Bajaj Hindustan Sugar - Distillery and Cogen Feasibility Report - 2024

Establishment of new Cane Juice Syrup / Grains / B or C-Heavy Molasses Based Distillery
Having Capacity - 570 KLD along with 10.0 MW Co Gen Power at Village: Muradabad Urf Final
Nakta, Gulada Macchwapur, Tehsil: Bisalpur, District: Pilibhit (Uttar Pradesh) of M/s Bajaj EIA/EMP
Hindusthan Sugar Limited, Unit: Barkhera
CHAPTER No. - 02:

PROJECT DESCRIPTION
2.1 Type of project

M/s. Bajaj Hindusthan Sugar Limited (BHSL) has fourteen (14) sugar plants in eastern,
western and central Uttar Pradesh. Now Bajaj Hindusthan Sugar Limited, Unit Barkhera is
going to proposed new distillery Plant.
The Barkhera unit located at Barkhera, Pilibhit district of Uttar Pradesh. The present average
crushing capacity of the plant is 10000 TCD the present encouraging prices announced by
Govt. of India for Ethanol produced from Cane Juice Syrup / Grains / B or C-Heavy
Molasses. BHSL would like to implement a Cane Juice Syrup / Grains / B or C-Heavy
Molasses Based Distillery Having Capacity - 570 KLD along with 10.0 MW Co Gen Power by
completely utilizing the cane crushing, all type of molasses and Grains for Ethanol production.
The proposed distillery will be produced Absolute alcohol / ENA.
As per EIA Notification dated 14th September, 2006 and as amended from time to time; the
project falls in Category ‘A’, Project or Activity - 5(g) [Molasses based distilleries >100 KLD].
2.2 Need for the project

Advancement in science and technology has created so many products that have enhanced the
quality of human life in every passing year. The human race is largely dependent on
industrialization for up gradation in quality of life. Progress of the nation is judged through its
economic growth which is largely dependent on industrial productivity. In Indian economy
(which is agro based) many industries are dependent over agricultural produce for production
of luxury and need based commodities. Alcohol has assumed a very important place in the
Country’s economy. It is a vital raw material for a number of chemicals. It has been a source
of revenue by way of excise duty levied by the State Government on alcohol liquors. It has a
potential of being used as a fuel in the form of power alcohol for blending with petrol in the
ratio of 20:80.
Products & By-Products: This project is a unique project for the production of RS /ENA/AA
from Cane Juice Syrup, Molasses and grains and a comprehensive project involving
Cogeneration of Power, CO2 production as well as Cattle Feed (DDGS) production as by-
products. Use of spoilt grains also indirectly helps the farmers as such grains find use in
distilleries for production of Ethyl Alcohol (ENA) as well as value added cattle feed (DDGS).
Revenue to State: Ethyl Alcohol, when used in Potable Industry as ENA / RS, brings
significant revenue to the State Exchequer through State Excise Department, which in turn
Prepared by: ETRC Consultants Pvt Ltd 15 | P a g e

levies taxes on all products and by-products from production. The total revenue generation
from this project for the State Government.
Employment: Proposed project will be generating about 200 direct employment opportunities,
of which about 150 will be for skilled and about 50 for unskilled persons. Apart from this, the
project is anticipated to give plenty of indirect opportunities to transporters, shopkeepers and
various facility providers such as schools, medical facilities, etc.
Consumption of Ethanol in India:

In Indian economy (which is agro based) many industries are dependent over agricultural
produce for production of luxury and need based commodities. Alcohol has assumed a very
important place in the Country’s economy. It is a vital raw material for a number of chemicals.
It has been a source of revenue by way of excise duty levied by the State Government on
alcohol liquors. It has a potential of being used as a fuel in the form of power alcohol for
blending with petrol in the ratio of 20:80. The use of alcohol for the purpose of potable liquor
is as high as its use for industrial purposes. According to analysts, the Indian alcoholic
beverages industry is expected to witness accelerating growth in coming years with the
consumer base likely to expand amidst rising disposable income. The domestic alcoholic
drinks market is estimated around $13 billion and has been growing at a compounded annual
growth rate in excess of 10% in the past few years. The growth rate is higher than other major
Asian markets like China and South Korea, etc. In the path of company’s growth and
development this project will serve as yet another milestone.
Almost 50% of the ethanol production in India is consumed by the industrial sector for
production of ethanol-based chemicals like acetaldehyde, acetic acid, esters, butanol, glycol,
pentaerythritol, vinyl acetate etc. The remaining 40-50% is utilized by the potable sector.
However, with the Government removing controls on price and allocation of molasses, the
ethanol-based chemicals industry is facing difficulties as the procurement price of alcohol has
increased substantially in the last few years. India has around 330 distilleries which can
produce over 4.5 billion liters of rectified spirit (alcohol) per year. Of this total, about 162
distilleries have the capacity to distillery over 2.2 billion litters of conventional ethanol. India’s
ethanol program is based on sugar molasses, a by-product of the sugar industry, and not
directly from sugarcane or corn.
The ethanol production and consumption in India has been increasing over the years as
predicted by Indian Sugar Mills Association (ISMA) and the US Department of Agriculture
(USDA) gives the data tabulated in Table 2.1.

Table-2.1:
Ethanol Production and Consumption in India (MT or billion liters /Annum)
Calendar Year 2013 2014 2015 2016 2017 2018
Production 2057 2002 2292 2061 1651 1894
Imports 108 194 203 400 500 600
Exports 233 180 165 136 100 120
Consumption 1932 2000 2345 2290 2080 2420
Blend Rate (%) 1.6 1.4 2.3 3.3 2.0 2.2
An estimated 1.65 billion liters of ethanol will be produced in 2017, almost 20 percent less
than last year. Limited availability of molasses due to short sugarcane production, particularly
in Southern and Western states, will keep the supply tight. Theoretically, the ethanol available
is sufficient to meet the 5 percent blend target, but demand rationing, particularly from potable
and industrial sectors, will limit ethanol market penetration close to 2 percent. Industry
sources indicated that the OMCs may procure upwards of 700 million liters in 2017.
As per 2017 monsoon, ethanol production in 2018 will improve to 1.9 billion liters on
anticipated rise in sugarcane production, the result of farmers planting more canes to recover
area lost to adverse weather conditions. In turn, OMCs should be able to procure an estimated
850 million liters of ethanol for blending with gasoline in 2018, which will raise the national
blend average slightly to 2.2 percent.
Against the background M/s Bajaj Hindusthan Sugar Limited, Unit: Barkhera plans
to propose Cane Juice Syrup / Grains / B or C-Heavy Molasses Based Distillery Having
Capacity - 570 KLD along with 10.0 MW Co Gen Power to meet the ever-growing demand of
Ethanol for industrial and blending in Petroleum.
2.3 Proposed Distillery

2.3.1 Location of proposed project
For EIA Study 5.0 & 10.0 km radial study area is covered and the same is shown on SOI Topo
sheets 53P/10, 53P/14, 53P/11 & 53P/15 in the map below Figure-2.1. Map showing corner
of proposed project site given in Figure-2.2. Latitude and Longitude of the site at four corners
and in the centre given below in Table- 2.2.

Table-2.2: Latitude and Longitude of the project site
Corners Directions Latitude Longitude
1st North 28°15'1.63"N 79°59'53.98"E
2nd North East 28°14'57.17"N 80° 0'2.11"E
3rd South 28°14'25.17"N 80° 0'6.14"E
4th West 28°14'42.22"N 79°59'28.45"E
5th North West 28°14'51.52"N 79°59'34.69"E
- Centre 28°14'45.15"N 79°59'51.53"E
2.3.2 Connectivity
Plant site is well connected to SH-29 at adjacent to the project site in East direction. The
nearest railway station is Barkhera Railway Station (~2.64 km in South East direction). The
site is suitably located with respect to availability of raw material, water, road network,
skilled/ semiskilled/ unskilled and professional manpower etc. All communication facilities
such as telephone, telefax & internet are available in the vicinity of the plant site. Location
map of proposed location is given in Figure-2.3.

