EXPANSION OF EXISTING DISTILLERY PLANT FROM 200 …...Nearest Airport Jolly Grant, Dehradun (130 km...

Pre-Feasibility Report Dhampur Sugar Mills Ltd.

Expansion of Molasses Based Distillery Unit from 200 to 350 KLPD and 10.5 MW(3 MW existing & 7.5 MW new) Cogeneration PowerPlant

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PRE-FEASIBILITY REPORT

For

EXPANSION OF EXISTING DISTILLERY PLANT FROM 200 KLPD TO 350KLPD ALONG WITH 10.5 MW (3 MW Existing &7.5 MW New)

COGENERATION POWER PLANT(MOLASSES/GRAIN BASED)

Project Proponent:M/s. DHAMPUR SUGR MILLS LTD.

(CHEMICAL DIVISION)Dhampur, District-Bijnor

(December, 2017)

Environmental Consultant:

ENVIRO INFRA SOLUTIONS PVT.LTD.Accredited by NABET (Quality Council of India)

for EIA studies as ‘A’ Category Consultant(S. No. 45th, as on 7th December, 2017)

Address: - 301, 302 & 305, SRBC, Sec.-9, Vasundhara, GZB-201012Ph.: 0120-4151183 Email: [email protected]

Website: www.enviroinfrasolutions.com



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SUMMARY

1.0 Dhampur Sugar Mills Ltd. (DSM)is a company registered under Indian Companies Act,

1956(Now under the Companies Act, 2013)having its Registered Office at 241, Okhla Industrial

Estate, Phase – III, New Delhi,

2.0 The company is planning to expand its existing distillery plant from 200 KLPD to 350 KLPD and

incineration boiler based cogeneration power plant of10.5 MW (3.0 MW existing &7.5 MW New)

at their existing location at Village Alhapur, Tehsil Dhampur& District Bijnor, Uttar Pradesh. The

industry also plans to install a 100 KLPD grain based distillery plant at the same premises.

After expansion, the industry can adopt any of the following mechanisms for the production of

alcohol;

100 % molasses based operation @ 350 KLPD, or upto

100 KLPD grain based operation, producing a total daily alcohol @ 350 KLPD.

3.0 Bijnor district is in the northern region of India and is a part of the Indo-Gangetic alluvial plains.

The exact co-ordinates of site are 29°17'18.54"N and 78°30'47.63"E. It has an average

elevation of 239 meters (783 ft).

4.0 The promoters of the project are already having 40 acres of land at Village Alhaipur, Tehsil

Dhampur& District Bijnor, Uttar Pradesh. The benefits of the location are as below;

Required raw material is abundantly available in the nearby adjoining area.

Good availability of groundwater

Well connected by road/rail network

Proximity tospirit and ethanol consuming market

Manpower available for industrial purposes

5.0 The molasses based distillery process will have process steps namely - molasses receiving

and storage, fermentation, multi-pressure distillation, multi-effect evaporation, spirit storage.

Grain based distillery process will have process steps namely - grains receiving and storage,

grains handling and milling, slurry preparation/liquefaction, saccharification and instantaneous

fermentation, fermentation, multi-pressure distillation, decantation, multi-effect evaporation,

spirit storage.



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6.0 The industry is generating 3.0 MW power through cogeneration, after expansion total power

cogeneration capacity 10.5 MW power will be produced from incineration boiler based

cogeneration power plant. Bagasse/coal/rice husk would be used as support fuel @ 30 %

along with concentrated spent wash @ 70 % for the boiler furnace.

7. The industry would enhance its utilities for 350 KLPD distillery plant by making the capacity of

water treatment plant (DM plant) @ 1000 m3/day and that of cooling towers@ 12000 m3/Hour.

8. The distillery will use molasses/grains as basic raw material.Besides this, processing chemicals

would be used for the production of ethanol and other Distillery products.The daily fuel

requirements for the 75 TPH& 40 TPH boiler furnaces would be around 900 MT/ day conc.

spent wash along with 500 MT/Day (bagasse) or 300 MT/Day (coal).

9. Besides the main products as mentioned before, the company would also produce byproducts

such as CO2.

10. Fresh water requirements after the expansion project of the industry would be around 3275

m3/day. The source of fresh water will be ground water.

11. After expansion, waste water in the form of spent wash (2800 m3/day), spent lees (350

m3/day), MEE condensate (1975 m3/day) would be generated. Besides this, misc. effluent such

as floor/fermenter washing effluent @ 40 m3/day, cooling towers blow down @ 100 m3/day,

D.M. plant reject @ 100 m3/day and boiler blowdown @ 25 m3/day would be generated.

12. The industry already has two nos. of Multiple Effect Evaporators of 2800 m3 / day capacity

(1400 m3 / day X 2), which is sufficient for the treatment of spent wash after expansion.

However, enhancement of MEE capacity will be done if required after expansion, thereby

maintaining the Distillery as ZERO EFFLUENT DISCHARGE INDUSTRY.The spent lees and

MEE condensate would be reused in the process after treatment in CPU.

13. The estimated cost of expansion project from 200 KLPD to 350 KLPD distillery project and

cogeneration of 10.5 MW (3.0 MW existing & 7.5 MW New) of power would be around Rs

115.0 Crores. The cost does not include the land cost as expansion would be done within the

premises of existing plant.



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CHAPTER – 1

INTRODUCTION

Dhampur Sugar Mills Ltd. (DSM) is an agro based industry having started their operations in the year

1933 with a 300 TCD sugar mill located at Dhampur, Uttar Pradesh in North India.The company has a

successful track record of about seven decades of efficient operation. During this period, it has grown

into one of the largest sugar manufacturing groups in India, owning at present five sugar mills in the

State of Uttar Pradesh with a combined cane crushing capacity of more than 45,500 TCD with Bagasse

based power cogeneration Units in all five Sugar Units.

With the passage of time, DSM has diversified into molasses based chemicals manufacturing, by

setting up a distillery facility for alcohol & alcohol based chemicals, such as Ethyl acetate. Licensed/

Installed molasses based distillery having a capacity of 200 KLPD is already in operationat Village

Alhaipur, Tehsil Dhampur& District Bijnor, Uttar Pradesh for the production of Ethanol, Extra Neutral

Alcohol, Rectified Spirit, Industrial Alcohol, Industrial Gases- CO2 and Bio-fertilizers. Besides this, the

company is having another molasses based distillery unit of 100 KLPD capacity at village Asmoli, Tehsil

and District Sambhal, Uttar Pradesh.

Based on their successful past experience and growing demand, DSM is now proposing to expand

thedistillery capacity from 200 KLPD to 350 KLPD along with Co-Generation Power Plant of 10.5 MW (3

MW existing &7.5 MW new) within existing plant premises at Village Alhaipur, Tehsil Dhampur& District

Bijnor, Uttar Pradesh. The industry plans to install a 100 KLPD grain based distillery plant at the same

premises. After expansion, the industry can adopt any of the following mechanisms for the production of

alcohol;

100 % molasses based operation @ 350 KLPD or upto 100 KLPD grain based operation producing a

total daily alcohol @ 350 KLPD.

