Detailed Project Report: Integrted Grain Based Distillery

DETAILED PROJECT REPORT
FOR
INTEGRTED GRAIN BASED DISTILLERY
SUITABLE TO PRODUCE 2 x 45,000 LPD OF

ENA/ETHANOL/RECTIFIED SPIRIT/MALT SPIRIT WITH
2 X 3.0 MW CAPTIVE POWER PLANT ALONG WITH 8000
CASES/DAY OF IMFL/IMIL BOTTLING UNIT
SUBMITTED BY
STARTLIGHT ENERGY PVT. LTD.

KALAHANDI, ODISHA
CONTENTS
CHAPTER TITLE PAGE NOS.
EXECUTIVE SUMMARY 1-3
1.0 INTRODUCTION 4-5
2.0 PROJECT LOCATION 6 - 12
3.0 PROCESS DESCRIPTION 13 - 26
4.0 RAW MATERIALS 27 - 28
5.0 PRODUCTION 29 - 30
6.0 ENVIRONMENTAL MANAGEMENT AND POLLUTION 31 - 48

CONTROL
7.0 PROJECT COST ESTIMATE 49 - 51

Starlight Energy Pvt. Ltd.
SUMMARY
1.0 Starlight Energy Pvt. Ltd. (SEPL) is a company registered under Indian Companies Act, 1956
having its registered office at Village Goud Sargiguda, Taluka Junagarh, Dist Kalahandi,
Odisha.
2.0 The company is planning to set up a 2 x 45 KLPD capacity grain based distillery unit having 2 x
3.0 MW cogeneration power plant alongwith around 8000 cases/day of IMFL/IMIL bottling unit
at Village Goud Sargiguda, Taluka Junagarh, Dist Kalahandi, Odisha.
3.0 The project is planned to be established in two phases. In phase 1, the company would install a
45 KLPD grain based distillery unit having 3.0 MW cogeneration power plant along and around
8000 cases/day of IMFL/IMIL bottling unit. After the commissioning of the phase 1, the
promoters of the project would implement the phase 2 having identical project of 45 KLPD grain
based distillery unit having 3.0 MW cogeneration power plant alongwith additional around 8000
cases/day of IMFL/IMIL bottling unit.
4.0 Kalahandi district occupies the Southwestern portion of Orissa and is situated at 20o4’58.8’’ N
latitude and 82o12’00’’ E longitude. Kalahandi district has an area of 8,364.89 sq.km and ranks
7th among the 30 districts of Orissa. Forest occupies 4,964 of the total geographical area of the
district, i.e. not cultivated area of the District in the year 1993 is 375752 Hect. The district has
two distinct physiographic regions, the plain lands and the hilly tracts. The plan region runs
Southward upto Bhawanipatna and then westward through Junagarh and Dharmgarh and then
further up to the boundary of the district. The plains cover about 59 percent of the total area of
the district. The hilly tracts are mostly located in the south western part of Bhawanipatna sub
division. Some of the hilly regions are covered with dense forest.
5.0 The average annual rainfall of the district is 1378.20 mm. There are large variations in the day
and night temperature. The summer seasons starts from the beginning of March. May is the
hottest month when the maximum temperature is about 45 oC. December is the coldest month,
as the mean daily minimum temperature is recorded at 11 oC. Relative humidity is generally
higher from June to December.
Detailed Project Report – 2 x 45 KLPD capacity Grain Based Distillery Unit, 2 x 3.0 MW Cogeneration Power Plant and 1
8000 cases/day of IMFL/IMIL bottling
6.0 The district has five types of soils. The area on the river bank of Udanti, Utei and Sagada are
alluvial sandy and sandy loam spills. Tel, Indravati which form the tributaries of large rivers like
Mahanadi and Godavari are amongst the principal rivers of Kalahandi. Bauxite, Graphite,
Manganese, Iron and Quartz are some of the minerals available in the district.
7.0 The promoters of the project are already having more than 90 acres of land at village Village -
Goud-Sargiguda, Taluka Junagarh, Dist. Kalahandi. Out of this, the promoters of the project
would yearmark 40 acres of land for the proposed 2 x 45 KLPD grain based distillery project.
The benefits of the location are as below;
 Required raw material is abundantly available in the nearby adjoining area.
 Raw materials can also be easily procured from grain surplus nearby states such as
Chhatisgarh, West Bengal, Jharkhand
 Good availability of water
 Well connected by road/rail network
 Proximity to spirit and ethanol consuming market
 Manpower available for industrial purposes
8.0 The grain based distillery process will have process steps namely - grains receiving and
storage, grains handling and milling, slurry preparation/liquefaction, saccharification and
instantaneous fermentation, HIFERM fermentation, multi-pressure distillation, decantation,
multi-effect evaporation, spirit storage.
9.0 The industry would install 3.0 MW extraction cum condensing turbine for the cogeneration
power plant. The industry plans to install a 30 TPH capacity fluidized bed boiler (FBC) for the
production of 3.0 MW of cogeneration of power with steam. Biomass would be used as fuel for
the boiler furnace.
10. The industry would install 2 x 300 m3/day water treatment plant (D M plant), 2 x 1500 m3/day
cooling towers, two D G sets of 500 KVA capacities as a part of the utilities.
11. The distillery will use grains such as broken rice, maize, bajra, jowar and other starch
containing grains etc. as basic raw material. Besides this, processing chemicals would be used
for the production of ENA/RS/ethyl alcohol. The daily fuel (biomass) requirements for the 30
TPH boiler furnace of the cogeneration power plant would be around 5.5 MT/hour or 160
MT/day. Biomass is abundantly available in the Kalahandi district.
12. Besides the main products as mentioned before, the company would also produce byproducts
such as CO2, Fusel Oil, DDGS, Corn Oil (in case of maize used as raw material).
13. Fresh water requirements for the industry would be around 750 m3/day for each phase and
total requirements would be around 1500 m3/day. This includes water requirements for grain
based distillery operations, bottling requirements and boiler requirements.
14. During the operation of each phase of the project, waste water in the form of spent wash (355
m3/day), spent lees (100 m3/day), MEE condensate (215 m3/day) would be generated. Besides
this, misc. effluent such as floor/fermentor washing effluent @ 10 m3/day, cooling towers blow
down @ 35 m3/day, domestic effluent @ 9 m3/day, D.M. plant reject @ 15 m3/day, bottle
washing and spillages @ 22 m3/day and boiler blowdown @ 15 m3/day would also be
generated.
15. The industry would install multiple effect evaporators for the treatment of spent wash thereby
making the project as ZERO EFFLUENT DISCHARGE INDUSTRY. The spent less and MEE
condensate would be reused in the process/utilities. The other misc. streams effluent after
treatment would be used on land for irrigation purposes.
16. The estimated cost of project for the Phase 1 for 45 KLPD distillery project, 8000 cases of
bottling of country liquor/IMFL and cogeneration of 3.0 MW of power would be around Rs.
50.00 Crores. The cost does not include the land cost. The estimated cost of project for the
Phase 2 for 45 KLPD distillery project, 8000 cases of bottling of country liquor/IMFL and
cogeneration of 3.0 MW of power would be 25 % more as the phase 2 commissioning would
take atleast 2 years from the date of commissioning of the phase 1.
CHAPTER – 1
INTRODUCTION
Starlight Energy Pvt. Ltd. (SEPL) was incorporated on 20.10.2004 having its registered office at Village
Goud Sargiguda, Taluka Junagarh, Dist Kalahandi, Odisha. The company is having two full time
directors namely Shri Sunil Choudhary & Shri. Dulal Choudhury. The description of the directors is as
below;
1. SHRI SUNIL CHOUDHARY, Director, Age : 44 years

Father’s Name : Late Pawan Kumar Choudhary
Address : F – 9, Civil Township Rourkela – 769004 Orissa, India
Education Qualification : B. E. (ChE) U.S.A University of Louisiana
Experience : 15 years of Industrial Management
2. DULAL CHOUDHURY, DIRECTOR, Age : 62 years