Figure-2.1: Topo sheet showing 15 Km radial distance of study area

Figure-2.2: Google Satellite Image depicting proposed distillery

Figure-2.3: Location Map of Project site

2.3.3 Land requirement
The company owns 54.319 hectares (543,190 square meters) or 134.22 acres of land. Out of
the total land, 43.127 hectares is allocated for sugar production and the proposed distillery. So
out of available land, a provision of approx. 14.231 Hectare is for green belt and rest is for the
proposed distillery and ancillary units thereof such as boiler house, turbine, storage etc.
Table-2.3: Land Use Breakup within Premises
Sr No Land use Area (sqm) Area in %
1 Roof Top (Building, Covered Shed) 7547.23 17.5
2 Green Belt 14231.91 33
3 Road and paved 8841.04 20.5
4 Open Area 12506.83 29
Grand Total 43127 100
Landuse breakup within premises
Roof Top (Building, Covered Shed)

17%
29% Green Belt
Road and paved
33% Open Area

21%
Figure-2.4: Land Use Breakup with in premises

Figure-2.5: Layout Plan with Greenbelt

2.4 Size or Magnitude of the operation
Proposed proposal is for Establishment of Cane Juice Syrup / Grains / B or C-Heavy
Molasses Based Distillery Having Capacity - 570 KLD along with 10.0 MW Co Gen Power
Plant. Plant will run on one mode at a time. For Cane Juice Syrup based operation, Cane
Juice Syrup will be used as feedstock also if available.
Major Product of project will Rectified Spirit / Extra Neutral Alcohol / Absolute Alcohol.
Maximum of operational capacity of Distillery at a time will be 570 KLD. Proposed unit will
run on two different feedstock - based modes but one mode at a time. Single mode will be run
at a time either Cane Juice Syrup or Grain, which are as follows: -
Mode - 1: 100 % Cane Juice Syrup based Distillery capacity 570 KLD
Mode - 2: 100 % Grain based Distillery capacity 570 KLD
Mode - 3: 100 % Molasses (B or C Heavy) based Distillery capacity 570 KLD
Product: Rectified Spirit / Extra Neutral Alcohol / Absolute Alcohol: 570 KLD,
By Product: Carbon Dioxide (CO2) is the by-product from the fermentation section of
proposed Distillery will be 399 TPD (on Mode-I, Mode-II & Mode-III). Details of Distillery
Capacity with products name is given in Table-2.4,
Table- 2.4: Project capacity and other details of project
Sr No. Unit Capacity Products
Cane Juice Syrup / Grain Ethanol/Extra Neutral
1. / Molasses (B Heavy & C 570 KLD Alcohol (ENA)/
heavy) based Distillery Rectified Spirit (RS)
2. Co gen power plant 10.0 MW Power
3. Number of working days 350 Days / Annum -
4. Total Cost of the project Rs 70294.59 Lakhs -
Cost for Environmental Rs 7560 Lakh or
5. -
Management Plan 75.60 Crores
Source: Pre-feasibility Report
2.4.1 Plant setup

Single plant will be establishing which can be run on three different modes. Mode - 1 (Cane
Juice Syrup based), Mode - 2 (Grains based) and Mode - 3 (B or C Heavy based operation).
Industry will install two different setups for treatment of spent wash, one for treatment on
Mode - 1 & Mode - 3 and other for treatment on Mode - 2. Preparation part and spent wash
treatment scheme will be different in Mode - 1 & 3 and Mode - 2.
2.5 Other Basic Requirement

The requirement for the Cane Juice Syrup / Grain / Molasses (B or C Heavy) based distillery
can be broadly categorized as follows:
➢ Cane Juice Syrup, B or C Heavy Molasses and Grain
➢ Enzymes & Chemicals
➢ Water
➢ Steam
➢ Fuel
➢ Power
➢ Manpower etc.
2.5.1 Raw Material Requirement and Source

(a) Cane Juice Syrup
Cane Juice Syrup will be the basic raw materials for Mode - 1 in making 570 KLD Rectified
Spirit/Extra Neutral alcohol/Absolute Alcohol. The total requirement of raw material (Cane
Juice Syrup) for the distillery will be 1628 MT/ day (569800 MT/Annum). Cane Juice Syrup
will be procured from own sugar mill.
(b) Grain
Grains like broken rice, bajra, maize etc will be used in making 570 KLD rectified spirit/ Extra
Neutral alcohol/Absolute Alcohol in Mode - 2 based operation. The total requirement of
grains for the distillery in Mode - 2 will be 1268 MT/ day (443800 MT/Annum). Grains will
be procured from local market through vendor.
(c) Molasses (B or C Heavy)
Molasses will be the basic raw materials for Mode - 3 in making 570 KLD Rectified
Spirit/Extra Neutral alcohol/Absolute Alcohol. The total requirement of raw material
(Molasses) for the distillery will be 1900 MT/ day (665000 MT/Annum) B-Heavy or 2478
MT/ day (867300 MT/Annum) C-Heavy.
As the proposed distillery is near to many standalone sugar units located in central, eastern &
western Uttar Pradesh. During the Sugar Cane Season industry will be able to meet 100 %
molasses requirement. Industry will procure the molasses from nearby sugar mills. Molasses
will be transported through tanker. Details regarding quantity of raw materials, other
chemicals required, their source & mode of transportation for proposed Cane Juice Syrup and
grain-based distillery are given in Table-2.5 below:

Table-2.5: Raw Material requirement, source and transportation
Sr. Quantity, Source of raw material &
Particular Storage
No. MT/Day Mode of Transportation
Mode - 1: Cane Juice Syrup based
Adjacent sugar mill.
1. Cane Juice Syrup 1628 MT/Day 24 Hour
Through Pipelines.
or
Mode - 2: Grain Based
Nearby market and truck
2. Grain 1268 MT/Day 30 Days will be used for
transportation
or
Mode - 3: Molasses (B or C heavy) based
1900 MT/Day
(B-Heavy)
Molasses Adjacent sugar mill.
3. or 30 Days
(B or C heavy) Through Pipelines.
2478 MT/Day
(C-Heavy)
Other Chemicals
4. Sulphuric Acid 410 kg/Day 15 Days Nearby Market by Truck.
Sodium 15 Days storage will be
Hydrooxide 658 Kg/Day 15 Days provided.
(Caustic)
Enzymes 219 kg/Day 15 Days
NH2-CO-NH3
822 kg/Day 15 Days
(Nutrient: 46% N2
Antifoam Agent 68.4 kg/Day 15 Days
2.5.2 Water Requirement

Water required for proposed project will be different during Cane Juice Syrup/ Grain/B heavy
Molasses or C heavy Molasses based operation. Maximum fresh water requirement will be
2280 KLD among all three modes of operation. Water balance for the proposed distillery unit
is given in Figure-2.6 - 2.8.
Necessary fresh water requirement for the proposed project will be met from tube well /
groundwater sources. Water will be required for domestic, industrial process and utility
purpose. As the area fall in block: Barkhera of District: Pilibhit (UP) and Safe as per CGWA
Ground water assessment 2020. Water level in the ranges from 3.6-3.9 m bgl during pre-
monsoon season.
Water requirement for the project is given in Table-2.6. Water requirement and waste
generation is shown in Table-2.7(A), 2.7(B) for Mode - 1, Mode - 2 and Mode - 3 based
operation in distillery respectively.