The distillery will be based on most modern technologies and the state of art features. Project will result

in higher efficiencies, energy conservation and Zero Effluent Discharge.The company has already

obtained the Environmental Clearance for 200 KLPD molasses based distillery from MoEFCC, New

Delhi vide Letter No. J11011/605/2007 IA II (I) dated 17th September, 2007.The proposed expansion

project again comes under the preview of Environmental Clearance and is listed at Sr. No. 5(g) under

Category ‘A’, of the schedule of EIA Notification, 2006 and its amendments.



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The proposed expansion will be done within the existing plant premises. Raw materials i.e. molasses

and bagasse will be sourced from the sugar mill located within the existing plant, other sugar plants of

the group and from other sugar mills located nearby. In case of grain based operation @ 100 KLPD,

grains such as broken rice, bajra, maize etc. would be procured.

The estimated cost of expansion project would be around Rs 115.00 Crores. The project would be

installed and commissioned within 8 to 12 months from the date of receipt of Environmental Clearance

from the Ministry of Environment, Forests & Climate Change, New Delhi.

The industry would operate for 365 days in a year. After expansion, the distillery plant would require a

power input of around 10.5 MW which would be available from their in-house co-generation power

plant. After, expansion, the total manpower requirements for the ethanol plant would be around 300

persons.

Project Description Existing Capacity Proposed Additional

Capacity

Expansion of

Molasses/Grainbased Distillery

Unit and Cogeneration Power

Plant

200 KLPD molasses based

distillery and 3.0 MW

Cogeneration Power Plant

based on Incinerator Boiler

Molasses/Grain based 150

KLPD alcohol production and

7.5 MW Cogeneration Power

Plant based on Incinerator

Boiler.

Table1: Salient Features of the Project

S.No.

Particulars Details

1. Nature & Size of the Project Proposed expansion of Molasses/Grain BasedDistillery from 200 KLPD molasses based operationto 350 KLPD molasses/grainbased operation alongwith Co-Generation Power Plant of 10.5 MW(3.0MW existing &7.5 MW New) within existing plantpremises

2. Category of the Project Sr. No. 5(g); Category ‘A’

3. Location Details

Village Alhaipur

Tehsil Dhampur



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District Bijnor

State Uttar Pradesh

Latitude 29°17'18.54"N

Longitude 78°30'47.63"E

Toposheet No. H74M7, H74M8, H74M11, H74M12

4. Total Plant Area 40 Acres. No additional land is required for theproposed expansion, as the same will be donewithin the existing plant premises.

5. Greenbelt / Plantation Area 13.5 Acres, i.e. ~33% of the project area will becovered under greenbelt/ plantation

6. Environmental Setting Details

Nearest Village Alhaipur

Nearest Town & City Dhampur (2.5 km in South direction)

Nearest National Highway /

State Highway

NH 74 (2.6 km)

SH 49 (Adjacent)

Nearest Railway station Dhampur Railway Station (2.5 km)

Nearest Airport Jolly Grant, Dehradun (130 km )

National Parks, WildlifeSanctuaries, Conservation Reserves,Tiger / Elephant Reserves

No National Parks, Wildlife Sanctuaries,Conservation Reserves, Tiger / Elephant Reservesfall within 10 km radius from the plant site

River / Water Body (within 10 kmradius)

Khoh River – 3.2 kmPreshaknahar – 1.8 km

7. Products to be manufactured Ethanol/RS/ENA – 350 KLPD

Cogeneration of power – 10.5 MW (existing-3.0MW & new 7.5 MW)

8. By Products Conc. spent wash – 825 KLD, CO2–320 MT/day,DDGS – 60 MT/day

9. Raw Material Consumption Molasses – upto 1600 MT/day

Grains – 250 MT/day

Chemicals - enzymes (@28 kg/day), SulphuricAcid (@8050 kg/day), Urea (@395 kg/day), anti-foam agent (@1400 kg/day), yeast (@700 kg/dayand DPA @ 130 kg/day)

10. Fuel Consumption Conc. Spent Wash 37.5 MT/hour and Bagasse-20.8 MT/hour or Coal – 12.5 MT/hour

11. Water Requirement & Source Total 6050 KLD water will be required. GroundWater @ 3275KLD& Recycled Water @ 2775KLD.



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12. Quantity of Effluent generation Spent Wash @ 2800 m3/day

13. Disposal of treated effluent Concentrated Spent Wash will be used as fuel inBoiler &condensates to be reused for dilution ofmolasses and cooling tower make-up aftertreating in CPU.

14. Details of process emissions Process emissions from boiler furnace of 75 TPH& 40 TPH capacities

15. Proposed air pollution control devicealongwith stack height

Bag Filter, Stack height – 80 meters

16. Cost of the Project: Rs (in Crores) 115.0 Crores

17. Working Days 365 days / annum



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CHAPTER – 2

PROJECT LOCATION

Dhampur Sugar Mills Ltd.are proposing to expand theirexisting 200 KLPD molasses based distillery

plant to 350 KLPD molasses/grainbased plant along with Co-Generation Power Plant of 10.5 MW(3MW

existing &7.5 MW new) capacity within the existing premises located at Village Alhaipur, Tehsil

Dhampur, districtBijnor, Uttar Pradesh. The company is already havingadequate land at the existing

location for the proposed expansion project.

2.1 SELECTION OF SITE

The basic criteria for the selection of site for the molasses/grain based distillery plant and

cogeneration power plant are as below;

a) Raw material and biomass availability

b) Raw material cost

c) Transportation cost

d) Accessibility to markets within and nearby states

e) Availability of water

f) Availability of land in abundance

g) Connectivity of road/rail network.

h) Market for final Product

Advantages of the location at Village Alhaipur, Tehsil Dhampur, District Bijnor, Uttar Pradesh

for expansion of the existing project.

The promoters of the project are already having around 40 acres of land at Village Alhaipur,

Tehsil Dhampur, District Bijnor, Uttar Pradesh. Besides this, the other benefits of the location

are as below;

a. Required raw material is available in the at site and nearby adjoining area.

b. Good availability of ground water

c. Well connected by road/rail network

d. Govt. of India support for Ethanol for mixing in fuel gasoline

e. Manpower available for industrial purposes

As regards to raw material availability, Bijnor district ranks second in the State in terms of cane

area and cane production. The area under sugarcane cultivation in Bijnor has increased by



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10,000 hectares this year and now stands at 2.20 lakh hectares, according to a survey

conducted by the sugarcane department. Last year, cane cultivation area was 2.10 lakh

hectares.Total 169.47 Lac Ton Cane was produced in the district.

2.2 Details of Alternative Sites

The proposed capacity expansion will be done within the existing plant premises and hence no

additional land will be required.Therefore, no alternative site has been considered by the

company.The following points justify implementation of the expansion project:

Proposed project is located adjacent to the company owned existing sugar mill.

Easy availability of raw material i.e. molasses from the existing and nearby sugar mill(s).

Nearness to NH-74 (within 3.0 km) and State Highway SH-49 (adjacent) makes it easier to

transport raw materials & final product to market.

There is no National Park, Wildlife Sanctuary, Conservation Reserves and Tiger Reserves

within 10 km radius of the project site.