Name: Mr. Dulal Choudhury
Father’s Name: Shri. B Choudhury
Address: Basanti Colony, Rourkela
Education Qualification: B.Com
Experience: 35 Years of Industrial Management
Besides this, the management team comprises of many other senior members. The company is
managed by well - qualified persons having progressive attitude and qualification.
The promoters of the project are already having a small distillery unit, M/s Suidihi Distillery Pvt. Ltd. at
Village Suidihi, Post Lathikata, District Sundergarh, Odisha. This unit is the first grain based unit in the
state of Odisha. The promoters having learnt from the operation of the unit strongly believe that there is
ample scope for a larger integrated grain based distillery in the State of Odisha.
Based on the past experience of the directors of the company, the company is planning to set up a 2 x
45 KLPD capacity grain based distillery unit having 2 x 3.0 MW cogeneration power plant along and
around 8000 cases/day of IMFL/IMIL bottling unit at Village Goud Sargiguda, Taluka Junagarh, Dist
Kalahandi, Odisha. The project is planned to be established in two phases. In phase 1, the company
would install a 45 KLPD grain based distillery unit having 3.0 MW cogeneration power plant alongwith
around 8000 cases/day of IMFL/IMIL bottling unit. After the commissioning of the phase 1, the
promoters of the project would implement the phase 2 having identical project of 45 KLPD grain based
distillery unit having 3.0 MW cogeneration power plant alongwith additional around 8000 cases/day of
IMFL/IMIL bottling unit.
The proposed project shall be catering to the demand of Odisha State and neighboring States where-in
almost all liquor companies like Seagram, Jagatjit, ABD, Radico, USL and many others are
manufacturing their reputed IMFL brand and due to shortage of ENA are importing ENA from other far
away States which is taking time and also incurring losses of Government revenue. Also, the demand
of Ethanol is growing and the government has made it mandatory for blending of minimum 5% Ethanol
in Petrol. The implementation of the project shall be as below:
Phase Project Description Installed Capacity Expected COD

I Integrated Distillery Unit with 45 KLPD with 8000 cases/ day of 15-12-2015
IMFL/IMIL Plant, Biomass Power IMFL/IMIL Bottling Plant and 3.0
Plant- Phase I MW Captive Power Plant
II Integrated Distillery Unit – Phase 45 KLPD with 3.0 MW Captive 15-12-2017
II Power Plant
CHAPTER – 2
PROJECT LOCATION
Starlight Energy Pvt. Ltd. are planning to set up a 2 x 45 KLPD capacity grain based distillery unit
having 2 x 3.0 MW cogeneration power plant along and around 8000 cases/day of IMFL/IMIL bottling
unit at Village Goud Sargiguda, Taluka Junagarh, Dist Kalahandi, Odisha. The company has already
purchased land at the said location for the proposed project.
2.1 About the State : Odisha, formerly known as Orissa is an Indian state on the subcontinent's
east coast, by the Bay of Bengal. It is surrounded by the Indian states of West Bengal to the
north-east and in the east, Jharkhand to the north, Chhattisgarh to the west and north-west
and Andhra Pradesh to the south. Odisha is the 9th largest state by area in India, and the 11th
largest by population. Oriya (officially spelled Odia) is the official and most widely spoken
language, spoken by three quarters of the population.
DISTRICT MAP OF ODIHSA
2.2 ABOUT THE DISTRICT
Kalahandi district occupies the Southwestern portion of Orissa and is situated at 20o4’58.8’’ N
latitude and 82o12’00’’ E longitude. It is bounded in the North by the District of Balangir and
Nuapara, South by the District of Rayagada, West by the District of Nawarangpur and Raipur
(Chhattisgarh) and East by the District of Rayagada and Boudh. The District Headquarters is at
Bhawanipatna town which stands almost to the Eastern border. Kalahandi district has an area
of 8,364.89 sq.km and ranks 7th among the 30 districts of Orissa. Forest occupies 4,964 of the
total geographical area of the district, i.e. not cultivated area of the District in the year 1993 is
375752 Hect. In the same year, 11,602 hectors were left as fallow lands or cultivable
wasteland.
2.2.1 Topography : The district has two distinct physiographic regions, the plain lands and the hilly
tracts. The plan region runs Southward upto Bhawanipatna and then westward through
Junagarh and Dharmgarh and then further up to the boundary of the district. The plains cover
about 59 percent of the total area of the district. The hilly tracts are mostly located in the south
western part of Bhawanipatna sub division. Some of the hilly regions are covered with dense
forest.
2.2.2 Physiographics : The district has two sub-divisions, 12 Police Stations, five Tahsils, 13
Blocks, 1 Municipality, two N.A.Cs., 1 Treasury, 5 Sub-Treasuries and 195 Gram Panchayats
of 2185 villages.
2.2.3 Rainfall and Climate : The climate of the district is of extreme type. It is dry except during
monsoon. There are large varieties of day and night temperature. The average annual rainfall
of the district is 1378.20 mm. The variation in the rainfall from year to year is not large. The
monsoon starts late in June and generally lasts up to September. 90% of the rainfall is received
from June to September. August is the month with more number of rainy days. About 28 % of
rainfall is received during this month. Drought is normal feature of this district.
2.2.4 Temperature and Humidity : There are large variations in the day and night temperature. The
summer seasons starts from the beginning of March. May is the hottest month when the
maximum temperature is about 45 oC. The temperature drops down with the onset of monsoon
towards the second week of June and throughout the monsoon the weather remains cool.
December is the coldest month, as the mean daily minimum temperature is recorded at 11 oC.
Relative humidity is generally higher from June to December. It is lower (27 %) in the non-
monsoon months. During August, it is the highest (70 %) and March is the month lowest when
it is lowest (27 %). Northern plateau (at 2150 MSL) of Sunabeda in Komna Block of Nuapara
district has a cooler climate so also the Rampur area (at 2700 Feet MSL).
2.2.5 Soil and Land Classification : The district has five types of soils. The red laterite soil which is
different in phosphorus and nitrogen is found all over the district. Occurrence of heavy soil is
common mostly under the foothill and hillocks in Bhawanipatna and Dharmgarh Tehsil. It is rich
in potassium and Nitrogen but poor in Phosphorus. Sandy loan soil is seen in Lanjigarh and of
the Bhawanipatna Tahsil. The area on the river bank of Udanti, Utei and Sagada are alluvial
sandy and sandy loam spills. The fertility of soil in Dharmgarh and Jaipatna Tahasil areas is
high.
The red soil, black clay, sand loam, yellow soils occur in the district with following percentages;
Red soil - 31.68%
Black clay (heavy) - 13.90%
Clay & sandy loam - 54.44%
2.2.6 Rivers : Tel, Indravati which form the tributaries of large rivers like Mahanadi and Godavari are
amongst the principal rivers of Kalahandi. However, Tel is by far the longest and most
important river of the District. The tributaries of river Tel and Moter, Hati Sagada, Ret, Uttei,
Raul, Sundary, Undanti lands are also the important other rivers. Most of the rivers are rained
and go dry during summer.
2.2.7 Minerals : Bauxite, Graphite, Manganese, Iron and Quartz are some of the minerals available
in the district. Of these, only Bauxite and Graphite has been commercially exploited. Bauxite is
found in Lanjigarh Block at Niamgiri in large scale. Manganese deposits are found mostly in
Khariar Plateau of Nuapada District and Iron ores in places adjoining Koraput district. All these
ores are of poor grade and are not considered suitable for economy exploitation. According to
the National Council of Applied Economic Research, the known deposits of minerals in the
district cannot by themselves sustain heavy mineral based industry.
MAP OF KALAHANDI DISTRICT
KALAHANDI DISTRICT AT A GLANCE
S. NO. Parameter
1. Total Geographical Area of the district 8364 sq. km.
2. Area under Forests 2538.01 sq. km. (32 %)
3. Area under agriculture (including forest land) 7920 sq. km.
4. Total population of the district 1573054
5. Sex ratio (female : male) 1003 : 1000
6. Literacy Ratio 60.22 %
7. Population Density 199/sq. km.
8. Administrative setup
Number of Sub-Division 2
Number of Tahsils 7
Number of Municipality 1
Number of N.A.C. 2
Number of Blocks 13
Number of Police Station 12
Number of Gram Panchayat 273
Total Number of villages 2236
No. of Inhabited Villages 2099
9. Land Data
Govt. Land 229337.58 hectares
Forest Land 253801 hectares
Non-forest Land 200681.86 hectares
Gochar/Communal/Nalas 18618.99 hectares
10. Total cultivable area 393550 hectares
Area under paddy cultivation 183000 hectares
Total irrigable area (through any means other 114840 hectares
than rain water)
11. Agricultural economic pattern
Marginal farmers (below 1 hectare) 64751
Small Farmers(1 to 2 hectare) 42516
Semi medium farmers(2 to 4 hectares) 35481
Medium farmers(4 to 10 hectares) 17548
Large Farmers (10.09 hectares and above) 1791