Table-2.6: Water requirement for proposed distillery
Sr. Fresh water requirement
Particulars Remark
No. (KLD)
2166 KLD (@ 3.80 KL/KL Maximum water
570 KLD Cane Juice Syrup
1. of product) (Net fresh water requirement of water
based operation (Mode - 1)
requirement after recycling) in day will be 2280
OR KL as plant would be
2280 KLD (@ 4.0 KL/KL of run either on Mode 1
570 KLD Grain based
2. product) (Net fresh water or Mode 2 or Mode 3.
operation (Mode - 2)
requirement after recycling)
OR
2280 KLD (@ 4.0 KL/KL of
570 KLD Molasses based
3. product) (Net fresh water
requirement after recycling)
AND
Domestic water requirement 50.0 KLD
Source: Pre - Feasibility Report
Table-2.7 (A):
Total Water Requirement for proposed distillery
(During Mode-1, Mode-2 & Mode-3 based Operation)
Water Water
Water
Consumption Consumption
Consumption
Propose (KLD) (KLD) Remark
(KLD)
Cane Juice C or B Heavy
Grains based
Syrup based Molasses based
INDUSTRIAL
Process 3174 4261 3934
Total water
Boiler 333 266 333 consumption will be
Cooling 2700 1972 2378 higher in Molasses
Washing 110 110 110 based operation in
comparison to Cane
Total 6317 6609 6755 Juice Syrup or Grain
Domestic 50 50 50 Based operation.
Grand Total 6367 6659 6805

Table-2.7 (B): Waste water generation for proposed distillery
(During Cane Juice Syrup / Grains / C or B heavy Molasses based Operation)
Water Water
Water
Consumption Consumption
Consumption
Propose (KLD) (KLD) Remark
(KLD)
Cane Juice C or B Heavy
Grains based
Syrup based Molasses based
Process Other effluent
3078 4275 3990
(Spent Wash) generation
Process (Others) 684 684 684 will be higher
in Grains
Boiler 50 50 50 based and
Cooling 510 510 510 Molasses (B -
C Heavy)
Washing 110 110 110 based
operation.
Other 33 26 33
Total Industrial 4465 5635 5357
Domestic 30 30 30
Hence, Water required for proposed project will be different during Cane Juice Syrup /
Grains / C or B heavy Molasses based operation. Maximum fresh water requirement will be
2280 KLD (@ 4.0 KL / KL of product). Source of fresh water requirement will be met through
Ground water. Fresh Water requirement for Cane Juice Syrup based operation 2166 KLD (@
3.80 KL / KL of Product), for Grain based operation 2280 KLD (@ 4.0 KL/KL of Product)
and Molasses (B heavy Molasses or C Heavy Molasses) based operation 2280 KLD (@ 4.0 KL
/ KL of product).
During Sugar Season, Fresh water requirement will be reduced due to utilisation of
treated water from Sugar Unit. 100 % Condensate water will be utilised in proposed Distillery
plant. Fresh water consumption will be 1166 KLD during Sugar Season. Water Balance for
Sugar Season with utilisation of treated water is given in Fig no 2.9.

Figure-2.6: Water Balance Flow Chart during 100% Cane Juice Syrup based operation - 570 KLD

Figure-2.7: Water Balance Flow Chart during 100% Grain based operation - 570 KLD

Figure-2.8: Water Balance Flow Chart during 100% Molasses based operation - 570 KLD

Figure-2.9: Water Balance Flow Chart during Sugar season with treated water utilisation

2.5.3 Steam Requirement:
Steam requirement for the proposed project is 62.92 TPH during Cane Juice Syrup based
operation, 88.08 TPH during grain based operation and 85.57 TPH during B or C Heavy
Molasses based operation at 3.5 Kg/cm2 (g) for 570 KLD. Therefore, two Slop fired boilers of
capacity 25 TPH & 100 TPH with 45 Kg/cm2 (g) pressure will be installed and this will supply
steam to proposed 10.0 MW turbo alternator for power generation and utilised in process of
Distillery. Total 02 Number of boiler is proposed, will be slop fired boiler capacity 25 TPH and
100 TPH.
Steam generated from boiler will also be used for boiler feed water heating and distillery. Fuel
in the steam boiler will be burnt with the help of air in the boiler furnace. Water will be
circulated in the boiler drum and tubes thus getting heated by the flame burning in the boiler
furnace. Water comes out of the boiler drum located at the top of the boiler as steam. Flue
gases rise in the boiler furnace and come in contact with the steam coming out of boiler drum.
Steam after coming in contact with flue gases gets 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.
After economizer, flue gases pass through air pre-heaters where they heat the air which is fed
to the boiler furnace for burning the fuel.
After air pre-heaters flue gases pass through ESP where the dust particles are collected on
charged electrode. After passing through ESP, clean flue gases with dust particle concentration
also known as SPM level less than 50 mg/Nm3 through a chimney of prescribed height. The
dust is collected from the bottom of the ESP. High pressure superheated steam from boiler will
pass through a steam turbine will be used for distillery. While passing through the turbine, the
high pressure and temperature steam will rotate the turbine rotor and an electric alternator
mounted on the same shaft. Electric power will be generated by the alternator. This electric
power generated will be consumed in house i.e. for running the distillery and utilities like
boilers auxiliaries etc.
2.5.4 Fuel Requirement

Slop and Bagasse will be used as a fuel for the steam generation activity of the proposed
industry. The requirement of Bagasse and slop is given in table below:
Details regarding quantity of fuel required, their source along with distance & mode of
transportation for proposed project are given in Table- 2.9.

Table-2.9: Fuel Requirement
B Heavy Molasses
Grains based
Cane Juice Syrup based or C Heavy
operation
operation (Mode - 1) Molasses based
(Mode - 2)
Bagasse / Other
Slop: 479 TPD & Bagasse / Slop: 1107 TPD, Bagasse /
Biomass:
Other Biomass: 746 TPD Other Biomass: 393 TPD
1200 TPD.
Source: From in house / nearby sugar mills / open market.
2.5.5 Power Requirement

The maximum power requirement for the proposed project will be 5470 KWH in Cane Juice
Syrup (Mode - 1) based operation, 7730 KWH in Grains (Mode - 2) based operation and 5800
KWH in B or C Heavy Molasses (Mode - 3) based operation, which will be sourced from
inhouse Co-generation power plant of 10 MW and for emergency backup DG set will be
installed.
2.5.6 Man Power Requirement

For the establishment of proposed distillery will be employed directly which include 150 no
person semi-skilled, skilled personnel and approx.: 50 no of contract unskilled person.
Employment in unskilled category, preference will be given to local people. Selection of
employ will be done by interview. Employment in skilled category will be done from outside if
the skilled labour force is not available in local areas. Indirect employment generation will be
250 nos. Details of employment are given in Table - 2.10.
Table - 2.10: Employment Details of Project
Skilled Semi-Skilled Contractual
50 100 50
2.5.7 Proposed schedule and approval for implementation

The project commissioning activities will be started after getting Environmental Clearance
(EC) from the MoEF&CC, New Delhi and relevant Consents from State Pollution Control
Board, Uttar Pradesh. Tentative schedule for getting approvals for installation of project with
the status of implementation is given in the table below: -
Table-2.11: Proposed schedule for approval & implementation
Sr. No Particulars Schedule
1 NoC/ CTE (from SPCB) After 3 - 6 months of obtaining EC
from MoEF&CC, New Delhi