2.3 Site Details

The plant site is located around 2.6 Km away from Dhampur Town. The connectivity of the site

to airport, railway and road is as follows:

a. Airport connectivity- The nearest airport is Jolly Grant, Dehradun which is about 130

Kilometers.

b. Rail connectivity- The nearest railway station is Dhampur, which is about 2.5

kilometers from the site.

c. Road connectivity- Nearest highway is SH-49, which is adjacent to the plant.

d. Police Station – DhampurKotwali at the distance 3 km.

e. Hospital- Government PHC & CHC within 3.0 to 5.0 km in Dhampur Town.

f. Schools, Colleges, Bank, ATM, Dispensaries, Hospitals, Markets, Police Station &

Places of Worship in nearby area of the project site.

Topography &Climate :The Topography of the area is mainly a plain. The project area has a

pleasing climate with cool and foggy winter and generally hot and humid summer. The wet

session starts from July to October during which the area receives rainfall. The temperature of

the project area is varying from 480C in summer and 30C in winter.



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2.4 Utilization of Land

The distillery plant can be divided into four sections w.r.t land utilization i.e. (1) boiler area (2)

process and distillation area (3) utilities and (4) green area. The industry has planned the

expansion of ethanol plant in their existing 40 acres of land. The detailed breakup of the land

for various uses would be as follows;

S. No. Particulars Land Area (Acres)

1. Area for plantation/green area 13.5

2. Area for roads/open spaces 2.3

3. Covered Area 2.7

4. Area for fuel/ash storage 6.8

5. Boiler & Cogeneration Plant 1.0

6. Area for other plant and machinery 13.7

Total land area 40

2.5 Need for the Project

The Government of India, through Oil Marketing Companies (OMCs), is implementing the

Ethanol Blended Petrol (EBP) Programme under which, OMCs sell ethanol blended petrol with

percentage of ethanol upto 10%. The Government has fixed the price of ethanol for the ethanol

supply year 2016-17 at Rs.39/ per litre. Additionally, Excise Duty, VAT/GST and transportation

charges (as decided by OMCs) are to be paid by OMCs. OMCs have procured 103 crorelitres

of ethanol during the ethanol supply year 2015-16 (till 7.11.2016). In 2015, the Government has

asked OMCs to target 10 % blending of ethanol in as many States as possible. A Steering

Committee and a Working Group on biofuels have been constituted in Ministry of Petroleum

and Natural Gas. They are holding regular consultations with concerned stakeholders.

Environmentally, the use of ethanol blends has assisted in reducing carbon monoxide

emissions. In the United States, one out of every eight gallons of gasoline sold contains

ethanol. Most of this ethanol is purchased as blends of 10% ethanol and 90% gasoline, known

as E10, and is used as an octane enhancer to improve air quality.Domestic ethanol production

in CY 2017 will decline by eight percent to 1.9 billion liters due to the decline in sugarcane area

planted for a second consecutive year (marketing year (MY) 2016/17). Fuel ethanol will achieve

a two-percent national average blending rate, as ethanol will replace 700 million liters of

gasoline. The current average for ethanol blending is estimated at 1.9 percent.



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CHAPTER – 3

PROCESS DESCRIPTION

3.0 Dhampur Sugar Mills Ltd.are proposing to expand theirexisting 200 KLPD molasses based

distillery plant to 350 KLPD molasses/grainbased plant along with Co-Generation Power Plant

of 10.5 MW (3 MW existing &7.5 MW new)capacity within the existing premises located at

Village Alhaipur, Tehsil Dhampur, district Bijnor, Uttar Pradesh. The company is already having

adequate land at the existing location for the proposed expansion project. The industry would

be operational for 365 days in a year.

3.1 MOLASSES BASED DISTILLERY PLANT OPERATION

The process will have following steps/operations;

a) Molasses storage and handling

b) Fermentation

c) Multi-pressure distillation

d) Multi-effect evaporation

e) Spirit storage

3.1.1 Molasses storage and handling

Molasses is a by-product of the sugar factory and is generally stored in steel tanks. It is either

pumped directly into the steel storage tanks or first unloaded in a pit and then transferred into

the storage tanks. Sometimes, external cooling is done in these tanks to control the

temperatures in molasses tanks.

In the distillery plant, as per the requirement, molasses is pumped using positive displacement

pumps and transferred to the fermentation section. It is first weighed and then pumped into

individual fermenters through magnetic type flow meters. The weighing is done generally with

load cell based system having a counter for measurement of quantity of molasses being

processed in a given period of time. After weighing of molasses, it is then pumped to the

molasses dilutor/broth mixer located alongside each fermenter.

3.1.2 Fermentation

The fermentation process is engineered to operate in Batch Mode depending upon the quality

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

During fermentation, sugars are broken down into Alcohol. Significant heat release takes place



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during fermentation. The fermenter temperature is maintained by forced recirculation flow

through plate heat exchangers. Some quantity of spent wash would be recycled in the

fermentation depending on solids concentration in fermented wash and molasses composition.

Fermentation Process & Sections

Molasses Handling and Distribution - Screened molasses from day storage is transferred to

molasses receiving tank and molasses is weighed. Weighed molasses is distributed to cell

mass propagation, fermentation and yeast activation section.

Yeast Propagation -Culture yeast is grown in laboratory during plant start up. Yeast

propagation section comprises of molasses diluter and hygienically engineered yeast vessels

equipped with heating, cooling and air sparging facility.

Pre-fermentation-In pre-fermenter vessel, molasses, process water, nutrients and additive are

added for activation/growth of cellmass. Filtered air is sparged as required for repairing of cell

membranes and other cell components. Activated cellmass is transferred to fermenter- 1 to

maintain desired cellmass concentration in Fermenter.

Dilute molasses media is prepared in yeast vessel by recirculating media through molasses

diluter. Laboratory propagated cell mass is scaled up in series of yeast vessels. Sterile air is

sparged in pasteurized and cooled dilute molasses medium for optimum growth of yeast.

Temperature is maintained by recirculation cooling water through jacket of yeast vessels.

Cellmass from yeast vessel is transferred to yeast activation vessel to build up cellmass

required for fermentation by cellmass transfer pump.

Yeast culturing and propagation

Some quantity of molasses would be received into the yeast culturing vessel and sterilized by

steam. Yeast seed material would be prepared and added to the yeast culture vessels (VI1-

CV4) by inoculation molasses with yeast. The contents of the yeast culturing vessel would then

be transferred to the yeast activation vessel (pre-fermentor) which would be continuously

aerated to allow oxygen for the yeast cell growth/multiplication.



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3.1.3 Multi-pressure distillation

This process utilizes columns namely the analyser column, degassifier column, Rectifier cum-

Exhaust column, recovery column Dehydration molecular seives in ideal heat integration in

order to reduce the energy consumption.