12. Crops production (MT/annum)
Paddy 46497.33
Wheat 6.46
Maize 93.10
Ragi 92.76
Mung 99.14
Biri 104.58
Kulthi 161.93
Til 9.53
Groundnut 131.51
Mustard 10.80
Potato 120.47
Sugarcane 3317.52
13. % of village having electricity supply 62.96
2.3 SELECTION OF SITE
The basic criteria for the selection of site for the grain based distillery project are as below;
 Raw material availability

 Raw material cost
 Transportation cost
 Accessibility to markets within and nearby states
 Availability of water
 Availability of land in abundance
 Connectivity of road/rail network.
 Market for final Product
Based on the above assumptions, following states are fit for the installation of the grain based
distillery projects;
• West Bengal
• Punjab
• Haryana
• Odisha
• Jharkhand
• Chhattisgarh
Advantages of the location at Village - Goud-Sargiguda, Taluka Junagarh, Dist. Kalahandi

(Odisha) for setting up 2 x 45 KLPD grain based distillery project.
The promoters of the project are already having more than 90 acres of land at village Village -
Goud-Sargiguda, Taluka Junagarh, Dist. Kalahandi. Out of this, the promoters of the project would
yearmark 40 acres of land for the proposed 2 x 45 KLPD grain based distillery project. Besides this,
the other benefits of the location are as below;
 Required raw material is abundantly available in the nearby adjoining area.

 Raw materials can also be easily procured from grain surplus nearby states such as
Chhatisgarh, West Bengal, Jharkhand
 Good availability of water
 Well connected by road/rail network
 Proximity to spirit and ethanol consuming market
 Manpower available for industrial purposes
CHAPTER – 3
PROCESS DESCRIPTION
3.0 Starlight Energy Pvt. Ltd. are planning to set up a 2 x 45 KLPD capacity grain based distillery
unit having 2 x 3.0 MW cogeneration power plant alongwith around 8000 cases/day of
IMFL/IMIL bottling unit at Village Goud Sargiguda, Taluka Junagarh, Dist Kalahandi, Odisha.
The company would be installing the project in two phases. In phase 1, 45 KLPD capacity grain
based distillery unit having 3.0 MW cogeneration power plant alongwith additional around 8000
cases/day of IMFL/IMIL bottling unit would be installed. After the commissioning of the first unit,
the company would start the installation of the similar second unit in phase 2.
3.1 Grain based Distillery Process/Operations
The grain based distillery process will have following steps/operations. Similar process steps
would be followed in both the phases. Accordingly, common process steps/operations for both
the phases of the distillery project are described below;
a) Grains receiving and storage

b) Grains handling and milling
c) Slurry preparation/liquefaction
d) Saccharification and instantaneous fermentation
e) HIFERM Fermentation
f) Multi-pressure distillation
g) Decantation
h) Multi-effect evaporation
i) Spirit storage
Figure 1 shows the schematic flow diagram of the process operations.
3.1.1 Grain receiving and storage
Grains such as broken rice/rotten rice, rotten wheat and other edible grains are procured from
various sources, and are stored in gunny bags in covered storage godowns. Grains may also
be stored into silos.
3.1.2 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.
3.1.3 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.
3.1.4 Saccharification and instantaneous fermentation
Yeast seed material is prepared in Prefermentor by inoculating sterilized mash with yeast.
Optimum temperature is maintained by circulating cooling water. The contents of the
Prefermentor 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 Prefermentor.
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.
3.1.5 HIFERM 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. The fermenter temperature is maintained at around
30 – 32oC by forced recirculation flow through plate heat exchangers. We have given a
provision for spent wash recycled to Fermentation depending on solids concentration in
fermented wash.
3.1.6 ECOFINE – MPR WE 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 Thermosyphon reboiler. 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
Thermosyphon reboiler. 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 1:9 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
Thermosyphon reboiler. 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.
3.1.7 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 30-32% 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 35-40% 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).
3.1.8 ECOVAP 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 35-40% 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
• 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 the
vapors.
3.1.9 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 Rotary Tube Bundle is enclosed in an insulated dryer housing and its
outer flights are fixed. Dry saturated steam is to be supplied to the tube bundle through
rotary joint at one end & the condensate is discharged through rotary joint mounted on
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 Control panel.
3.1.9 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.
Fiber/Husk
Grain Milling Section
Dirt/Dust
Thin slops
Fresh Water Liquefaction
Steam
Fresh Water Fermentation CO2
Steam Condensate
DM Water
Spent Wash
Multi-pressure Distillation
Steam Spent Lees
Alcohol
Thin Slops
Decanter Wet Cake
Multi Effect Evap.
Thick Syrup
Multi Effect Evap.

Steam Steam Condensate
Condensate
Steam Dryer DDGS

(Wet Cake and Thick syrup)
Figure 3.1 : Process Flow Chart of Grain based distillery
3.2 Bottling of country liquor/IMFL
Starlight Energy Pvt. Ltd. are planning to set up 8000 cases per day of bottling plant (each in
phase 1 and phase 2, totaling 16000 cases per day after the commissioning of both the
phases) for the production of Indian Made Foreign Liquor and country Liquor at Village Goud
Sargiguda, Taluka Junagarh, Dist Kalahandi, Odisha.
The process would involve mixing of ENA with DM water along with liquor essence blends,
caramels, and colours in stainless steel blending tanks. The ratio of spirit to DM water would be
controlled by proof requirements in the end product. For example, one case (equivalent to 9
litres) of IMFL (75% proof) requires 4 litres of spirit and 5 litres of DM water. The blend would
be subjected to physical filteration. Subsequently, the blend would be filled in bottles. The
bottles would be labeled, packed, and stored for final dispatch. The industry would install 4
bottling lines in phase 1 and similarly 4 bottling lines in phase 2 would be installed for the
production of Indian Made Foreign Liquor and country Liquor.
3.3 Co-generation Power Plant
Starlight Energy Pvt. Ltd. are planning to set up 2 x 3.0 MW biomass based cogeneration
power plant (3.0 MW each in phase 1 and phase 2, totaling 6 MW after the commissioning of
both the phases) for the production of power and extraction of steam for distillery process use
at Village Goud Sargiguda, Taluka Junagarh, Dist Kalahandi, Odisha.
The industry would install 3.0 MW extraction cum condensing turbine for the cogeneration
power plant. Once the industry commissions the phase 1 for whole of the project, the
promoters of the project would install another 3.0 MW cogeneration power plant of similar
configuration.
The cogeneration power plant is divided in three parts, namely;

