Centrifuge Decanters for separation
of Suspended Solids separated as Wet Cake.
� Thin Slops from the Decanter Centrifuge will be partly recycled back to process (30-
35%) and partly taken to Thins Slops Evaporation Plant for concentration of
remaining solids to form a Syrup. This Syrup is mixed with the Wet Cake coming out
of Decanter Centrifuge and forms part of Cattle Feed. (Also known as Distillers Wet
Grain Solubles - Collectively known as DWGS).
� DWGS is taken to a dryer operating on steam and is dried to make it DDGS – Distillers
Dried Grain Solubles.
� The process condensate is cooled and collected into a neutralization tank with
sufficient residence time. After Neutralization, this process condensate will be
recycled into process and is used for green belt development within the complex.
� Solid waste from the Grain based operations generally comprises of Fibres and
proteins in the form of DDGS, which will be ideally used as Cattle Feed.
� Ash from the Boiler will be sold to Brick manufacturers and Cement manufactures.
� Yeast sludge will be sent to the Sludge Drying Beds or may be added to the Wet
Cake.
� Used oil & grease generated from plant machinery / Gear boxes & D.G. Set will be
partly used in oiling & greasing as lubrication of external parts of machinery & partly
will be sold to the CPCB authorized recycler.
4.0 SITE ANALYSIS
(i) Connectivity
The project site is well connected to National Highway SH - 32 (~ 2.5 Km in WSW direction)
& NH-113 (~10.5 km in SE direction). The nearest railway station is Dungarpur Railway
Station (~ 58 km in West direction) and nearest airport is Maharana Pratap Airport,
Udaipur (~ 100 km in NNW direction). The site is suitably located with respect to
availability of raw material, water, road network, skilled/semi skilled/unskilled and
professional manpower etc. All communication facilities such as telephone, telefax &
internet are available in the vicinity of the project site.
ii) Land from Land use and Land ownership
Total plant area is 20 acres (8.10 ha) and the same has been acquired by the company.
Proposed 90 KLPD Grain Based Distillery along with 3.0 MW Co-Generation Power Plant
At Village Ganora, Tehsil Ghatol, District Banswara (Rajasthan).
Pre - feasibility Report
M/s. Express Digital Payment Services Private Limited 20
(iii) Topography
Topography of the core zone of the proposed project is almost flat.
(iv) Existing land use pattern (agriculture, non-agriculture, forest, water bodies
(including area under CRZ), shortest distances from the periphery of the project to
periphery of the forests, national park, wild life sanctuary, eco sensitive areas,
water bodies (distance from the HFL of the river), CRZ. In case of notified industrial
area, a copy of the Gazette notification should be given
Table 9
Environmental Settings of the Area
S. NO. PARTICULARS DETAILS
1. Nearest Village Dukwara Village (0.7 km in SE direction)
2. Nearest Town & City • Nearest Town: Ghatol (~12.5 km in ESE direction)
• District Headquarters: Banswara (~30 km in SSE
direction)
3. Nearest National Highway / State
Highway
• SH - 32 (~2.5 Km in WSW direction)
• NH - 113 (~10.5 Km in SE direction)
4. Nearest Railway station Dungarpur (~58 km in West direction)
5. Nearest Airport Maharana Pratap Airport, Udaipur (~ 100 km in NNW
direction)
6. National Parks, Wild Life
Sanctuaries, Biosphere Reserves,
Tiger/ Elephant Reserves, Wildlife
Corridors etc. within 10 km radius
No National Parks, Wild Life Sanctuaries, Biosphere
Reserves, Tiger/ Elephant Reserves, Wildlife Corridors
etc. falls within 10 km radius from the plant site.
7. Reserved Forests (RF) / Protected
Forests (PF) etc. within 10 Km.
radius
• Kundli Dudka Block PF (~3.5 km in ENE direction)
• Bhoyar Borda PF (~4.5 km in ESE direction)
• Loharia Block A PF (~7.0 km in WSW direction)
• Gargiyamarga Block PF (~7.5 km in ENE direction)
• Loharia Block B PF (~8.4 km in West direction)
• Suliya Venka Block PF (~8.5 km in North direction)
8. River / Water Body (within 10 km
radius)
• Budanpura Minor (~2.5 km in South direction)
• Mahi River (~5.7 km in NW direction)
• Mahi Canal (~7.2 km in East direction)
• Shakliya Nadi (~8.5 km in ESE direction)
• Som River (~9.0 km in NW direction)
Proposed 90 KLPD Grain Based Distillery along with 3.0 MW Co-Generation Power Plant
At Village Ganora, Tehsil Ghatol, District Banswara (Rajasthan).
Pre - feasibility Report
M/s. Express Digital Payment Services Private Limited 21
9. Soil Type Black soil & Red soil
10. Seismic Zone Seismic Zone - II as per IS: 1893 (Part-I): 2002.
(v) Existing Infrastructure
Proposed project is new project. There are no existing infrastructures.
(vi) Soil classification
The soils of the district fall under the following broad categories
• Black soil
• Red soil
Black soil is found predominantly in the district mostly in northern, southern, central and
eastern parts. Red soil is mostly found in western portion of the district from north to
south.
(vii) Climatic data from secondary sources
Average annual rainfall of the district is 935.5 mm. However normal rainfall for the period
1901 to 1970 is 870 mm. The annual rainfall gradually decreases from southern part to
northern part. The maximum average rainfall is 1118 mm at Dhanpur and minimum average
rainfall is 790 mm at Loharia.