Pre-heated fermented wash will be fed to Degasifying Column. Fermented wash will strip off

alcohol by ascending vapors in Analyser Column. Rectifier vapours provide energy to Analyser

Column through a Thermosyphonreboiler. Vapours of Degasifying Column are condensed and

taken to Recovery Feed Tank. First calandria of Integrated evaporator are run by

Analyservapours. These vapour are condensed and taken into Rectifier Feed Tank. Analyser

Condensate is concentrated in Rectifier Column, which operates under pressure. Condensing

steam provides energy to Rectifier Column through a vertical Thermosyphonreboiler. Fusel Oil

build up is avoided by taking fusel oil draws from appropriate trays. Final industrial alcohol

product draw is taken from the top of the rectifier column and collected into the feed tank of

recovery column. Now this alcohol fed into the recovery column. The vapours drawn from the

recovery column is superheated and sent to molecular sieve bed 1, where the vapour is

dehydrated, condensed and cooled and pumped to storage. A portion of dry vapour is purged

to molecular sieve bed 2, under vacuum, to regenerate the bed in preparation for cycle

changeover when bed 2 goes on line. The regeneration process releases the absorbed water

and ethanol low strength vapours. These are condensed and recycled with the feed to the

Recovery Column. A stillage stream is obtained from the bottom of the recovery column.

Heat Integration and Energy Input Points

• Condensing steam through a vertical ThermosyphonReboiler provides energy to Rectifier

cum Exhaust Column.

• Rectifier cum Exhaust Column meets the energy requirement of Analyser cum Degasifying

Column

• Condensing steam through a vertical ThermosyphonReboiler provides energy to Recovery

Column.

• Condensing Analyservapours through Istcalanderia of integrated evaporator provides the

energy to integrated evaporator.



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3.1.4 Multi Effect Evaporation

The spent wash generated from the distillation process would be fed to two stage evaporation

system.The MEE would be having two stages and would be integrated with the main ethanol

plant. In stage I, the MEE columns would concentrate the solids from 18.0 % w/w to 25.0 %

w/w. In stage II, MEE system would increase the concentration of solids from 25 % to60 % w/w

by using steam. The vapours evolved would be condensed in the condensers and collected in

a collection tank. Some part of the condensate would be used in slurry preparation and balance

after treatment in the condensate polishing units would be reused in the cooling tower for

makeup water.

3.1.5 Spirit storage

Spirit storage would be divided into two sections. One would be daily spirit receiver section and

the other would be bulk storage section. The spirit coming out of distillation would be

transferred to daily spirit receivers. Subsequently, after gauging, the spirit would be transferred

to respective bulk storage tanks. The bulk storage tanks would be fabricated in MS and would

be having a storage capacity of 3000 KL.

3.2 Grain based Distillery Process/Operations

The grain based distillery process will have following steps/operations;

a) Grains receiving and storage

b) Grains handling and milling

c) Slurry preparation/liquefaction

d) Saccharification and instantaneous fermentation

e) Fermentation

f) Multi-pressure distillation

g) Decantation

h) Multi-effect evaporation

i) Spirit storage

3.2.1 Grain receiving and storage

Grains such as broken rice, rotten wheat, maize, bajra and other edible grains are procured

from various sources, and are stored in silos.



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3.2.2 Grain handling and milling

The grain would be lifted in bucket elevators, screened followed by removal of stones and iron

matter. Cleaned grains would then be milled using dry milling process in hammer mills. The

flour would be fed through the bucket elevators and conveyed to the batch tipping machine

through a screw conveyor. The flour addition would be metered through the batch tipping

machine with load cell arrangement, before transferring the flour to the slurry tank through

another screw conveyor (pre-masher) for slurry preparation process.

3.2.3 Slurry preparation/liquefaction

In liquefaction process, starch is hydrolyzed to dextrin. The Liquefaction is carried out in Single

stage Liquefaction Tank. Feedstock Flour is transferred to Premasher and mixed with Recycle

Streams and liquefying enzyme. Slurry from Premasher is taken to Liquefaction tank where

temperature is maintained by means of steam. Necessary retention time is maintained in the

Liquefaction Tank. Slurry pH is maintained by supplying dilute caustic solution. Contents in

Slurry Tank are kept in suspension by Agitation. The Liquefied Slurry is then cooled in Slurry

Cooler using cooling water supply and transferred to Pre-fermentation and Fermentation

section.

3.2.4 Saccharification and instantaneous fermentation

Yeast seed material is prepared in Pre-fermenter by inoculating sterilized mash with yeast.

Optimum temperature is maintained by circulating cooling water. The contents of the Pre-

fermenter are then transferred to Fermenter. 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 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 recirculating pumps also

serve to empty the fermenters into Beer Well. CO2 can then be taken to CO2 vent line where it

is 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.



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3.2.5 Fermentation

The fermentation process is engineered to operate in batch mode depending upon the quality

of raw material. 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.

3.2.6 Multi-Pressure Distillation

Multi-Pressure Distillation system has Seven 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.

Wash to ENA Mode:

Following Columns will be under operation:

1. Analyser Column

2. Degasser Column

3. Pre-Rectifier Column

4. ED Column

5. Rectifier cum Exhaust Column

6. Recovery Column

7. Simmering Column

Pre-heated fermented wash will be fed to Degasser column. Fermented wash is stripped off

alcohol by ascending vapors in Analyser column. Rectifier vapors provide energy to Analyser

column through a Thermosyphonreboiler. Vapors of Degasser column are condensed and

taken to Recovery Feed Tank. The condensed Analyser vapors are taken to Pre-Rectifier

Column. Analyser Condensate is concentrated in Pre-Rectifier column, which operates under

pressure. Condensing steam provides energy to pre-rectifier column through a vertical

Thermosyphonreboiler. A Technical Alcohol cut of about 1-2% of total spirit is taken from the

Pre-Rectifier column.

Concentrated alcohol draw from Pre-Rectifier column is fed to ED column for purification.

Dilution water in the ratio of 1:10 is added in this column for concentrating higher alcohol at the

top. Top of this column is condensed in its condensers and fed to recovery feed tank while

bottoms are fed to Rectifier cum Exhaust Column for concentration. Rectifier Column operates

under pressure and condensing steam provides energy to this column through a vertical



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Thermosyphonreboiler. Technical Alcohol cut is taken out from the top of this column while

ENA draw is taken out from appropriate upper trays and fed to Simmering Column after

cooling. Fusel Oil build up is avoided by taking fusel oil draws from appropriate trays.

These fusel oils along with the condensate of Degasifying & Extractive Distillation columns are

fed to recovery column for concentration. A technical alcohol cut is taken out from the top of

this column.

Simmering Column is operated under high reflux for better separation of methanol and di-

acetyls. Final ENA product draw is taken from the bottom of this column.

3.2.7 Decantation & Thin Slops Recycle Section

Decantation section comprises of a Centrifuge Decanter for separation of suspended solids

from Spent Wash coming out of Grain Distillation Plant. Wet cake has upto 30% w/w solids as

removed from bottom of Decanter which can be sold directly in wet form as cattle feed (DWG).

Thin slops coming out of Decanter are collected in a tank and partly recycled into the process &

further for Evaporation for concentration upto 30% w/w solids. 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 DDGS Dryer and then sold in dry form as Cattle feed (DDGS).

3.2.8 Evaporation System - Integrated Evaporation Scheme

The suggested treatment scheme Effect working on the principle of falling film & Force

Circulation

Analyzer vapors is fed to the first effect evaporator shell side and steam is fed to shell side

finisher at the given pressure and temperature as the heating medium.

Vapors from last effect are condensed in Surface Condenser. A Shell & tube type Multi-

pass Surface condenser is employed for condensing the shell side vapors.