Boiler & Auxiliaries
Turbine & Auxiliaries
Generator & Auxiliaries
3.3.1 Boiler & Auxiliaries
Boiler : The industry plans to install a 30 TPH capacity fluidized bed boiler (FBC) for the
production of 3.0 MW of cogeneration of power with steam. FBC boiler is most suitable
technology for the biomass fuel to be used. When air passes upward at low velocities through a
mass of finely divided solid particles (such as ash & crushed refractory) the particles are not
disturbed. As air flow is gradually increased, the particles become suspended. Further increase
in the air flow gives rise to bubble formation and vigorous turbulence. The bed of solid particles
has the same characteristics of the liquid and thus the bed is termed as Fluidised Bed.
Combustion of fuel in this bed is termed as Fluidised Bed Combustion (FBC). The boiler would
be having other auxiliaries as described below;
Drum : The feed input, separation of steam and water & blow down are all carried through the
drum.
Furnace : It is the primary part of boiler where the chemical energy available in the fuel is
converted to thermal energy by combustion. It is the designed for efficient & complete
combustion.
Super Heater : These are meant for raising the steam temperature above the saturation
temperature to a maximum of around 5500 C (due to the metallurgical problem, the percentage
of heat to super heater is approx 30%).
De-Super Heater : To control the super heater temperature & always try to maintain the steam
temperature constant during variation of load, de-super heater is used.
Draft System : The combustion process in a furnace can take place only when it receives a
steady flow of air & has the combustion gases are continuously removed.
Economizer : The economizer absorbs heat from the flue gas mainly as sensible heat to the
feed water. By this, the efficiency of boiler is improved.
Water Wall/Evaporator : Where water converted into steam by latent heat addition.
Support : All modern boilers are top support units. The hanger rods are designed for the direct
tensile stress resulting from the weight of units & the bending stress from the pressure part
expansion.
Soot Blower : Deposits result from combustion of husk & relatively smaller extent from oil.
Means have to be provided to prevent an accumulation of deposit from chocking the boiler gas
passes & to maintain boiler heating surface in a suitably clean condition for effective heat
transfer whilst on load. Steam is used for soot blowing.
Air Heater : It is now an essential boiler auxiliary because hot air necessary for rapid & efficient
combustion in the furnace & also for the husk & to recover waste heat from the flue gas to
increase boiler efficiency.
Primary Fluidising Air Fan : It is used for fluidising the bed of fuel and giving the upward
movement.
Forced Draft Fan : To take air from atmosphere at ambient temperature to supply essentially
the combustion air required, in addition to fluidising air.
Induced Draft Fan : To evacuate the gases out of the furnace & exhaust through the stack.
The ID Fan maintains the negative draft inside the furnace.
Ash Collection : The method used for removal of ash from the flue gas consists of mechanical
dust collector & electrostatic precipitator. The mechanical dust collector removes the coarser
particles through cyclones.The ESP consists of two sets of electrodes. Wires which are
charged at HVDC are called emitting electrodes. The collecting electrodes are in the form of
plates, which are at earth potential.The dust particles in the flue gas get charged while coming
in contact with the emitting electrodes. The charged particles are attracted to the earthed
collecting particles and get discharged and fall down the hopper.Very high efficiency of ash
collection upto 99.90% can be achieved in the ESP
Boiler Feed Pump : It is multistage pump provided for pumping feed water from the deaerator
storage tank to economizer of the boiler. Generally two pumps each of 100% capacity are
provided.
3.3.2 Turbine & Auxiliaries
Turbine : The turbine shall be horizontal, single cylinder, Extraction cum condensing design
coupled to a generator to generate the rated output of 3.0 MW of electricity with the steam inlet
parameters as specified in this specifications. The Steam turbine, gear box, main oil pump with
its interconnecting piping and its supports shall be assembled and aligned on a single skid and
shall be delivered. All the cabling within the skid shall be laid in the metal conduits and shall
be fixed to the base frame with respective junction boxes mounted on the skid. Main
component & associated system of the Turbine are described below;
Casing : It is essentially a pressure vessel, which must be capable of withstanding the working
pressure & temperature of the steam. The casing is supported on each end, with provision to
permit expansion at one end. The fixed blades (Orifice) are supported in the casing.
Rotor : It supports the moving blade.
Blades : These are the most important component of turbine as these are responsible for the
converting heat energy to mechanical.
Gland Sealing System : Glands are used on turbine to prevent or reduce the leakage of steam
air between rotating & stationary components which have a pressure difference with the
atmosphere. If the cylinder pressure is higher than the atmospheric pressure then there will be
a leakage of steam outward (HP sides). If the cylinder is below atmospheric pressure, then
there will be leakage of air (LP side). Steam is generally used for sealing of labyrinth glands.
Condensate System : Water Cooled Condenser which minimizes the water requirement by
85%.
Condenser : It is basically a heat exchanger which condenses the exhaust steam from turbine
into water (Condensate). It helps maintain negative pressure at the turbine exhaust thus
enabling maximum utilization of enthalpy of the steam and thus improving cycle efficiency. An
air cooled condenser shall be provided to reduce the requirement of water.
Condensate Extraction Pump : These are multistage, vertical centrifugal pumps which pump
the condensate from the condenser to the deaerator through the water cooled condenser shall
be provided.
Air Ejector System : Is needed to continuously remove air & other non-condensable gases
from the condenser to maintain vacuum in the condenser. Steam jet air ejectors and vacuum
pumps are used for this purpose.
LP Heater : The condensate pumped by the condensate pump is heated in the LP heater by
steam extracted from the turbine after it has performed some useful work. This improves the
cycle efficiency.
Deaerator : The presence of certain gases like oxygen, carbon dioxide, & ammonia dissolved
in water is harmful because of their corrosive action on boiler metal parts particularly at
elevated temperatures. The condensate is sprayed inside the deaerator and it is heated by the
extraction steam from the turbine. The airs etc are thus liberated from the condensate. The
deaerated condensate thus comes to the storage tanks, from which the boiler feed pump
pumps the condensate to the boiler.
Turbine Oil System : The high pressure hydraulic oil for turbine control, oil for bearing
lubrication of turbine generator are received from the turbine shaft mounted main oil pump.
Start up AC and emergency DC pumps are provided for start up and maintain bearing oil flow
during turbine trip. Turbine Oil Coolers are provided to cool the bearing oil.
Turbine Governing System : The main purpose of governor is to maintain speed of turbine
during fluctuation of load on the generator by varying steam input to the turbine. The governing
system consists of hydraulically operated Control Valves. It helps to start the turbine from rest
to rated speed and synchronizing with the grid. The load on the generator can be controlled in
a pre-determined manner by the control valves. Emergency stop valve is provided to shut off
the steam supply to the turbine completely in abnormal & emergency situation.
3.3.3 Generator & its Auxiliaries
Generator : The generator shall be of CACW, brush less design with horizontal shaft
mounted AC exciter driven by a steam turbine through reduction gearing and fitted
with one PMG on the extended shaft of alternator. Supplier shall clearly specify the
excitation arrangement in case PMG is not applicable. The Generator shall be
capable of delivering the maximum output obtainable from the steam turbine under
any operating conditions at 0.8 power factor lag, 11 kv output with a frequency of 50
Hz. Main component & associated system of the generator are described below;
Stator : The stator houses the armature winding also supports the rotor bearings. The
insulation of the windings is Class “F”, but designed for temp rise for Class “B” insulation.
Rotor : The generator rotor is cylindrical in construction and carries the DC field windings. The
field is normally of 2 or 4 pole design.
Generator Bearing : These are the pedestal type of spherical sealing to show self-alignment &
are support on s separate pedestal on suffering sides & turbine side.
Generator Cooling System : The heat loss in the generator windings are dissipated by air
circulated by the rotor mounted fans. This heat should be taken off for safe operation of the
generator. The air is in turn could be generator air coolers, located at four corners. Water is the
cooling medium.
Generator Excitation System : The DC Power supply to the field winding will be given either
through a static excitation system or through shaft mounted brush-less excitation system. The
control system varies the DC Current to change the terminal voltage or reactive power.
Generator Protection : Generator has to protected from faults occurring within generator
stator or rotor & also from external faults/ abnormal operating condition in the grid which
effected the generator. Various devise are used to detect which can give warning alarm or trip
the unit automatically as required.
3.4 Utilities
3.4.1 Water treatment plant – 2 x 300 m3/day
It is proposed that the water to be used will be received from the river water. The water quality
will require pre-treatment to satisfy the quality required for boiler feed water, process
requirement, and blending during bottling. Treatment will involve sedimentation, sand filtration,
activated carbon filtration, softening and ion exchange treatment (as required for different
process requirements), suitable for quality of water required.
3.4.2 Electrical system
The plant power requirement (including that for power plant auxiliaries) will be about 2.0 MW
each for 2 x 45 KLPD plants. Out of total installed power generation capacity of about 6 MW,
the surplus power, after meeting in-house requirements, will be exported to state grid.
3.4.3 Standby electrical generator
It is proposed to install two 500 kVA diesel generator set to provide standby power in case of
state power supply failure. They would be complete with synchronization panel.
3.4.4 Cooling water – 2 x 1500 m3/hour
The maximum process and power plant cooling water requirement will be 1500 m3/hour for
each of the 45 KLPD distillation units. The cooling tower will be counter/cross flow induced draft
cooling tower with total capacity of about 2 x 1500 m3/hr capacity divided into four cells. The
cooling tower shall be designed for a cooling range of 8°C, and an app roach of 5°C while
operating under the atmospheric wet bulb temperature of about 27°C. The cooling tower shall
be carefully sited such that there is no re-entertainment of the vapors into the cooling tower.
Evaporation and drift loss will depend on season and an average figure will be about 1.65 %.
The cooling tower blow-downs will be approximately 0.1%. Whole of the quantity lost will be
made-up by adding fresh water/treated condensate from the process.
CHAPTER – 4
RAW MATERIALS
unit having 2 x 3.0 MW cogeneration power plant along and around 8000 cases/day of
based distillery unit having 3.0 MW cogeneration power plant and around 8000 cases/day of
IMFL/IMIL bottling unit would be installed. After the commissioning of the first unit, the company
would start the installation of the similar second unit in phase 2. The distillery would be
operational for 330 days in a year.
4.1 Raw Materials Requirements for Grain based Distillery
The distillery will use grains such as broken rice, maize, bajra, jowar and other starch
containing grains etc. as basic raw material. Besides this, processing chemicals would be used
for the production of ENA/RS/ethyl alcohol. Phase wise daily consumption of raw materials for
the distillery plant is given below;
S. Item Unit Phase 1 Phase 2 Total