2 Installation of plant 12 - 18 months
3 Consent to Operate (from SPCB) After installation of the plant
4 Commencement of plant operations After obtaining Consent to Operate
Plant activities will commence within 1.5 years of acquiring Environment Clearance.
2.6 Technology and Process Description

A. Cane Juice Syrup Based Operation (Mode - 1)
The production process involves the following stages:
1. Cane Crushing & syrup preparation
2. Fermentation
3. Distillation
1. Cane Crushing & Cane Juice Syrup preparation
Cane is crushed in mills and juice is extracted. Extracted juice from cane is subjected to
clarification process after heating to 70°C. Milk of lime and SO2 gas are added to juice to
precipitate impurities. Then limed and sulphited juice is heated to 103°C and allowed to settle
in clarifiers where impurities settle down as mud. Clear transparent juice (Clear juice) flows
out from the clarifier. Clear juice is concentrated in multiple effect evaporators and about 75%
water content of clear juice is removed and partially concentrated. Then syrup is concentrated
up to around 30 brix in vacuum pan. The fermentable sugar (FS) content, which is the total of
sucrose and other sugars that could be fermented, is the most important criteria to decide on
the quantity of ethanol that could be produced from the molasses. The syrup contains some
form of sugars that are not fermentable and the total sugars in syrup, both fermentable and
nonfermentable, are called total reducing sugars (TRS). The syrup proposed to be used is
expected to have a fermentable sugar content of 27.7%. With this FS the ethanol yield in the
distillery will be around 357 litres of syrup. For the proposed 570 KLD distillery at BHSL, the
syrup requirement with the FS of 57.3% will be 1628 MT/day.
2. Fermentation
Cane Juice Syrup is the chief raw material used for production of alcohol. Cane Juice Syrup
57.3 % fermentable sugar. During the fermentation, yeast strains of the species Saccharomyces
cerevisiae, a living microorganism belonging to class fungi converts sugar present in the Cane
Juice Syrup such as sucrose or glucose in to alcohol. The continuous fermentation process
involves addition of fresh nutrients medium either continuously or intermittent withdrawal of
portion of nutrient for recovery of fermentation products. In continuous process, fermenter is
in constant usage with little shut down and after initial inoculation of yeast culture, further
inoculation is not necessary.

3. Distillation
After fermentation, the next stage in the manufacturing process is to separate alcohol from
fermented wash and to concentrate it to 95%. This is called Rectified Spirit (RS). For this
purpose, method of distillation is employed. After separation of alcohol, the remaining part is
the effluent of the process i.e. spent wash and spent lees.
Re-distillation to manufacture Extra Neutral Alcohol (ENA)
ENA is prepared by re-distillation of the rectified spirit (RS) for the removal of impurities like
higher alcohols, aldehydes and methyl alcohol. This is done by, remixing rectified spirit with
soft water and distilling it in the ENA column.
Anhydrous Alcohol (AA)
Anhydrous alcohol is an important product required by industry. As per IS specification it is
nearly 100% pure or water free alcohol. Alcohol as manufactured by Indian distilleries is
rectified spirit, which is 94.68% alcohol. It is not possible to remove remaining water from
rectified spirit by straight distillation as ethyl alcohol forms a constant boiling mixture with
water at this concentration and is known as azeotrope. Therefore, special process for removal
of water is required for manufacture of anhydrous alcohol.
The various processes used for dehydration of alcohol are as follows
i) Azeotropic Distillation
ii) Molecular Sieves
iii) Pervaporation / Vapour permeation system.
We will use Molecular Sieves process for dehydration of alcohol.

Figure-2.9: Schematic Flow chart of RS / ENA /AA on Mode - 1

B. Grain based operation
1. Liquefaction
Single Tank Liquefaction: In liquefaction process, starch is hydrolysed to dextrins. The
Liquefaction is carried out in single liquefaction tank. Feedstock flour is transferred to
premasher and mixed with recycle Streams, thin stillage and liquefying enzyme. Slurry from
premasher is taken to liquefaction tank where temperature is maintained by injection of direct
steam through steam sparger / Ejector.
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.
2. Fermentation
Yeast Activation:
Yeast seed material is prepared in Yeast Activation Vessel (Pre-Fermenter) by inoculating
sterilized mash with yeast. Optimum temperature is maintained by circulating cooling water.
The contents of the Yeast Activation Vessel 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 Yeast Activation Vessel (Pre fermenter). Significant heat release takes
place during Fermentation. This is removed by passing the mash through heat exchangers to
maintain an optimum temperature. The re circulating 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 for next batch.
3. Distillation
Wash to ENA Mode
Multi-Pressure distillation system having several distillation columns operating at various
pressure conditions. Heat energy from columns operating under high pressure is utilized for
columns operating under low pressure to optimize the operation for energy consumption.
Following Columns will be under operation
➢ Analyser Column
➢ Degasifying Column
➢ Pre-Rectifier Column cum
➢ Exhaust Column
➢ Extractive Distillation Column
➢ Rectifier cum Exhaust Column
➢ Recovery Column
➢ Simmering Column
Pre-heated fermented wash is fed at the top of the degasifying column. Analyser column is
provided with re boiler. Top vapors of analyser column containing all the alcohol in the wash
are sent to Pre- Rectifier column. Rest of the fermented wash flows down the Analyser column
and is taken out as thick slops from Analyser column bottom. Low boiling impurities are
concentrated in the Pre-Rectifier column. A draw of impure alcohol is taken out from the top
of the Pre-Rectifier column. RS draw is taken from the top of Pre rectifier column, which
further is sent to Extractive Distillation column.
4. Evaporation
The suggested treatment scheme is a Four Effect (Integrated) plus Two Finisher working on
the principle of falling film Evaporation & Forced circulation. Simmering vapours is fed to the
first effect evaporator shell side and exhust vapour is fed to shell side of finisher at the given
pressure and temperature as the heating medium. The Feed at predetermined temperature is
fed from the top of First effect evaporator. Vapours generated in 1st effect VLS (Vapour Liquid
Separator) are used as heat source in the 2nd effect which is in series to the first effect & so on.
A Shell & tube type Multi-pass Surface condenser is employed for condensing the shell side
vapours. The product at the desired concentration is obtained at the outlet of last effect. 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 / drain by using centrifugal pump. The system operates under vacuum.
Water-ring vacuum pumps will be used to maintain a desired vacuum. Cooling water from
cooling tower is used in the surface condensers for condensing the vapours.
5. 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 on its outer flights is 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 of another end.
❖ During the course of rotation, these flights pick up the material and shower them on to the
tube bundles. The heat transfer is primarily by conduction. The water vapors are

exhausted through an Exhaust Blower & passed through a cyclone separator for separating
fines.
❖ Dry product partially recycled back to feed conditioner for feed conditioning through
Product Screw & Recycle Conveyor.
❖ Entire operation of the dryer is controlled through Control panel.
Figure-2.10: Process flow diagram during grain-based operation