The product at the desired concentration of upto 35% is obtained at the outlet of Finisher.

Each effect is provided with recirculation cum transfer pump.

The condensate from surface condensers is collected in a common condensate pot. The

condensate is transferred for further treatment / Recycle by using centrifugal pump.

The Pure steam condensate are collected in receiving vessels and can be pumped to

desired battery limit



Page 18

Highly efficient operating pumps have been provided for pumping the required fluid.

The plant is having high level of automation to get consistent output at required

concentration.

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

desired vacuum.

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

3.2.9 DWGS Dryer with Cooling and Conveying System

System Description for Dryer

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

feeding system. The Fluidised Bed Dryer is enclosed in an insulated dryer housing and its

outer flights are fixed. Dry saturated steam is to be supplied to the dryer through rotary

joint at one end & the condensate is discharged through joint mounted on another end.

During the course of fluidization, 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 Control panel.

3.2.9 Spirit storage

Spirit storage would be divided into two sections. One would be daily spirit receiver section and

the other would be bulk storage section. The spirit coming out of distillation would be

transferred to daily spirit receivers (separated for Ethanol/RS/ENA). Subsequently, after

gauging, the spirit would be transferred to respective bulk storage tanks.

3.3 POWER COGENERATION

The power plant will be using the combustion technology. The basic steps involve fuel

handling, boiler, turbo generator and power evacuation system.

Proposed cogeneration plant would consist of a high-pressure water tube steam boiler and a

steam turbine. Fuel in the steam boiler will be burnt with the help of air in the boiler furnace.



Page 19

Water will be circulated in the boiler drum and tubes thus getting heated by the flame burning in

the boiler furnace. Water would come out of the boiler drum located at the top of the boiler as

steam. Flue gases from the boiler furnace would come in contact with the steam coming out of

boiler drum. Steam after coming in contact with the flue gases would get heated up further thus

getting superheated. Super-heated steam leaves the boiler in a pipe. Flue gases after super

heating the steam pass through economizer where they pre-heat the boiler feed water before it

enters the boiler drum.

High pressure superheated steam from boiler would be passed through steam turbine. While

passing through the turbine, the high pressure and temperature steam rotates the turbine rotor

and an electric alternator. This electric power generated is consumed in house, i.e., for running

the ethanol plant and utilities like power plant auxiliaries, etc., and surplus power will be

exported to the state grid.

A part of the MP/LP steam is extracted for use in ethanol plant operations. The condensed

steam returns to the steam boiler as condensate and is again boiled as steam.

To the possible extent, feed water requirements of the boiler would be met essentially by the

condensate. The steam condensate will be available at 45-50oC and will be directly used in the

feed water circuit, although with certain monitoring for certain circuits. The make up for the

plant operation would be condensate water and a DM water treatment plant of adequate

capacity would be provided. The power generation cycle would be provided with a de-aerator

serving the dual purpose of de-aerating the feed water as well as heating the feed water with

the extraction steam.

3.4 SUNDRY UTILITIES

3.4.1 Steam Generator

The industry would install an incinerator boiler of 75 T/hour of steam generation capacity with

concentrated spent wash and bagasse/coal as fuel in the ratio of 70:30 respectively. The

design of the boiler will be of single drum, vertical, natural circulation, radiant furnace with water

cooled membrane walls, three-stage super heater with interstage de-super heater, balanced

draft, water tube type and continuous ash discharge.

Major accessories of the boilers would consist of the following:

a) FD, ID & SA fans

b) HP and LP chemical dosing system



Page 20

c) Blow down tank

d) Spray-cum-tray type de-aerator

e) 2 x 100% capacity boiler feed pumps

f) Fuel feeding system

g) Controls and instruments

Boiler Feed Water

The boiler shall be capable of operating with the following feed water quality* requirements;

a) pH (at 25ºC) : 8.8-9.2

b) Oxygen : ≤0.005 ppm

c) Hardness : NIL

d) Total Iron : ≤0.01 ppm

e) Total Copper : ≤0.01 ppm

f) Total Silica : ≤0.02 ppm

g) Residual hydrazine : 0.01-0.02 ppm

h) Total CO2 : NIL

i) Specific electrical conductivity : 0.5 micro ohms/cm

* At 25°C measured after cation exchanger in the H+ form and after CO2 removal (max.)

Steam Purity

The boiler shall be capable of supplying uninterrupted steam at the MCR rating with following

steam purity levels.

a) Total dissolved solids : 0.1 ppm (max)

b) Silica (max) : 0.02 ppm

3.4.2 Condensate system

The condensate recovered from the surface condenser and that from the process plant will be

used to meet the dilution water requirements. De-mineralized (DM) water would be used for the

make-up water requirements of the boilers.

3.4.3 Water Treatment (DM) plant – 1000 m3/day

It is proposed that the water to be used will be received from the ground water. The water

quality will require pre-treatment to satisfy the quality required for boiler feed water and some



Page 21

other process operations. Treatment will involve sand filtration, activated carbon filtration,

softener and reverse osmoses treatment suitable for ultimate quality of water required (RO).

3.4.4 Electrical system

The industrial plant power requirement (including that for power plant auxiliaries) will be about

10.5 MW. The industry would get the required power from their in-houseincineration boiler

based power cogeneration plant. Existing cogeneration capacity of the plant is 3.0 MW and

industry plans to enhance the power cogeneration capacity up to10.5 MW by installing 7.5 MW

turbine.

3.4.5 Cooling Water

The maximum cooling water requirement after expansion will be less than12000 m3/Hour. The

cooling tower will be counter/cross flow induced draft cooling tower. The cooling tower shall be

designed for a cooling range of 10°C, and an approach of 3°C while operating under the

atmospheric wet bulb temperature of about 28°C. The cooling tower shall be carefully sited

such that there is no re-entertainment of the vapors in to the cooling tower. Evaporation loss

will depend on season and an average figure will be less than1.25 % in the region. The cooling

tower blow-downs will be 775 m3/day. The quantity of water lost in the cooling tower would be

met through recirculation water addition, multiple effect evaporation condensate and fresh

water addition.

3.4.6 Fuel requirements and Fuel handling

The boiler will be designed to accept concentrated spent wash and biomass/coal as fuel. The

maximum fuel requirement will be about 37.5 MT/hr spent wash and20.8 MT/hour bagasse

or12.5 MT/hr coal.In case of use of coal, the same would be sourced from the local traders of

the area.The fuel from the storage will be mixed in a yard and conveyed to the boiler by a

combination of belt conveyors. The system shall have provision for returning the excess fuel to

the storage yard from the boiler. The fuel handling system shall be designed for a capacity of

40 TPH.



Page 22

Figure 2.2 :Idealised Water Balance (200 KLPD Molasses Based Distillery Operation)

All values are for 24 hours (per day) operationsValues are in Volume basis expect specified, Density of Molasses @ 1500 kgs./m3

Alcohol concentration in wash @ 8.7 % approx.