The climate of the district is dry except S-W monsoon season. The cold season is from
December to February and is followed by summer from March to June. From mid of
September to end of November constitutes post monsoon season. The district
experiences either mild or normal drought once in two years. Severe type of drought has
been recorded very rarely. Most severe type of drought has never occurred in the district.
(viii) Social Infrastructure available
There are primary schools, dispensaries, small hospitals, places of worship in nearby area
of the project site.
5.0 PLANNING BRIEF
(i) Planning Concept (type of industries, facilities, transportation etc.) Town and
country Planning/ Development authority classification.
The proposed project is an distillery unit. Facilities required for the proposed project will
be provided as per requirement. Transportation of raw material and final product will be
done via existing road network and cement concrete road will be developed within the
proposed project area.
(ii) Population Projection
Temporary influx of people will be there as the managerial and supervisory staff will
Proposed 90 KLPD Grain Based Distillery along with 3.0 MW Co-Generation Power Plant
At Village Ganora, Tehsil Ghatol, District Banswara (Rajasthan).
Pre - feasibility Report
M/s. Express Digital Payment Services Private Limited 22
generally be outsider. A projection may be made by a governmental organization, or by
those unaffiliated with a government.
(iii) Assessment of infrastructure demand (Physical & Social)
The Company will assess the demand of infrastructure (Physical & Social) in nearby area of
the proposed site and will be developed in under corporate social responsibilities
programs
(iv) Amenities/Facilities
The Company will be developed the Amenities/Facilities in nearby area of the proposed
project site as per requirement of local people of the nearby area under corporate social
responsibilities programs.
6.0 PROPOSED INFRASTRUCTURE
(i) Industrial Area (Processing Area)
Approx. 20 acre area will be required for proposed Distillery unit.
(ii) Residential area (Non Processing area)
Residential colony is not proposed for proposed project. The local labor will be preferred
to provide employment opportunities.
(iii) Green Belt
Greenbelt will be developed in 33% of the total area of the proposed project.
(iv) Social Infrastructure
Proposed project will result in growth of the surrounding areas by increased direct and
indirect employment opportunities in the region including ancillary development and
supporting infrastructure.
(v) Connectivity
The proposed project is well connected with Road.
(vi) Industrial Waste management
The proposed Grain based distillery would be based on “ZERO DISCHARGE”.
(vii) Solid Waste Management
� Solid waste from the Grain based operations generally comprises of Fibres and
proteins in the form of DDGS, which will be ideally used as Cattle/Poultry/Fish or
Prawn Feed.
� Ash from the Boiler will be sold to Cement and Brick manufacturers.
� Yeast sludge will be sent to the Sludge Drying Beds or may be added to the Wet
Cake.
Proposed 90 KLPD Grain Based Distillery along with 3.0 MW Co-Generation Power Plant
At Village Ganora, Tehsil Ghatol, District Banswara (Rajasthan).
Pre - feasibility Report
M/s. Express Digital Payment Services Private Limited 23
(viii) Power requirement and source
The total power requirement for the proposed project will be 2.1 MW, which will be
sourced from Co generation power plant of 3.0 MW & D.G Sets (1000 KVA & 500 KVA) (for
emergency).
7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN
(i) Policy to be adopted (Central/State) in respect of the project affected persons
including home oustees, land oustees and landless labourers (a brief outline to be
given).
Any rehabilitation and resettlement plan is not applicable in this case since there is no
habitation on the proposed site location.
8.0 PROJECT SCHEDULE AND COST ESTIMATES
(i) Likely date of start of construction and likely date of completion (time schedule for
the project to be given).
The project will start only after obtaining Environmental Clearance and all other required
clearance and will complete within 2 to 3 years of commencement.
(ii) Estimated project cost along with analysis in term of economic viability of the
project.
� Total cost of the Project: Rs. 170.75 Crores
� Cost for Environment Protection Measures:
� Capital Cost: Rs. 20 Crores
� Recurring Cost/annum: Rs. 1.5 Crores/annum
9.0 ANALYSIS OF PROPOSAL
(i) Financial and social benefits with special emphasis on the benefit to the local
people including tribal population, if any, in the area.
The proposed project is expected to bring significant socio-economic and environmental
benefits both at local level as listed below:
SOCIAL INFRASTRUCTURE:
Social awareness programmes will be improved by the local authority such as sanitation
and hygiene, HIV Prevention Program.
Adult education and female education programme is planned to the illiterate adults and
backward females of the villages in the project surrounding area.
EMPLOYMENT POTENTIAL:
Proposed 90 KLPD Grain Based Distillery along with 3.0 MW Co-Generation Power Plant
At Village Ganora, Tehsil Ghatol, District Banswara (Rajasthan).
Pre - feasibility Report
M/s. Express Digital Payment Services Private Limited 24
The project is going to create some employment. Due to this project activity, some
persons in the project area will be recruited as skilled and semi skilled workers by the
company as per its policy. Therefore, some employment and income are likely to be
generated for the local people. So, the project will contribute in a positive manner
towards direct employment in the project area. Some employment potential benefits are
given below:
� Long term employment of up to 60 people in the operation phase.
� Plus indirect employment shall be generated substantially.
BENEFITS TO THE REGION
The company will supply its product to the domestic market which is likely to improve the
regional economy.
PERIPHERAL DEVELOPMENTS:
The Company intends to take up developmental work in the periphery area. The activities
that have been considered include the following:
� Supporting existing schools for development of education in the area.
� Help in imparting vocational training to local eligible youth.
� Provide health facilities by way of medical check up, by holding medical camps etc.
in the neighbourhood.
Thus, the proposed project shall usher in the social and economic up-liftment of the
persons living in the vicinity of the Project i.e. of society at large.
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