C. Molasses (B or C Heavy) Based Operation
Alcohol is produced from carbohydrates by fermentation with yeast. Yeasts are unicellular,
uninucleate fungi that can reproduce by budding, fission or both. They have been used for
centuries to brew alcoholic beverages and are the most commonly used microorganism in the
industrial production of alcohol by fermentation. Ethanol production by fermentation
comprises four steps:
➢ Yeast propagation from yeast slant from the laboratory.
➢ Fermentation to produce fermented wash containing alcohol.
➢ Recovery, enrichment and purification of alcohol from fermented wash to produce 95.5
V/V alcohols.
➢ Production of absolute alcohol by dehydration of 95.5% V/V alcohol to produce absolute
alcohol.
A proper choice of appropriate technology in each of these steps governs the efficient and
viable operation of fermentation alcohol plant.
1) Yeast Propagation
Yeast, for the production of alcohol is characterized by high selectivity of the yeast species,
low production of by-products (side products), high ethanol yield, high fermentation rate, good
tolerance towards both high ethanol concentration and high in organics in the fermenting
substrate, high temperature tolerance, land high genetically stability. Although finding a strain
that has all these characteristics is difficult, a proper selection and development of the best
possible strain is needed. Sacharomycetes cervisiae and Sacharomycetes pombe are the
commonly deployed yeast strains in alcohol fermentation of sugars. The purity and sterility of
yeast culture used as inoculums have great influence on the alcohol yield and longevity of
yeast in fermenter. Flocculating yeasts are deployed for continuous fermentation particularly
with yeast recycle system. The selectivity of yeast is also essential to maintain the required
metabolic reaction pathways specific to conversion of sugars to alcohol. The side products are
higher alcohols, acids, etc. which naturally reduce the alcohol yields and final quality of
alcohol. It is, therefore, customary to propagate yeast from laboratory strain in increasing
volumes under sterile and aerobic conditions protecting the same from other wild yeasts and
moulds during their growth. This is done in 3 or four stages starting from a 1litinoculums
developed in laboratory from a well-preserved yeast culture slant. Yeast will be developed in
plant from fresh slant to laboratory flash culture and then in 3 stage S.S. yeast propagation
vessels which operate in series but in batch mode. When enough bio mass strength is
developed, it is pitched into Fermenter.
2) Fermentation
The yeast propagation is only at the start and stabilization of the fermenter. When once the
continuous fermentation is on, the yeast propagation is stopped and only a periodic
continuous addition of small make up of fresh culture from yeast vessel is done to maintain the
activity of yeast in the active yeast count in the fermenter. The yeast vessels are fitted with
jacket for sterilizing and cooling the medium in situ. Sterile air is supplied to these vessels
through compressor and the sterilization-system comprising a series of fine filters followed by
HEPA filters. Molasses from the molasses tank in the yard are pumped to transfer pump into
tipper type molasses weighing system and weighed molasses feed tank from where molasses
feed pump it to yeast vessels (when necessary) or to fermenter through a static mixer type
molasses diluter. Main fermenter could be one or two stages depending on the control system
envisaged based on the final designs. The heat of fermentation is extracted by circulating the
fermenter contents through wort coolers. Temperature in the fermenter is to be maintained at
32 - 34°C. Carbon dioxide evolved during fermentation is vented out through scrubber to
recover entrained alcohol vapors. Dilute molasses are fed to the fermenter continuously. The

final fermented wash is transferred by wash pump to yeast separation system comprising
hydrocolones and centrifuge. The sludge and dead yeast are purged into sludge tank and yeast
cream is returned to the fermenter while clear fermented wash is collected in wash tank.
Sludge from sludge tank is fed to the bottom of Analyzer Column in the distillation section.
Part of spent wash from a selected tray in the column C-01 is returned to fermenter after
cooling the same to as near to ambient temperature as possible. Anti-foam oil is added from
whenever necessary when the level in the fermenter rises beyond a limit due to foaming
because of runaway fermentation rate. The operations in the fermenter can be controlled
closely through automation. Process water is taken into scrubber water tank from where it is
fed to scrubber and overhead water tank by water pump. All process water in the fermentation
section is supplied by gravity from this overhead tank.
3) Rectified /ENA Spirit Distillation

Fermented wash from wash holding tank is pumped by wash feed pump to the top of
degassing column after preheating the same in beer heater and spent wash heat exchanger. The
vapors along with non-condensable gases from the top of degassing column are rectified in
Heads column, to expel the high volatiles, technically know as heads. Bottom liquid from the
degasser flows into analyzer column where alcohol is stripped from the liquid. The liquid from
bottom of analyzer column is completely stripped of alcohol and is pumped out by spent wash
discharge pump through heat exchanger where it preheats the fermented wash before it enters
degassing column. Part of spent wash from a tray, few numbers above the bottom tray is
cooled and returned to the fermenters as a measure of water saving and reduction of effluent
discharge. The dilute alcohol vapors from near the top of analyzer column are condensed first
in beer heater while exchanging heat with wash feed and then in analyzer condenser. Degasser
and analyzer operate under vacuum. The condensate is collected in Rectifier Feed Tank. The
vapors for stripping alcohol are generated from analyzer column bottom liquid in the analyzer
column re-boiler by using the rectified column top vapors, as discussed subsequently. Vapors
from the top of heads column are condensed in heads column condenser and then in head
column vent condenser. Part of the condensate is returned to column as reflux while a small
portion is taken out as an impure spirit cut. Liquid from bottom of column is also taken into
Rectified feed tank.
Dilute alcohol water mixture from rectifier feed tank are pumped by rectifier feed pump
through rectifier feed pre-heater in to rectifying column. Rectifier and its associated equipment
work under pressure so that these vapors can supply the necessary heat for generating the
vapors. The condensate from Analyzer is then pumped as Reflux to rectifying column. Rich
alcohol vapors at a concentration of 95.5% v/v from top of rectifying column are condensed

first in Analyzer and then in Reflux Vent Condenser. The liquid from analyzer and reflux vent
condenser are collected in Rectifier Reflux Tank. Part of the liquid from reflux vent condenser
may be drawn off as impure spirit. The impure spirit cut will be maintained as little as possible
to maintain aldehyde levels to meet the required limits in Absolute Alcohol.
Liquid from the reflux tank is pumped by Product Pump partly as product and partly as reflux
to the top of the Rectifying Column. The necessary rectifying vapors to Rectifying column are
generated by boiling the bottom liquid in Rectifier Column Reboiler using medium pressure
steam. Some side streams are drawn from rectifier column as light and heavy fractions of
higher alcohols called fusel oils and cooled in fusel oil coolers and are mixed with water and
allowed to separate out in fuel oil separator. All vents from High column vent condenser,
analyzer condenser, rectified feed tank and reflux vent condenser are connected to Vent Gas
Absorber where the vent gases are scrubbed with water to recover entrained alcohol. The
scrubber water is used for washing the fusel oils in fusel oil separator to recover alcohol from
the fusel oil fractions. The absorber vent is connected to vacuum pump which is used to create
vacuum in the analyzer and degasser.
The products Rectified Spirit and Impure Spirit, are cooled in product coolers and collected in
the respective receiver tanks prior to pumping the same through respective transfer pumps into
storage tanks in the excise godown. Impure spirit, is however, returned to Ethanol plant along
with the rectified spirit feed, subject to maintaining, the Absolute Alcohol quality required for
blending with petrol.
4) Fuel Grade Ethanol

Absolute alcohol is manufactured by dehydration of Rectified Spirit. The process adopted here
is based on Pressure Swing Adsorption (PSA) system using Molecular Sieves. The flow
scheme is shown in above referred flow diagram.
Rectified spirit, after preheating by waste hot streams, is vaporized and superheated in analyser
condenser and analyser by using medium pressure steam at 6 Kg/cm2g pressure. Hot vapors at
kg/cm² g pressure and 130° C temperature pass through PSA column, where the water vapors
are retained while water free alcohol is released as vapors. The vapors are condensed in high
column vent condenser and Rectified column reboiler and collected as Absolute Alcohol.
When the molecular sieve bed is saturated with water the alcohol vapors are shifted to the
other tower and the first tower is taken for regeneration. Regeneration is done first by pressure
releasing and creating vacuum and then by elutriating with dehydrated alcohol vapors from
the tower in dehydration operation. The vapors are condensed in Head column condenser and
reflux vent condenser and the vent vapors are recovered through scrubber degassing column.
Vacuum can be created vacuum by rectified feed pump. (Eductor may also be considered for

this duty). Product is cooled in fusel oil cooler and transferred to Absolute Alcohol receiving
tank and then on to storage tank.
➢ Molecular Sieve Technology
Molecular sieve technology works on the principle of pressure swing adsorption. Here water is
removed by adsorbing on surface of ‘Molecular sieve’ and then cyclically removing it under
different conditions (Steaming).
Figure-2.11 Molecular Sieve Technology

❖ Benefits of Molecular Sieve Technology
➢ The process ensures high process yield and negligible losses as 99.5 to 99.75% of the
ethanol in feed are recovered in the product.
➢ High Energy efficient process.
➢ The plant is automated, which virtually eliminates the human error.
➢ The plant can suitably be operated to 60 - 65 % turndown.