Fresh Water (890)

Yeast Culturing andFermentation (2000)

CO2

Multi-pressure Distillation(2000)

Steam (500)

Steam Condensate (500)

Spent Wash (1600)

Spent Lees (200)

Alcohol (200)

Multi Effect Evap. (1600)


Conc. Spent Wash (470)

Steam (300)

MEE Condensate (1130)

Treated Lees/Condensates(510)

Molasses (900 MT/600 KL) &



Page 23

Figure 2.3: Idealised Water Balance (350 KLPD Molasses Based Distillery Operation)

All values are for 24 hours (per day) operationsValues are in Volume basis expect specified, Density of Molasses @ 1500 kgs/m3

Alcohol concentration in wash @ 9.5 % approx.

Fresh Water (1700)

Yeast Culturing andFermentation (3500)

CO2

Multi-pressure Distillation(3500)

Steam (850)


Spent Wash (2800)

Spent Lees (350)

Alcohol (350)

Multi Effect Evap. (2800)


Conc. Spent Wash (825)

Steam (525)

MEE Condensate (1975)

Recycled Lees/Condensates(750)

Molasses (1600 MT/1050 KL)



Page 24

Figure 2 :Idealised Water Balance (for proposed 100 KLPD grain baseddistillery plant)

Milling SectionGrain (250 MT)

Spent Lees (100 KL)

Alcohol (100 KL)

Wet Cake (85 MT)

Thin Slops (515 KL)

Decantation (600 KL)

Thick Slop (60 MT)

Steam (50 MT)

Fresh Water (310 KL)

MEE (450 KL)

Liquefaction(700 KL)MEE/Lees Cond. (250 KL)

MEE condensate (390KL)

CO2Fermentation (700 KL)

DDGS (60 MT)

Steam Condensate (320 MT)

Spent Wash (600 KL)Multi-pressure Distillation(700 KL)

Steam (100 MT)

Steam (320 MT)

D M water (100 KL)

Dryer (145 MT)

Thin Slops (65)

Steam (75 MT)

Steam condensate (100 MT)

Condensates (85 MT)

Fiber/Dust/Husk (15 MT)



Page 25

All values are in V/V except grains which are in MT/day

Water Balance for Cooling Towers(200 KLPD Molasses Based Distillery Operation)

Water Balance for Cooling Towers(350 KLPD Molasses/Grain Based Distillery Operation)

Cooling Tower (1820)

Fresh Water (1000)

Evaporation Losses (1370)

CT Blow Down (450)

Recycled Condensate (820)

Cooling Tower (3075)

Fresh Water (1090) CT Blow Down (775)

Recycled Condensate (1985) Evaporation Losses (2410)



Page 26

CHAPTER – 4

RAW MATERIALS



of 10.5 MWcapacity within the existing premises located at Village Alhaipur, Tehsil Dhampur,

district Bijnor, Uttar Pradesh. The company is already having adequate land at the existing

location for the proposed expansion project. The industry would be operational for 365 days in

a year.

4.1 Raw Materials Requirements for Grain based Distillery

The distillery will use molasses/grains as basic raw material. Besides this, processing

chemicals would be used for the production of Ethanol.Phase wise daily consumption of raw

materials for the distillery plant is given below;

S.No.

Item Unit ExistingRequirementRequirement for

Proposedexpansion

TotalRequirementafter

Expansion

1. Molasses MT 900 700 1600

2. Grains MT 0 250 250

3. Enzymes Kgs. 16 12 28

4. Sulphuric

Acid

Kgs. 4600 3450 8050

5. Urea Kgs. 225 170 395

6. Anti-foam

agent

Kgs. 800 600 1400

7. Yeast Kgs. 400 300 700

8. DAP Kgs. 75 55 130

4.2 Raw Material Availability

Dhampur Sugar Mills Ltd. are having their own sugar mills adjoining to the proposed expansion

project having a daily cane crushing capacity of 14000 TCD. The sugar mills operate for more

than 180 days in a year. Annual molasses generation from the sugar mills is more than75000

MT. Besides this, the promoters of the industry are having 4 more sugar mills in Uttar Pradesh



Page 27

nearby the site. Molasses would be made available from those sugar mills. Further, molasses

is available from open market also.Grains such as broken rice, maize, bajra etc. is abundantly

available in the state.

4.3 Transportation

Dhampur Sugar Mills Ltd. is located at Village Alhaipur, Tehsil Dhampur& District Bijnor, Uttar

Pradesh. The road connectivity to the site is through an existing metalled road. The required

raw materials would be transported through the metalled road connected to the site only.

The molasses for the ethanol plant would be available from within the complex only as the

promoters of the project have sugar mill of 14000 TCD capacity. The external molasses

required would be transported through the molasses tankers and the molasses would be stored

in the molasses storage tanks at site. Similarly, around70 % of the fuel requirements would be

met in-house from the concentrated spent wash. The remaining fuel requirements would be

met through biomass/coal which would be transported at site through covered trucks. The

alcohol would be transported to various destinations through alcohol tankers only. The

company would make adequate arrangements for the parking of trucks at site, separately. In

all, the parking arrangements for 50 commercial vehicles would be made at site.

4.4 Storage of Raw Materials

The molasses would be stored in molasses tanks for 30 days capacity. Adequate number of

molasses tanks would be constructed near the process area. Chemicals would be stored in

HDPE bags/cans and would be kept in storage shed having a surface area of more than 1000

sq. meters. The chemicals storage shed would be completely impervious in construction. Fuel

for boiler furnace i.e. biomass/coal would be stored in open area and partially in covered area

with a storage capacity of 15 days.

Grains would be stored in silos. The industry would construct silos @ 3000 MT capacity for the

storage of grains required for the 100 KLPD grain based plant.



Page 28

4.5 Fuel Requirements for Boiler

Dhampur Sugar Mills Ltd.would be installing 7.5 MW cogeneration power plant along with the

Ethanol Plant. The industry would generate power through incinerator boiler of 75 T/hour of

steam generation capacity with concentrated spent wash and bagasse or coal as fuel in the

ratio of 70 % : 30 % respectively. The daily fuel requirements for the 75 TPH boiler furnaces

would is given below;

S.No.

Item Unit FuelRequirements forthe 75 TPH Boiler

FuelRequirements forthe 40 TPH Boiler

Total

1. ConcentratedSpent Wash

MT/day 600 300 900

2. Bagasse MT/day 330 170 500

3. Coal MT/day 200 100 300



Page 29

CHAPTER – 5

PRODUCTION



of 10.5 MW (3 MW &7.5 MW new)capacity within the existing premises located at Village

Alhaipur, Tehsil Dhampur, district Bijnor, Uttar Pradesh. The company is already having


be operational for 365 days in a year.

5.1 Production from Molasses/grain based Distillery

Phase wise daily production of products and by-products from the distillery plant is given below;

S.No.

Item Unit Existingcapacity

Proposedexpansion

Totalcapacity

1. IndustrialAlcohol/Ethanol/ENA

KL 200 150 350

5.3 Production from Cogeneration Power Plant

Phase wise daily production of power and steam from the cogeneration power plant is given

below;

S.

No.

Item Unit Existingcapacity

Proposedexpansion

Totalcapacity

1. Electrical Power MW 3.0 7.5 10.5

2. Steam MT/Day 960 1800 2760



Page 30

CHAPTER – 6

ENVIRONMENTAL MANAGEMENT AND POLLUTION CONTROL



of 10.5 MW (3 MW &7.5 MW new)capacity within the existing premises located at Village

Alhaipur, Tehsil Dhampur, district Bijnor, Uttar Pradesh. The company is already having


be operational for 365 days in a year. During the operation of the distillery unit and the

cogeneration power plant, environmental pollution would be generated from different sources.