No.
1. Broken rice, maize, MT 115 115 230
bajra, jowar and other
starch containing
grains etc.
2. Enzymes Kgs. 100 100 200
3. Sodium Hydroxide Kgs. 50 50 100
4. Urea Kgs. 225 225 450
5. Anti-foam agent Kgs. 25 25 50
6. Yeast Kgs. 100 100 200
4.2 Biomass Requirements for Boiler
Starlight Energy Pvt. Ltd. would be installing 2 x 3.0 MW cogeneration power plant alongwith
the distillery unit. The cogeneration power plant would be installed in two phases. After the
commissioning of the first phase, the company would start the installation of the similar second
unit in phase 2.
The daily fuel (biomass) requirements for the 30 TPH boiler furnace of the cogeneration power
plant would be around 5.5 MT/hour or 160 MT/day. Phase wise daily consumption of biomass
for the cogeneration power plant is given below;

No.
1. Biomass consisting of MT 160 160 320
rice husk, cotton
stalk, mustard stalk
etc.
Agriculture occupies a vital place in the economics of Kalahandi District. It provides direct and
indirect employment to around 68 % of the total work force of the district. The total cultivable
area of the district is 391000 hectares covering 49.3 % of the total geographical area of the
District.
In Kalahandi district, there are 93 nos. of rice mills established by different entrepreneurs for
milling paddy with a total capacity 258 MT/H. So the total rice husk generation is around
225000 tonnes/year. The surplus biomass available for the power generation purpose in and
around Kalahandi district is around 300000 tonnes/year, which mainly consists of rice husk and
other crop & agricultural residues. The total power potential available in Kalahandi district is
around 30 MW. Hence the biomass is readily available for the proposed total capacity of 6 MW
(2 x 3.0 MW).
CHAPTER – 5
PRODUCTION
would start the installation of the similar second unit in phase 2. The distillery would be
operational for 330 days in a year.
5.1 Production from Grain based Distillery
Phase wise daily production of products and by-products from the distillery plant is given below;

No.
1. ENA/RS/Ethyl KL 45 45 90
Alcohol/Malt spirit
2. By-products
CO2 MT 40 40 80
Fusel Oil MT 1 1 2
DDGS MT 25 25 50
Corn Oil (in case of MT 2 2 4
maize used as raw
material)
5.2 Production from Bottling Plant
Phase wise daily production of IMFL/country liquor from the bottling plant is given below;

No.
1. IMFL/country liquor Cases 8000 8000 16000
5.3 Production from Cogeneration Power Plant
Phase wise daily production of power and steam from the cogeneration power plant is given
below;

No.
1. Electrical Power MW 3.0 3.0 6.0
2. Steam MT 600 600 1200
CHAPTER – 6
ENVIRONMENTAL MANAGEMENT AND POLLUTION CONTROL
would start the installation of the similar second unit in phase 2.
During the operation of the distillery unit, bottling plant 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 Fresh Water Requirements

6.1.1 Grain Based Distillery Process
The impending water uses and consequent water pollution that would be caused by the grain
based distillery may be because of the following;
a) Process and dilution water
b) Cooling water make-up
c) Washing (fermentor, bottle, floor, etc.)
d) Water treatment plant maintenance
e) Domestic consumption
Process and dilution water

The fresh water requirements in the process (in fermentation, liquefaction, ENA etc.) would be
about 292 m3/day for each unit (45 KLPD) of distillery plant. Besides this, 40 MT/day of direct
steam would be consumed in the process for liquefaction section, in each unit. This figure is
after adjusting for all recycle and reuse potential of various streams.
Cooling water make-up and blowdown

The cooling water throughput rate will be a maximum of 1500 m3/hour for each unit. Around
1.65 % of the total recirculation water is lost in evaporation, drift, and blow-down losses. A part
of the process water generated (215 m3/day of condensate from Multi effect evaporation and
100 m3/day of spent lees) would be reused for the cooling tower makeup water for each of the
unit. Thus, fresh make-up water requirement will be about 285 m3/day. The blow-down rate will
be less than 35 m3/day for each of the unit.
Washing
The wash water requirement (for washing of fermentor and floor) will be about 20 m3/day for
each of the unit. Whole of this water will contribute to wastewater generation.
Water treatment plant maintenance

The D M water treatment requirement is about 300 m3/day (soft water – for boiler, process,
bottling, etc., requirements) for each of the unit. Treatment plant maintenance will generate
about 15 m3/day of reject water for each of the unit. Whole of this water will contribute to
wastewater. The effluent streams may be acidic/alkaline (depending on regeneration of
cationic/anionic ionic exchanger) and will have high TDS. There is no other pollutional
parameter of concern.
Domestic consumption
Some of the water will be required for cooking, drinking, sanitation, etc. Average daily
requirement is expected to be about 10 m3/day, for each of the unit. Of this, less than 90%, i.e.,
~9 m3/day will be obtained as domestic wastewater for each of the unit.
Overall water requirement

Total average fresh water consumption for the grain based distillery project can be summarized
as under;
S. Purpose Phase 1 Phase 2 Total
No.
1. Process & dilution water 292 m3/day 292 m3/day 584 m3/day
2. Cooling water 285 m3/day 285 m3/day 570 m3/day
3. Washing Requirements 20 m3/day 20 m3/day 40 m3/day
4. Water treatment plant 15 m3/day 15 m3/day 30 m3/day
5. Domestic requirement 10 m3/day 10 m3/day 20 m3/day
Total 622 m3/day 622 m3/day 1244 m3/day
6.1.2 Fresh Water Requirements for Bottling Process

The average water requirement for blending during bottling of country liquor/IMFL will be about
25 m3/day, for each of the unit, which will completely be present in final product. There will be
no wastewater generation. Besides this, around 10 m3/day of water would be required for the
bottle washing and equipment washing.

No.
1. Water requirements for blending 25 m3/day 25 m3/day 50 m3/day
2. Washing Requirements 10 m3/day 10 m3/day 20 m3/day
6.1.3 Fresh Water Requirements for Boiler

The average boiler feed water requirement will be about 600 m3/day for each of the boilers, out
of which around 85%, i.e., about 510 m3/day, will be met through return condensate. Thus
about 15 %, of the steam generated, will be either used (in the industrial processes) or lost as
blow-down (in order to maintain desired TDS concentration in the boiler feed water, continuous
or intermittent blow-down of condensate is employed). Remaining feed water requirement will
be met through D.M. water. The D.M. water required for the purpose will be about 90 m3/day
for each of the boilers. The boiler blowdown, contributing to wastewater generation will be a
maximum of 15 m3/day form each of the boiler.