Figure-2.12: Flow diagram of Molasses based distillery operation

(D) Power Co-generation (10 MW)
The unit proposes to set-up 02 No boilers (01 no. 25 TPH Incineration boilers and 01 no. 100
TPH Incineration boilers boiler) and power turbine: 10 MW. Slop along with bagasse / Other
Biomass will be used as fuel for incineration boilers in Cane Juice Syrup or Molasses based
operation and only bagasse / other biomass will be used as fuel in grain-based operation.
These boilers will operate mainly to feed steam to Cane Juice Syrup / Grain / Molasses (B or
C Heavy) based operations and 10 MW power generations from Turbine.
Proposed 10 MW co-generation plant consists of a low-pressure water tube steam boiler
extraction cum condensing steam turbine. Fuel in the steam boiler will be burnt with the help
of air in the boiler furnace. Water will be circulated in the boiler drum and tubes thus getting
heated by the flame burning in the boiler furnace. Water comes out of the boiler drum located
at the top of the boiler as steam. Flue gases rise in the boiler furnace and come in contact with
the steam coming out of boiler drum.
Steam after coming in contact with flue gases gets 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.
After economizer, flue gases pass through air pre-heaters where they heat the air which is fed
to the boiler furnace for burning the fuel. After air pre heaters flue gases pass through ESP
where the dust particles are collected. The dust is collected from here.
High pressure superheated steam from boiler is passed through a steam turbine, which is used
for distillery process operations. While passing through the turbine, the high pressure and
temperature steam rotates the turbine rotor and an electric alternator mounted on the same
shaft. Electric power is generated by the alternator. This electric power generated is consumed
in house i.e. for running the distillery and utilities like boilers auxiliaries etc.
Figure-2.13: Process flow chart for co - generation power plant

2.7 Assessment of new & untested technology for the risk of technological failure
For this proposed project using different grades of Cane Juice Syrup or Grain or Molasses (B
Heavy or C Heavy) based, only proven technologies will be selected. No new or untested
technology will be used. The Process will be based on proven technologies i.e. HIFERM-
Fermentation, Multi Pressure Distillation with integrated / SA Evaporation followed by
Incineration.
2.8 Boiler Details

02 number of incineration boilers (01 no. 25 TPH Slop fired and 01 no. 100 TPH incineration
boiler) will be installed. Others details regarding this are mentioned in the Table-2.12 given
below: -
Table-2.12: Boiler details
Particulars Details
Type of Fuel Slop along with Bagasse / Biomass
B Heavy Molasses
Cane Juice Syrup Grains based
or C Heavy Molasses
based operation operation
based operation
Quantity of Fuel Slop: 479 TPD &
Bagasse / Other Slop: 1107 TPD.
Bagasse /
Biomass: Bagasse / Other
Other Biomass: 746
1200 TPD. Biomass: 393 TPD
TPD
Source: From in house / nearby sugar mills / open market.
Capacity of Boiler 25 TPH & 100 TPH (incineration boiler)
Stack Height 85 meters (common stack)
Pollution Control
ESP
Equipment
Source: Prefeasibility Report
Stack Details: Stack height calculation based on Sulphur content in bagasse and Slop,
H = 14 (Qs) 0.30
Where,
Qs: Sulphur emission in Kg/Hr,
H: Height of the Stack
SLOP will be used as fuel along with bagasse in boiler. As per CPCB, maximum Sulphur
emission in SLOP is 0.8 % and in Bagasse it is 0.05 %. Hence the adequate stack height for the
boiler is: -
H = 14 (394)0.3
H = 84.09 meter
Stack of height 85 meters will be made of RCC. Diameter at the top of the stack will be
approx.: 3.8 meters.
2.9 Details regarding the D.G. Sets
2 x 1500 KVA D.G. Sets will be installed for the power backup. Details regarding the D.G.
Sets are mentioned in the table given below:
Table-2.13: Details regarding the D.G. Sets
Sr. No. Details
1 Type of fuel HSD / LDO
2 Capacity 2 X 1500 KVA
3 Stack Height Approx. 7.7 m above roof top
Pollution control of equipment Adequate stack height of 7.7 m above roof
4
measures top & Acoustic Chamber
2.10 Storage Facilities

Storage facility is available for storage of Cane Juice Syrup & Molasses in Tanks, grain in silos.
Alcohol is stored in tanks. Bagasse / Biomass is being stored in fuel. Spent wash holding
lagoon having capacity of 7 days.
Table - 2.14: Storage provided for raw material, Product etc
Sr.
Type Storage facility Capacity
No.
1 Molasses Tanks Diameter: 23.5 m (30 Days
Storage), 04 Nos
2 Grain Silos 30 Days Storage (1 X 10000 MT)
3 Alcohol Tank 3000 KL Tank X 05 Nos
4 Spent wash Holding Holding Tank 29925 m2
Tank (Lined Lagoon) (Storage for 7 Days as per CPCB)
2.11 Major Equipment and Machineries

The detail of major equipment and machineries is given below:
Table: 2.15: Proposed Machinery with their capacity
Sr. No Proposed Machinery Capacity
01 Fermentation 570 KLD (150 x 4)
02 Analyser Column 570 KLD
03 Rectifier Cum Exhaust 570 KLD
04 MSDH Ethanol Plant 570 KLD
05 Evaporation Plant 5000 KLD
06 Incineration Boiler 100 TPH + 25 TPH
07 Steam Turbine 10 MW
08 CPU Unit, 5500 KLD

2.12 Estimated Project Cost
• Total cost of the Project: Rs. 70294.59 Lakhs
• Cost for Environment Protection Measures.
• Capital Cost: 7560 Lakh or 75.60 Crores.
• Recurring cost: Rs 8.50 Crores /Annum.
2.13 Treatment Scheme for Spent Wash