The industry would adopt the latest technologies for the abetment of pollution generated by the

production process.

6.1 Water Requirements

The impending water uses and consequent water pollution may be because of the following;

a) Process and dilution water

b) Boiler feed water make-up

c) Cooling water make-up

d) Washing

e) Water treatment plant maintenance

Process and dilution water

Average fresh water requirement on this account after the proposed expansion to 350 KLPDwill

be around 1700 m3/day and 750 m3/day treated water will be used for dilution. This figure is

after adjusting for all recycle and reuse potential of various streams. No effluent will result out

of these.

Boiler feed water make-up and boiler blow-down

The industry’s overall boiler feed water requirement will be about 385 m3/day. Boiler water

requirement will be met through fresh treated water. The maximum DM water required would be

385 m3/day. The blowdown, contributing to wastewater generation will be about 25 m3/day.

Cooling water make-up and blowdown



Page 31

The cooling water throughput rate after the proposed expansionwill be a maximum of 12000

m3/hour. Around 1.25 % water is lost in evaporation, drift, and blow-down losses.Cooling tower

make-up requirements would be partially met with MEE condensate and Spent lees, after its

treatment in CPU. Thus, fresh make-up water requirement for cooling towers would be 1090

m3/day.

Washing

The wash water requirement (for washing of fermenters and floor) will be about 40 m3/day.

Overall water requirement and wastewater generation

The industry will use ground water for meeting the fresh water requirements. Total average

water consumption by the project is summarized below;

S.

No.

Purpose ExistingRequirement

(m3/day)

Proposedexpansion(m3/day)

TotalRequirement(m3/day)

1. Process & dilution water 1400 1050 2450

2. Cooling water including MEE 1820 1255 3075

3. Washing Requirements 20 20 40

4. Boiler makeup water 220 165 385

5. DM Plant Maintenance 50 50 100

Total 3510 2540 6050

Different sources generating effluents for recycling of water are given in following table:

S.

No.

SourceGenerating Effluent Existing(m3/day)

Proposedexpansion(m3/day)

Total(m3/day)

1 Spent Lees 200 150 350

2 MEE Condensate 1130 845 1975

3 Washing effluent 20 20 40

4 Cooling tower blow down 450 325 775

5 DM Plant Reject Water 50 50 100

6 Boiler Blow Down 15 10 25

Total 1865 1400 3265

Losses @ 15 % 490

Treated effluent available for recycling 2775



Page 32

Fresh Water Requirements: Out of 6050 KLD water requirement, 3275 KLD would be fresh

water and 2775 KLD water requirement would be met from recycling of effluent. Total Water

Balance of the plant after expansion is given below table:

Table:- Water Balance after Expansion

S.

No.

Purpose Total Requirement(m3/day)

Fresh Water(m3/day)

Recycled Water(m3/day)

1. Process & dilution water 2450 1700 750

2. Cooling water including MEE 3075 1090 1985

3. Washing Requirements 40 0 40

4. Boiler makeup water 385 385 0

5. DM Plant Maintenance 100 100 0

Total 6050 3275 2775

6.2 Effluent Generation

The proposed expansion of the molasses based distillery process will result in generation of

following types of effluents from the process operations;

a) Spent Wash from Distillation Process : The project would result in generation of spent

wash from the distillation process. Spent wash @ 2800 m3/day would be generated after

the expansion of distillery plant @ 350 KL/day. Whole of the spent wash would go to multi-

effect evaporation system for further concentration. During this process Conc. Spent wash

having solids concentration of around 60 % would be generated @ 825 KL/day. The

concentrated spent wash would be used as fuel in the boiler furnace alongwith coal as fuel

in the ratio of 70 : 30 respectively.

b) Condensates from Process and MEE : After expansion, the project would result in

generation of process condensates (spent lees) from the distillation process and multiple

effect evaporation condensates. Spent lees @ 350 m3/day would be generated and MEE

condensate @ 1975 m3/day would be generated. A part of the condensates would be used

in the process for molasses dilution and the remaining after treatment would be used for

makeup water of cooling towers.

c) Effluent from other processes : Besides the above mentioned streams, effluent would be

generated from misc. other streams such as – floor/fermenter washing effluent @



Page 33

40m3/day, cooling towers blow down @ 775 m3/day, D.M. plant reject @ 100 m3/day and

boiler blowdown @ 25 m3/day. This effluent would be moderately polluted and after

treatment would be used in cooling tower makeup & dilution.

The details of effluent generation from each unit are as given below;

S.

No.

Purpose Existingcapacity(m3/day)

Proposedexpansion

(m3/day)

Totalcapacity(m3/day)

1. Molasses based distilleryprocess

1.1 Spent Wash 1600 1200 2800

1.2 Spent Lees 200 150 350

1.3 MEE Condensate 1330 845 2175

1.4 Washing effluent 25 25 50

1.5 Cooling tower blow down 450 325 775

1.6 Boiler blow down 15 10 25

6.3 Air Pollution Generation

The air pollution will be due to combustion emissions released by the boiler furnace attached to

the 75 TPH& 40 TPHincineration boiler. The boiler furnace, AFBC type, will use chiefly

concentrated spent wash and biomass/coal as fuel in the ratio of 70 % : 30 %. with a maximum

consumption of about 40.0 MT/hour.

The critical SPM concentration in the flue gas will be less than 30.0 g/Nm3. Majority of the

particulates (about 60-70%) will have sizes in the range of 2-10 m. The emissions are

expected to have temperature in the range of 140-150C.

As per the statutory norms (as applicable to the industry), the flue gas emission shall not have

SPM levels (in the stack) exceeding 50 mg/Nm3. Additionally, the stack height requirements for

discharge of emissions will need to be complied with.

6.4 Solid Waste Generation

Solid waste generated would be yeast sludge and ash from the boiler. Yeast sludge will

generate @ 840 MT/Day.The boiler furnace will result in maximum ash generation @ 100

MT/Day.The following are the management.



Page 34

Yeast sludge & ash will be used in bio-composting plant.

Surplus ash from the boiler would be supplied / utilized as per CPCB/MoEF&CC

guidelines.

6.5 Hazardous Waste Generation

The plant facility will result in generation of about 3.5 KL/year of spent oils (lubricants and

transformer oil), which will be stored on site and sold to authorised recyclers.

6.6 THE POLLUTION CONTROL SYSTEM

6.6.1 Wastewater Treatment System

The industry would install multiple effect evaporators for the treatment of spent wash generated

from the proposed expansion unit. Whole of the spent wash after decantation would be sent to

the MEE for concentration of solids. The details of the MEE for spent wash are as given below;

Multiple Effect Evaporation

The multiple effect evaporation system would be designed to handle the total spent wash @

3000 m3/day, after the proposed expansion. The multiple effect evaporation system will have

two stages. The spent wash generated from the distillation process would be fed to two stage

evaporation system. The MEE would be having two stages and would be integrated with the

main ethanol plant. In stage I, the MEE system would concentrate the solids from 18.0 % w/w

to 25.0 % w/w. In stage II, the evaporation system would increase the concentration of solids

from 25 % to 60 % w/w. The vapours evolved would be condensed in the condensers and

collected in a collection tank. Some part of the condensate would be used in slurry preparation

and balance after treatment in the condensate polishing units would be reused in the cooling

tower for makeup water.