No.
1. Boiler water requirements 90 m3/day 90 m3/day 180 m3/day
6.2 Effluent Generation
The grain 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 @ 355 m3/day would be generated during
from each of the unit during the the production of alcohol @ 45 KL/day. The spent wash
would be sent to the decanter where wet cake @ 45 MT/day would be separated from each
of the unit. Further apart of the thin slops (60 m3/day) would be reused in the process and
remaining 250 m3/day would be treated in multi-effect evaporation system.
b) Condensates from Process and MEE : The project would result in generation of process
condensates (spent lees) from the distillation process and multiple effect evaporation
condensates. Spent lees @ 100 m3/day would be generated and MEE condensate @ 215
m3/day would be generated from each of the unit. Whole of the condensates 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/fermentor washing effluent @ 10
m3/day, cooling towers blow down @ 35 m3/day, domestic effluent @ 9 m3/day, D.M. plant
reject @ 15 m3/day, bottle washing and spillages @ 22 m3/day and boiler blowdown @ 15
m3/day, from each of the two units. This effluent would be moderately polluted and after
treatment would be used on land for irrigation purposes.
The details of effluent generation from each unit are as given below;

No.
1. Grain based distillery process
Spent Wash 355 m3/day 355 m3/day 710 m3/day
Spent Lees 100 m3/day 100 m3/day 200 m3/day
MEE Condensate 215 m3/day 215 m3/day 430 m3/day
Fermentor/floor washing 20 m3/day 20 m3/day 40 m3/day
Cooling tower blow down 35 m3/day 35 m3/day 70 m3/day
Domestic Effluent 9 m3/day 9 m3/day 18 m3/day

D M plant reject 15 m3/day 15 m3/day 30 m3/day
2. Bottling Section
Bottle washing and spillages 12 m3/day 12 m3/day 24 m3/day
3. Boiler Section
Boiler Blowdown 15 m3/day 15 m3/day 15 m3/day
6.3 Air Pollution Generation
The air pollution will be due to combustion emissions released by the boiler furnaces. The
boiler furnaces, AFBC type, will use chiefly rice husk as fuel, with a maximum consumption of
about 5.5 MT/hour for each of the boiler.
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 µm. The emissions are
expected to have temperature in the range of 140-150°C.
As per the statutory norms (as applicable to the industry), the flue gas emission shall not have
SPM levels (in the stack) exceeding 100 mg/Nm3. Additionally, the stack height requirements
for discharge of emissions will need to be complied with.
DG sets : The industrial unit is planning to have two DG sets, each of 500 kVA as backup to
state power supply. As per the applicable norms, the DG sets will be housed in an acoustic
chamber. The combustion emission outlet, of the DG set, will be provided with a muffler along
with a minimum stack height of 5.5 m above the height of nearest building.
6.4 Solid Wastes Generation

The grain based fermentation will result in high protein solids @ 25 MT/day from each of the
unit. It has potential to be used for cattle feed making.
The boiler furnace will result in ash generation @ 15 MT/day from each of the unit.
6.5 Hazardous Waste Generation
The plant facility will result in generation of about 1 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 industry. 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 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 35-40% 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
 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 the
vapors.
Treatment of Condensates
The spent lees and condensates from stage I and stage II of multiple effect evaporation (315
m3/day) from each unit would be collected in a collection tank. The condensates would be
treated in a condensate polishing unit consisting of aeration, clarification, sand filteration and
activated charcoal filteration before its final reuse in cooling water makeup. The industry would
install two separate condensate polishing units with each unit of distillery plant as per Phase 1
and Phase 2, development. The detailed design consideration of one set of condensate
polishing unit are as follows;
Collection tank
The collection tank will be provided with an HRT of about 6 hours for 315 m3/day of effluent.
So, the collection tank will have a total capacity of around 80 m3. The tank will have
conventional rectangular geometry.
Aeration tank
The tank will have completely mixed flow regime. The specifications of the tank are as under;
Flow Rate − 315 m3/day
1. BOD loading − 500 mg/l
2. MCRT − 6 days
3. F/M − 0.2
4. MLSS − 3500 mg/l
5. MLVSS/MLSS ratio − 0.8
6. HRT − 20 hours
7. Effective tank volume − ~ 300 m3
8. Air requirement (for diffused aeration) − ~ 800 m3/hour
9. Nutrient ratio (BOD:N:P) required − 100:7:1
10. Treatment efficiency (BOD3 removal) − > 95%
The tank will be provided with fine-bubble diffused aeration system. The air is supplied by the
twin-lobe roots blowers of desired capacity at 0.5 kg pressure.
Secondary clarifier
The secondary settling unit is meant to separate the solids from the mixed liquor from the
aeration tank. The process is very critical for the efficient operation of the ASP. The clarifier can
be described as under;
a) Design overflow rate = 16 m3/m2.day
b) Peaking factor = 2.5
c) Design flow (at p.f.) = 33 m3/hour
d) Settling area required = 50 m2
The secondary clarifier will be rectangular in geometry. The separated solids (underflow) would
be either recycled back into the aeration tank or would be wasted (to adjust for the excess
sludge generated) onto sludge filter beds.
Intermediate Storage Tank

An intermediate storage tank of around 2 hours HRT would be provided for feeding the treated
effluent in the pressure sand filter and activated charcoal filter. The tank will have conventional
rectangular geometry.
Sand Filteration
The pressure sand filter will have following specifications;
a) Working principle – down flow
b) Maximum flow rate – 20 m3/hour
c) Minimum flow rate – 10 m3/hour
d) Maximum working pressure – 3 kg/cm2
e) Minimum working pressure – 1.5 kg/cm2
f) Pressure vessel type – vertical cylindrical
g) Filtration rate – 14 m3/m2.hour
h) Effective diameter – 1500 mm
i) Effective height – 2500 mm
j) Filteration media type – Graded sand with under bed
k) Top layer (anthracite 1-2 mm) – 700
l) Second layer (sand 0.4-0.8 mm) – 600 mm
m) Total bed depth – 1300 mm
n) Backwash velocity required – 0.8-1.2 m3/m2.min
o) Backwash water feed rate – ~1 m3/min
Activated Charcoal Filteration

The activated charcoal filter will have following specifications;
a) Working principle – down flow
b) Maximum flow rate – 20 m3/hour
c) Minimum flow rate – 10 m3/hour
d) Maximum working pressure – 3 kg/cm2
e) Minimum working pressure – 1.5 kg/cm2
f) Pressure vessel type – vertical cylindrical
g) Filtration rate – 16 m3/m2.hour
h) Effective diameter – 1500 mm
i) Effective height – 2500 mm
j) Filteration media type – charcoal with minimum 600 iodine value
k) Total bed depth – 1300 mm
l) Backwash velocity required – 0.8-1.2 m3/m2.min
m) Backwash water feed rate – ~1 m3/min
Final Treated Effluent Storage Tank

The final treated effluent storage tank will be provided with an HRT of about 4 hours. The tank
will have conventional rectangular geometry. Treated effluent from this tank would be
transferred to the cooling towers for their makeup requirements.
Treatment of Other Streams

Effluent generation from other misc. streams as discussed above would be less than 110
m3/day for each of the unit. The industry would install two separate condensate polishing units
with each unit of distillery plant as per Phase 1 and Phase 2, development. The mixed effluent
would be moderately polluted. The mixed effluent would be collected in a collection tank.
Thereafter it would be treated through anaerobic biofilteration, aeration and clarification. The
treated effluent would be disposed on land for irrigation purposes. The detailed design
consideration of effluent treatment plant for one set of the unit is as follows;
Collection tank
The collection tank will be provided with an HRT of about 8 hours for 110 m3/day of effluent.
So, the collection tank will have a total capacity of around 35 m3. The tank will have
conventional rectangular geometry.
Primary clarifier
The primary settling unit is meant to separate the solids from the untreated effluent. The
process is very critical for the efficient operation of the ETP. The clarifier can be described as
under;
The primary clarifier will be rectangular in geometry. The separated solids (underflow) would be
wasted onto sludge filter beds.
Anaerobic Biofilter
Average Flow Rate assumed 110 KLPD

Average COD Load 6000 mg/l
Peak daily COD Load 500 kg/day
COD loading assumed 0.3 kg/m2.day
Surface area required 2000 m2
Surface area available per m3 with media 110
Volume of media required 18
Capacity of tank 110 m3
Aeration tank
The tank will have completely mixed flow regime. The specifications of the tank are as under;
Flow Rate − 110 m3/day
1. BOD loading − 600 mg/l
2. MCRT − 6 days
3. F/M − 0.2
4. MLSS − 3500 mg/l
5. MLVSS/MLSS ratio − 0.8