Spent wash generation from the distillation, which is a variable in different mode operations.
Spent wash generation in Mode-1 (100 % Cane Juice Syrup based) operation will be 3078
KLD, in Mode-2 (100% Grain based) operation will be 4275 KLD and in Mode-3 (100% B or
C-Heavy Molasses based) operation it will be 3990 KLD. Spent wash treatment scheme will be
different in Mode - 1, Mode - 2 & Mode - 3 operation.
❖ Distillery - 570 KLD (Cane Juice Syrup based operation):
Effluent in the form of spent wash will be 3078 KLD. It will be partly (923 KLD) recycled
into the process and rest (2155 KLD) treated concentrated in Multi effect evaporation and
then concentrate from MEE will be utilised in Incineration fired boiler of capacity 25 TPH
as a fuel along with bagasse/other biomass.
❖ Distillery - 570 KLD (Grains based operation):
Spent wash generated (4275 KLD) will be first fed into the decanter for solid separation
then supernatant from the decanter will be concentrated in MEE. Concentrate from MEE
will be mixed with wet cake of decanter. Mixture will have fed into the dryer for the
moisture removal. After drying DDGS will be sold as cattle feed.
❖ Distillery - 570 KLD (B or C heavy Molasses based operation):
Effluent in the form of spent wash will be 3990 KLD. It will be treated concentrated in
Multi effect evaporation and then concentrate from MEE will be utilised in Incineration
fired boiler of capacity 25 TPH & 100 TPH as a fuel along with bagasse/other biomass.
Other Effluent: In both Mode 1, 2 & 3, the remaining moderately polluted effluent due to
spent lees and evaporating condensate will be treated in polishing unit and recycled in the
same unit. Estimated domestic effluent will be 30 KLD, which will be treated separately in
Sewage treatment plant. Quantity of waste to be generated & scheme for their disposal is given
in the following chart.
a) Evaporation Section:
• Spent wash generated from distillation section will be transferred to first calendria of the
evaporator section. Five calendria will be installed as per design to concentrate the

dissolved solids. Treatment scheme suggested is four FF + finisher evaporation plant for
evaporation of spent wash. The following points will elucidate the basic working principle:
• After Integrated evaporator spent wash will be fed to stand alone evaporators four effects
(3+1) Forced circulation to concentrate it up to 60 brix to burn in incineration boiler
• Shell & tube type evaporators working on the principle of falling film evaporation will be
used, with Plate type Preheaters for preheating of FEED stream which serves the purpose
of energy conservation.
• Analyzer vapor will be transferred to the first effect evaporator shell side at the given
pressure and temperature as the heating medium.
• The feed from the feed balance tank will be extracted to gain the best heat recovery.
• Vapours which will be generated in 1st effect VLS (Vapor Liquid Separator) will be used
as heat source in the 2nd effect and from 2nd to third and so on.
• The product at the requisite concentration will be obtained at the outlet from the last
effect.
• A Shell & tube type multi-pass surface condenser will be installed for condensing the shell
side vapors.
• The pure vapours and the rejected process condensate will be collected in receiving
vessels.
• High efficiency pumps will be provided for pumping the required fluid.
• Complete operation of the plant will be under vacuum. Vacuum will be created with the
help of a water ring vacuum pump.
• Complete plant will be based on maximised automated techniques/equipment to get
constant output at requisite concentrations.
• The system will operate under vacuum. Water-ring vacuum pumps will be installed.
b) Incineration boiler along with the turbine generator:

Incineration boiler along with the turbine generator: The concentrated spent wash will be
mixed with auxiliary fuel like bagasse/other biomass fired into specially designed Slop fired
Boiler (Incineration Boiler) to generate steam and power.

Figure-2.14: Flow Diagram of Spent Wash Treatment during Cane Juice Syrup and
Molasses (B heavy or C heavy based operation)

Figure-2.15: Flow Diagram of Spent Wash Treatment during Grain Based Operation

c) Distillery Effluent Treatment Scheme - RO based Process Condensate Treatment Plant:
Other effluent like MEE Condensate, spent lees, DM Reject, Boiler & CT blowdown, Floor
washing will be treated in Condensate Polishing unit which will be RO Based Condensate
unit.
Quantity ETP Capacity (KLD)

4525 KLD 5500 KLD
(From MEE Condensate, (Comprises of Equalisation Tank, buffer tank,
spent lees, DM Reject, Boiler USAB, Extended Aeration, Secondary Clarifier,
& CT blowdown, Floor Tertiary Clarifier, MGF, ACF, UV Treatment,
washing) Ultra-filtration and RO).
DESIGN PARAMETER OF ETP
Flow Rate 230 KL / Hr
pH 1.5 - 2.5
Temperature* Max 60 0C
COD 4000 - 5000 ppm
BOD 1500 - 2000 ppm
VA 3000 - 3500 ppm
TDS 150 - 250 ppm
The treatment steps for achieving required product water quality are :-
• Primary treatment
• Anaerobic System
• Secondary Treatment (Including Aerobic System)
• Tertiary Treatment (ETP Recycling system)
• Primary treatment
1. Bar Screen
Bar Screens are mechanical filter are normally installed as the first line of defence to
remove large objects primarily, rags, woods, Plastics that manage to escape and find their
way through the drainage systems. Usually, these objects can be of extreme nuisance
because if left around going to the main treatment plant, they pose a significant risk of
damaging pumps and blocking valves.
Bar screens come in many designs. Some employ automatic cleaning mechanisms using
electric motors and chains, some must be cleaned manually by means of a heavy rake.
Items removed from the influent are called screenings and are collected in dumpsters. As a

bar screen collects objects, the water level will rise, and so they must be cleared regularly
to prevent overflow.
2. Oil and grease pit (Oil Skimmers)

Organic toxic waste (oil and grease (O&G)) causes ecology damages for aquatic
organisms, plant, animal, and equally, mutagenic and carcinogenic for human being. They
discharge from different sources to form a layer on water surface that decreases dissolved
oxygen. O&G layer reduces biological activity of treatment process where oil film
formation around microbes in suspended matter and water. This lead to decrease
dissolved oxygen levels in the water. Then oxygen molecules are difficulty to be oxidative
for microbial on hydrocarbon molecules and cause ecology damages to water bodies.
The conventional techniques remove oil and grease using skimming tanks with skimmer
and oil and grease traps in treatment plants.
The skimmer is a rotating cylindrical device design to remove the surface oil layer. It
consists of using cohesive force between the oil and the surface of the material to be move
up. The metal part must be immerged in 1cm to 3cm of the free oil layer floating on the
top of the water. The oil catches in the rotary device drop in a conveyor which evacuates
oil in a container for oil recovery. After bar screen waste water will move to Oil and grease
pit. Here all the oil and grease will be removed from the waste water.
3. Equalization Tank
An equalization tank providing consistent flow and loading to a biological process is
important to maintain optimal treatment. Equalization (EQ) Basins are designed to
provide consistent influent flow to downstream processes by retaining high flow
fluctuations. Due to the additional retention time, aeration and mixing is required in
equalization basins to prevent the raw wastewater from becoming septic and to maintain
solids in suspension. We offer equipment that mixes your EQ Basin to keep suspended
solids in solution, add fine bubble aeration to minimize odors, and also ensure predictable
and constant flow equalization.
Effluent from the oil and grease pit comes to the equalization tank in wastewater
treatment. The main function is to act as buffer and to collect the incoming raw effluent
that comes at widely fluctuating rates and position to the rest of the CPU at steady
(Average) flow rate. During the peak hours CPU comes at high flow rate. The
equalization tank stores this effluent and lets it out during the non peak time when there is
no /little incoming effluent. The process condensate and the spent lees are mixed in the
equalization tank, from where it is pumped into the plated heat exchanger.