Treatment of Condensates

After expansion, out of the total quantity (2325 m3/day) of spent lees and condensates

generated, 750 m3/day would be used in the molasses dilution preparation process of the

ethanol plant. The remaining condensates& other effluent i.e. 1985 m3/day after treatment

would be used in the makeup of cooling towers. The condensates would be treated in a

condensate polishing unit consisting of anaerobic digestion, aeration, clarification, sand



Page 35

filtration and activated charcoal filtration before its final reuse in cooling water makeup. Industry

would install a CPU unit of 3000 m3/day for the treatment of condensates& other effluents.

Spent Wash Storage Lagoon

The industrial unit will provide spent wash storage lagoon of 15 days capacity. In all the

capacity of spent wash storage lagoon would be a maximum of 16000 m3. The spent wash

storage lagoon would be made impervious with HDPE lining below the concrete surface of the

lagoon for prevention of ground water pollution from any possible leachate. The spent wash

storage lagoon would be used in case of repair of the MEE or any other unforeseen

emergencies.

6.6.2 Air Pollution Control System

The air pollution will be due to combustion emissions released by the boiler furnace attached to

the proposed 75 TPH boiler. The boiler furnace will use chiefly spent wash and coal/bagasse

as fuel, with a maximum consumption of about 40.0 MT/hour.

Bag filters will be provided to spent wash incineration boiler for pollution control to control

particulate matter concentration within the CPCB prescribed limits. Stack height will be

provided as per CPCB norms. Bag filters are used as dust collector as the ash particle sizes

are 20 microns (80% of the qty.) The air to cloth ratio is limited to less than 0.5 m3/m2/min -

0.7 m3/m2/min. The bag filter shall be designed to provide an outlet dust concentration level of

50 mg/Nm3 with the boiler operating with concentrated spent wash and bagasse as fuel.

Ambient air quality and stack emission is regularly monitored to keep check on emissions.

Same will be continued in future. Green belt has already developed and the industry is

continuing developing green belt which will help in attenuating the pollutants emitted by the

plant.

Maximum dust content in flue gases at bag filter outlet will be 50.0 g/Nm3. The emissions are

expected to have temperature in the range of 150-1900C.

As per the statutory norms (as applicable to the industry), the flue gas emission shall not have

SPM levels (in the stack) exceeding 150 mg/Nm3. Additionally, the stack height requirements

for discharge of emissions will need to be complied with the applicable norms of CPCB.

DG Sets: The industrial have one DG set of 750 kVA as backup to power supply. The DG set

is housed in an acoustic chamber. The combustion emission outlet, of the DG set, is provided

with a muffler along with a minimum stack height as per the applicable norms of CPCB.



Page 36

6.6.3 Ash management

The air pollution control system, for the new boiler furnace, will comprise of;

a) Ash vessels

b) Conveying pipes

c) Ash silo

d) Ash storage

e) Ash disposal

This ash handling will be totally enclosed system. The ash handling system shall be designed

to take care of 100% fuel burning. Ash collected from the bottom of furnace (bottom ash) and

the ash collected in the air heater hoppers and Bag filters (air pollution control system) hoppers

will be taken to an ash silo through a pneumatic conveying system. Ash silo will have the

capacity of storage for 1 day of ash. The ash from the silo will be unloaded through the ash

conditioner and stored on land. This ash will be finally used in bio composting plant.

6.6.4 Bio Composting Plant

The factory is working on strong principle of Recycle - Reuse - Reduce concept. In 2008, the

bio-compost unit was established where Press Mud, a by-product of the sugar manufacturing

process, is converted to Bio-fertilizer, utilizing the distillery spent wash, thereby converting

waste to wealth.The industry has its own bio composting plant spread over an area of 16 Acers

in Dhampur, Bijnor. Press mud from existing sugar mill is stored in triangular shaped rows

known as windrows.Spent wash is sprayed on each windrow at specific intervals. It takes

typically 60 days to complete the composting cycle. The Plant produces bio-fertilizer 15,000

Tonnes Per Annum.



Page 37

CHAPTER – 7

PROJECT ESTIMATES

ESTIMATED OVERALL PROJECT INVESTMENT

The estimated cost of project for the expansion of the 200 KLPD to 350 KLPD distillery project and

Incinerator Boiler based cogeneration of 10.5 MW(3 MW existing &7.5 MW new ) of power would about

Rs. 115.0 Crores.



Page 38

CHAPTER – 8

CORPORATE SOCIAL RESPONSIBILITY

The company has constituted a Corporate Social Responsibility Committee as per the section 135 (1)of Companies Act, 2013. Thecomposition of the Corporate Social Responsibility Committee is asfollows:

a. Shri V.K Goel, Chairman

b. Shri GauravGoel, Member

c. Shri Ashwani K Gupta (Independent Director) , Member

Obligation of Dhampur Sugar Mills Limited (DSML) under CSR during FY 2016-17 is NIL.

Obligation of DSML under CSR during FY 2017-18 is Rs. 250 Lakhs.

DSML has already identified Projects for CSR activities. Expected Cost of Activities along with actualcost incurred till now are summarised as under:

CSR PROJECT DETAILS/ACTUAL EXPENCES: (Rs. In Lakhs)

Project TotalBudget

Budget till31/3/18

ExpensesIncurred a

up to31.10.2017

Education & Vocational Training for underprivileged

a. Skill Development Centre in GreaterNoida

350 175 55

b. Hall in Intermediate School(Bareilly)40

40 NIL

Health & Medical-PadmavatiSinghania Research Institute

44 44 44

Sports-Support to under privileged for their livelihood

45 45 9

Upgradation/Renovation of Ayurvedic DispensaryShri ShyamManoharDharmarthAushdhalayaBareilly

30 30 NIL

Other Projects 25 25 NIL

Total 534 359 108

The company had roped in an NGO Social Empowerment and Economic Development Society(SEEDS) for evaluation of the Skill Development Centres project and for further monitoring andimplementation of the project. The Project has already commenced and is expected to be completed by



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June 18 with total cost of project of Rs 700 Lakhs and the DSML shall contribute 50% i.e. Rs.350 Lakhs

The Company has been promoting sports for all for a long time and benefitting the unprivileged boysand girls to reach international arena in the sports and thereby resulting in improvement of villagechildren and their family. A number of children are playing at National and International Level in Squashand have earned proud for the Country and themselves. The company is supporting them forparticipation in National and International tournaments by way of providing them all means like travel,stay and sports equipment and also proving them world class training.

The Company will be building a Hall in the intermediate School at Bareilly which will help indevelopment of physical health of students.

The company is also finalising renovation and upgradation of an Ayurveda dispensary at Bareilly for itscomplete revamping into a full-fledged dispensary, which will provide health services to the poor andneedy persons.

Date post:	27-Jul-2020
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EXPANSION OF EXISTING DISTILLERY PLANT FROM 200 …...Nearest Airport Jolly Grant, Dehradun (130 km...

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