6. HRT − 24 hours
7. Effective tank volume − ~ 110 m3
8. Air requirement (for diffused aeration) − ~ 400 m3/hour
9. Nutrient ratio (BOD:N:P) required − 100:7:1
10. Treatment efficiency (BOD3 removal) − > 95%
The tank will be provided with fine-bubble diffused aeration system. The air is supplied by the
twin-lobe roots blowers of desired capacity at 0.5 kg pressure.
Secondary clarifier
The secondary settling unit is meant to separate the solids from the mixed liquor from the
aeration tank. The process is very critical for the efficient operation of the ASP. The clarifier can
be described as under;
The secondary clarifier will be rectangular in geometry. The separated solids (underflow) would
be either recycled back into the aeration tank or would be wasted (to adjust for the excess
sludge generated) onto sludge filter beds
Septic Tank for Domestic Treatment

The septic tank will provide and effective HRT of at least 48 hours, for maximum daily flow, to
biologically stabilize, partially, the organic pollution load. A two compartment septic tank will be
used for the purpose. The stabilisation compartment (first compartment) will have volumetric
capacity of 20 m3/day, with aspect ratio (length:width) of at least 3. Floor slope at 1:5 will be
provided for sludge accumulation. The effective submerged depth of tank will not exceed 2.5 m.
Provision will be made for periodic withdrawal (pumping out) of accumulated sludge. The actual
tank dimensions will be worked out to suit the process and site requirements.
6.6.2 Air pollution control system

a) The each of the boiler furnaces will use a maximum of 5500 kg/hour of biomass as fuel.
b) The air-fuel ratio (combustion air) required for complete combustion is 1:5.8, i.e., 1 kg of
fuel requires about 5.8 kg (~ 4.8 Nm3) of air – assuming 30% excess air.
c) Flue gas generation will be about 6.8 kg/kg of fuel.
d) Maximum rate of emission generation will be about 27000 Nm3/hour.
e) The temperature of the flue gas at the outlet of the furnace will be about 140-150°C.
f) The critical SPM levels will be less than 30000 mg/Nm3.
g) Sufficient velocity will be maintained in the ducts/conduits in order to ensure that there is
un-clogged flow.
h) All of the bends, in the gas flow ducts, are recommended to have throat radius of 2 times
the diameter of the duct. Sharp bends, in the ducts/conduits are to be completely avoided.
i) The emissions follow ideal gas behaviour. Gas flow is incompressible.
j) Due consideration has been accorded to the changes in gas properties and behaviour with
changes in temperature.
k) All inlets, outlets, and approaches are proper, so that there is no turbulence in the flow. The
inner surfaces of the ducts and the APCD (coming in direct contact of the gas flow) will be
reasonably smooth. There will not be any kind of leakage from any part of the duct/conduit,
APCD, or machinery.
l) The sampling port will be provided in the stack, such that its height is, at least, 8 times the
stack diameter, from the inlet to the stack. The emission shall be discharged into the
atmosphere at a height, above the sampling port, at least 2 times the stack diameter.
m) While the specifications and operating parameters, being specified hereunder, represent
theoretically optimised values, there may be some variation in any of these during actual
erection/commissioning (to suit site conditions) and operational fine-tuning of the system.
Every effort will be made to ensure that the system’s performance does not get affected
adversely.
Approach duct
There will be two ducts conveying furnace emissions into the APCD and each will have a
diameter of 1200 mm. All bends in the ducts will have throat radius of at least 2500 mm.
Electro-static precipitator (ESP)

Electrostatic precipitator would be installed to each of the boiler furnaces. The ESP will have
following technical specifications;
1. Design gas flow rate – 27000 m3/hour
2. Temperature – 140-150ºC
3. Maximum inlet dust load – 22 g/Nm3
4. Outlet emission dust load – <100 mg/Nm3
5. Plate area – 1000 m2
6. Specific collection area – 50 m2/m3s
7. Velocity through ESP – 0.50 m/s
8. Treatment time – ~22 s
9. Migration velocity – ~4.9 cm/s
10. Number of fields – 3
11. Efficiency – > 99.54%
Collection electrode specifications;

1. Height of Panel – 6 meters
2. Material – IS 513/CRCA
3. Total no. of plates – 240
4. Width of panel – 735 mm
5. Thickness – 18 SWG
Emitting (discharge) electrode specifications;

1. Height of panel – 6 meters
2. Total no. of electrodes – 1350
3. Type – Spiral
4. Material – ERW tubes and carbon steel
studs
5. Spacing between emitter & collector – 200 mm
electrode
6. Spacing between collecting plates - 400 mm
Electrical specifications;
1. TR sets – 3 nos.
2. TR control type – Microprocessor controlled
3. Nos. per field – 1
4. TR rating
Output voltage – 120 kV DC
Output current – 3 x 300 mA
Rapping system specifications;

1. Type – Microprocessor based
electromagnetic plunger
2. Total no. of rapper per unit – 18
3. Rapper impact force (max.) – 20 ft. lb. (adjustable)
Design pressure
1. Maximum – ± 300 mm WG
2. Maximum pressure drop – flange to – 20-25 mm WG
flange
Power consumption
• Maximum 120 kW – this includes corona (without losses), rapper, PA system, insulator
heaters, hopper heaters, RAVs.
• Power consumption is at steady state for the rated inlet parameters in the basis of design.
The flue gas cleaning system will achieve SPM removal efficiency of more than 99.54%,
resulting in emission discharge with SPM concentration of less than 50 mg/Nm3.
Stack
The stack shall have adequate height to properly disperse SO2 generated or 30 m, whichever
is more. The stack height is calculated using the equation;
H = 14 (Q)0.3
Where, H is stack height (in m), and
Q is quantity of SO2 generated (in kg/hour).
a) Rate of fuel combustion = 5.5 MT/hour
b) Rate of combustion of S (maximum) = 5.5 kg/hour

c) Maximum SO2 in the emissions (Q) = 11 kg/hour
d) Stack height (minimum) = 30 m
e) Stack diameter = 1.0 m
f) Height of sampling port above inlet = 12 m (minimum)
A sampling port with platform shall be provided for monitoring purposes. A ladder arrangement
shall be provided to access the sampling port.
Blower (ID fan)

To satisfy the suction requirements, and to compensate for the pressure drops (flow losses), a
centrifugal blower shall be provided. It will have the capacity to produce the flow rate of 30
Nm3/s and total pressure of 0.25 m of water column.
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 ESP (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 for the making of flyash bricks within the
premises.
Fiber/Husk (5)
Grain (115) Milling Section
Dirt/Dust (2)
Thin slops (60)
Fresh Water (192) Liquefaction

(400)
Steam (40)
Fresh Water (50) Fermentation CO2 (40)

(450)
Steam Condensate (150)
DM Water (50)
Spent Wash (355)
Multi-pressure Distillation
(500)
Steam (150) Spent Lees (100)
Alcohol (45)
355
Thin Slops, reuse (60)
Decanter Wet Cake (45)
Multi Effect Evap. (250)
Thick Syrup (35)
Multi Effect Evap.

Steam (30) Steam Condensate (30)
(250)
Condensate (215)
Steam (60) Dryer DDGS

( Wet Cake and Thick syrup75)
Figure 2 : Idealised Water Balance (for 45 KLPD distillery plant)

All values are in V/V except grains which are in MT/day
Cooling Tower Balance
Spent Lees (100)
Evaporation Losses (565)

M.E.E. Condensate (215) Cooling Tower (600)
Blow Down to ETP (35)

Fresh Water (285)
Water Balance for Misc. use
Bottle Washing (20) Bottle Wash to ETP (20)
Domestic Use (10) Domestic Eff. to ETP (9)
Soft Water for Blending (25) Spillages to ETP (2)
Water for Softening (300) Rejects to ETP (15)
Ferm./floor washing (10) Wastewater to ETP (10)
Figure 2 (contd…) : Idealised Water Balance (for 45 KLPD distillery plant)
All values are in MT/day
Water Balance for Treatment
Ferm./floor washing (10)
C. T. Blowdown (35)
Domestic Effluent (9) ETP (106) Irrigation purposes (106)
Bottle wash/spillages (22)
D.M. Reject (15)
Boiler Blow down (15)
CHAPTER – 7
PROJECT ESTIMATES
ESTIMATED OVERALL PROJECT INVESTMENT
The estimated cost of project for the Phase 1 for 45 KLPD distillery project, 8000 cases of bottling of
country liquor/IMFL and cogeneration of 3.0 MW of power would be as below;
Section DESCRIPTION AMOUNT

(Rs. in Lacs)
Section A Supply of Plant & Machinery : Grain Storage silos (30 days) 125.00
Section including Grain loading & pre-cleaning along with MCC
electricals and Instrumentation.
Supply of Plant & Machinery : Grain Milling Section Twin mill along 150.00
with MCC electrical and Instrumentation. (Indian Make)
Supply of Plant & Machinery : Grain flour handling & weighment,
common equipment along with respective MCC electricals &
Instrumentation
SECTION B Supply of Plant & Machinery : Liquefaction Section along with 1270.00
MCC electricals and PLC- SCADA based Instrumentation.
Supply of Plant & Machinery: Saccharification & Fermentation
Section (With MS+Epoxy Fermentors) along with MCC electricals
and PLC-SCADA based Instrumentation.
Supply of Plant & Machinery: Multi-Pressure Distillation Section
along with MCC electricals and PLC SCADA based
Instrumentation.
Supply of Plant & Machinery: Decantation Section including
Decanter Centrifuge along with MCC Electricals and
Instrumentation. Integrated Evaporation of Part Thin Slops Plant
alongwith MCC Electricals and (common) PLC- SCADA based
Instrumentation.
Supply of Plant & Machinery: DWGS Drier with Cooling &
Conveying, Semi-Auto Bagging system along with its MCC
Electricals & Instrumentation.
Supply of Plant & Machinery: Daily Spirit Receivers & Alcohol Bulk
Storage along with MCC Electricals & Instrumentation.
Auxiliaries for Process Sections including Cooling Tower, CWRP,
Diesel driven pump for distillation cooling tower in emergency,
Piping Valves & Electricals; Instrument Air compressor & its piping
from common Air compressor.
Evaporation process condensate treatment plant with its MCC,
electrical & instrumentation.
SECTION C Boiler with Accessories: (30 TPH; 45 kg/cm2g; 440OC) Section 400.00
along with MCC electricals and PLC Instrumentation. Includes
Main Boiler, Fuel Feeding, Ash Handling, Bag Filters, Multi-
Cyclone, PRDS/DSH, Part Steam Piping upto Turbine, etc.
Turbine & Alternator: Back Pressure Type (3.0 MW) along with 180.00
electrical and Instrumentation. (Make Triveni/Maxwatt)
Steam Piping &Valves, Interconnections, Condensate Piping,
PRDS/DSH, Insulation, Steam Header, etc.
SECTION D Electrical distribution : Transformer, DG Sets, Power Control 180.00
Center, Cabling from PCC to respective MCC, Earthing,
Synchronization Panel, In-Plant & Yard Lighting, etc.
SECTION E Borewell (1 No.) ; Water Treatment Plants (Soft Water & DM 120.00
Water), Water distribution Piping & Valves, Flow-meters &
Tantalizers, (Instruments) etc.
SECTION F Bottling & Blending Section : 6 Semi-Automatic Lines ; 16 Blending 440.00
Tanks ; 6 Finished Product Tanks, Misc. Electricals, Filteration,
ENA & DM Water Tank, etc. – Independent Bottling Hall Equipment
SECTION G Fire Fighting arrangement, weigh bridge, laboratory equipment. 125.00
SECTION H Effluent Treatment Plant (ETP) for miscellaneous streams. 90.00
SECTION I Complete MS Structural work for Process section and utility 1400.00
section such as columns, Beams, Roof truss, Gratings, Hand
railing, Staircases, Tie beams etc including interconnecting Steam
& Water distribution Pipe Racks, Cable Tray, Ash Silo,etc.
Complete Civil Works including Foundations, drains, land
preparation, roads, buildings, offices, stores, workshop, canteen,
guesthouse, Boiler Chimney, Blending & Bottling Halls, DDGS
Storage Godowns, Flooring, Boundary Wall, Gates, Underground
Water Tanks, Pits, Sumps, Borewells, Equipment & Structure
foundations, platforms, laboratory, etc.Also included in the scope is
Green Belt development, Rain Water Harvesting, etc.
Civil & Structural Works for above Bottling Hall
SECTION J Estimated TAXES & DUTIES – For all above scope 520.00
TOTAL FIXED ASSETS 4000.00
TOTAL PROJECT COST : 45 KLPD
Sr. No. Description Amount

1 Total Fixed Assets 4000.00
2 Working Capital Margin 270.00
3 Interest on Term Loan during Construction 270.00
4 Pre-Operative Expenses 120.00
5 Contingencies 150.00
TOTAL PROJECT COST 5000.00
The estimated cost of project for the Phase 2 for 45 KLPD distillery project, 8000 cases of bottling of
country liquor/IMFL and cogeneration of 3.0 MW of power would be around 25 % more as the phase 2
commissioning would take atleast 2 years from the date of commissioning of the phase 1.

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DETAILED PROJECT REPORT

SUITABLE TO PRODUCE 2 x 45,000 LPD OF

STARTLIGHT ENERGY PVT. LTD.

CHAPTER TITLE PAGE NOS.

EXECUTIVE SUMMARY 1-3

1.0 INTRODUCTION 4-5

2.0 PROJECT LOCATION 6 - 12

3.0 PROCESS DESCRIPTION 13 - 26

4.0 RAW MATERIALS 27 - 28

6.0 ENVIRONMENTAL MANAGEMENT AND POLLUTION 31 - 48

7.0 PROJECT COST ESTIMATE 49 - 51

1. SHRI SUNIL CHOUDHARY, Director, Age : 44 years

2. DULAL CHOUDHURY, DIRECTOR, Age : 62 years

Phase Project Description Installed Capacity Expected COD

DISTRICT MAP OF ODIHSA

2.2 ABOUT THE DISTRICT

MAP OF KALAHANDI DISTRICT

KALAHANDI DISTRICT AT A GLANCE

Large Farmers (10.09 hectares and above) 1791

2.3 SELECTION OF SITE

 Raw material availability

Advantages of the location at Village - Goud-Sargiguda, Taluka Junagarh, Dist. Kalahandi

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

3.1 Grain based Distillery Process/Operations

a) Grains receiving and storage

Figure 1 shows the schematic flow diagram of the process operations.

3.1.1 Grain receiving and storage

3.1.2 Grain handling and milling

3.1.3 Slurry preparation/liquefaction

3.1.4 Saccharification and instantaneous fermentation

After CIP, Fermenter is ready for next batch to be filled.

3.1.5 HIFERM Fermentation

3.1.6 ECOFINE – MPR WE Multi-Pressure Distillation

3.1.7 Decantation & Thin Slops Recycle Section

3.1.8 ECOVAP Evaporation System - Integrated Evaporation Scheme

3.1.9 DWGS Dryer with Cooling and Conveying System

System Description for Dryer

3.1.9 Spirit storage

Fresh Water Liquefaction

Fresh Water Fermentation CO2

Steam Spent Lees

Decanter Wet Cake

Multi Effect Evap.

Multi Effect Evap.

Steam Dryer DDGS

Figure 3.1 : Process Flow Chart of Grain based distillery

3.2 Bottling of country liquor/IMFL

3.3 Co-generation Power Plant

The cogeneration power plant is divided in three parts, namely;

3.3.1 Boiler & Auxiliaries

3.3.2 Turbine & Auxiliaries

Rotor : It supports the moving blade.

3.3.3 Generator & its Auxiliaries

3.4.1 Water treatment plant – 2 x 300 m3/day

3.4.2 Electrical system

3.4.3 Standby electrical generator

3.4.4 Cooling water – 2 x 1500 m3/hour

4.1 Raw Materials Requirements for Grain based Distillery