Effluent quantity at the out let of Equalisation tank will be are as follows:
EFFLUENT QUALITY AT OUTLET OF ET
pH 1.5 - 2.5
Temperature* Max 60°C
COD 4000 - 5000 ppm
BOD 1500 - 2000 ppm
VA 3000 - 3500 ppm
TDS 150 - 250 ppm
4. Plated Heat Exchanger

This is a type of heat exchanger in which heat is transferred by means of metal plates that
are inserted between two fluids. A large surface area is available for the exchange of heat
as the fluids are spread over the surface of the plates. As a result, they have high heat
transfer efficiency.
This design is generally suited for transferring heat between medium and low-pressure
fluids. The heat exchanger maybe welded, semi-welded and brazed heat exchangers. The
effluent from the equalization tank is passed through the plated heat exchanger where it
exchanges heat with the cooling water. After the heat exchange occurs, the temperature of
the effluent is reduced.
5. Buffer Tank
The effluent outlet from the plated heat exchanger is passed into a buffer tank, where,
sodium carbonate/caustic dosing is carried out along with nutrient dosing. The aim is to
ensure that sufficient food source is available for the bacteria to digest the effluent in the
UASB. This also ensures to maintain the desired Mixed Liquor suspended solids (MLSS
level within the UASB for the bacteria to act on. The nutrients and chemicals dosed in the
buffer tank are mixed by means of mechanical agitation to ensure uniform distribution of
the same within the effluent.
Anaerobic System
1. Anaerobic Up-flow Sludge Blanket Reactor (UASB)
The effluent from the buffer tank enters the anaerobic upflow sludge blanket reactor
(UASB) which is a single tank process capable of achieving a good reduction in the
organic pollutants. The effluent enters the reactor from the bottom and flows upward. A
suspended sludge blanket filters and treats the wastewater as it flows through it. The
bacteria present within the sludge helps to break down the organic matter by anaerobic
digestion. A by-product of this reaction is Methane, which is separated from the sludge by
means of a gas solid separator. A flare stack will be provided to burn the gas generated
from the process. The blanket floating of sludge floating on top provides a filtration effect
to retain the solids in the effluent. This results in an effluent with lower content of organic
pollutants in it. However, the effluent generated requires further polishing which can be
achieved by means of a secondary clarifier. Effluent quanlity at the out let of USAB
reactor will be are as follows:
EFFLUENT QUALITY AT OUTLET OF USAB
pH 6.7 - 7.0
COD 800 - 1000 ppm
BOD 250 - 300 ppm
VA 100 - 500 ppm
TDS 900 - 1100 ppm
Alkalinity 800 - 1500 mg/Lit
Figure-2.16: Anaerobic Up-flow Sludge Blanket Reactor (UASB)

• Secondary Treatment
1. Extended Aeration Tank
The UASB removes a major portion of the organic contaminant in the effluent, however,
some organic contaminants still pass through the outlet of the UASB. The sludge

generated in the UASB is anaerobic in nature. Extended aeration helps to remove the
residual BOD and COD escaping the UASB reactor. Effluent quality at the out let of
Aeration tank will be are as follows:
EFFLUENT QUALITY AT OUTLET OF USAB
pH 7.50 - 7.80
COD 120 - 150 ppm
BOD 25 - 30 ppm
TDS 500 - 550 ppm
2. Secondary Clarifier
A circular basin in which effluent from the activated sludge process is held for a period of
time during which the heavier biomass (microorganisms) settles to the bottom as
“activated sludge.” This sludge, teaming with hungry microorganisms, can be returned to
the aeration basin to begin the activated sludge treatment process all over again.
Secondary clarifier built with mechanical means for continuous recycling of Activated
Sludge. Clarifiers work on the principle of gravity settling. The heavier suspended solids
settle in the clarifier due to the quiescent conditions provided in the Clarification zone.
Settled culture from secondary tank will be recycle to Aeration to maintain the MLSS in
aeration tank.
3. High-Rate Solid Contact Clarifier (HRSCC) / Tertiary Clarifier

The effluent overflow from the secondary clarifier passes into a tertiary clarifier which is a
high-rate solid contact clarifier. Coagulant dosing, polymer dosing and sodium hypo
dosing is carried out before the inlet of the HRSCC. The HRSCC works on the principle of
solids contact which combines coagulation, flocculation and clarification in a single unit.
It uses minimum time and space while producing a high quality of effluent and is
extensively used for coagulation and clarification of water and wastewater containing high
turbidity and suspended solids.
The feed water is pumped into the contact zone at the centre of the clarifier. The feed is
intimately mixed in the mixing zone. A separate speed impeller in the solids contact zone
independently controls this solid contact. The rapid mixing results in the formation of
dense particles and compact sludge. From the mixing zone, the water enters into the
external settling room where solid particles settle rapidly at the bottom for process in the
centrifuge.
The sludge scrapper arms help to carry the sludge to the central sludge pit from where it is
easily drawn out as highly concentrated slurry. The clarified water exits at the top and
flows out through launders.
4. Decanter/ Centrifuge
The sludge collected from the extended aeration tank, secondary clarifier and tertiary
clarifier are collected in a common sludge sump by gravity. The sludge is then pumped by
means of decanter feed pump to a decanter centrifuge, which helps to recover some water
from the sludge. This device uses high rotational speed to separate components having
different densities. It separates solid materials from liquids in the slurry by means of
gravitational separation and is crucial in effluent treatment processes. Higher density
components would settle at the bottom of the mixture, whereas, the less dense
components would be suspended above the mixture. Employing a centrifuge reduces the
settling time of the components by a large margin. To aid in settling of the particles,
dewatering polyelectrolyte is dozed in the sludge inlet to the centrifuge. Generally,
thickening and dewatering are inhibited by the sludge particles, chemical characteristics
and physical configurations. The polyelectrolyte in solution act by adhering to the sludge
particle surface causing desorption of bound surface water and the agglomerization of
small particulates by bridging between particles. As a result, combination of dewatering
polyelectrolyte with centrifuge process results in recovering a good percentage of water
from the sludge as compared to other processes. The centrate from the centrifuge will be
transferred to the filtrate equalization tank, whereas the concentrated sludge will be
disposed as per the norms.
• Tertiary Treatment (ETP Recycling System)
1. Multi Grade Filter (MGF)
The treated effluent from the secondary clarifier will be collected in a clear water storage
tank of RCC construction from where it will be pumped into a multi grade filter. The
MGF reduces the level of suspended solids along with any turbidity of the influent water.
Graded sand & pebbled are used as the filtration media for MGF. With time, the top of
the filter gets clogged with particles that have been filtered out, which results in the
increase of differential pressure across the filter media. As a result, the quality and the
quantity of the filtrate will have affected. To restore the performance of the MGF to its
original levels, backwash will be carried out with the aid of filtrate water. The backwash of
the filter will be carried out by means of feed pumps itself. Air blowers are provided for
loosening the filter before the backwash is initiated.
2. Activated Carbon Filter (ACF)
The outlet of the MGF is fed into an activated carbon filter (ACF) to remove colour, odor,
organics and any free residual chlorine that escapes from the MGF. The contaminants are
removed by means of adsorption, whereby the pollutants get trapped inside the pore
structure of the carbon substrate. The high specific surface area of the activated carbon
particles enables the capturing of the contaminants from the influent water. With time, the
activated carbon pores get filled up, thereby downgrading the quality of the effluent. As a
result, the quality and the quantity of the filtrate will have affected. To restore the
performance of the ACF to its original levels, backwash will be carried out with the aid of
filtrate water. The backwash of the filter will be carried out by means of feed pumps itself.
3. Ultrafiltration (UF)
A portion of the effluent from the process water tank is passes into the ultrafiltration
system. The water from the outlet of the ACF may contain fine colloidal particles &
organics which may cause fouling of the RO membranes over a period of time, This may
affect the system performance in terms of treated water quality and quantity. The use of an
ultrafiltration system helps to reduce the colloidal particles and micro-organism. The UF
system is complete with cleaning in place (CIP) system to carry out chemically enhanced
cleaning of UF membranes. The permeate from UF is collected in a permeate cum
backwash water storage tank, from where it is pumped into the RO feed system and also
used for the backwash cum chemical cleaning of the UF membranes.
4. Reverse Osmosis (RO) System
The purpose of RO system is to remove the dissolved solids from the filtrate water and to
produce water of the desired quality for Cogen CT make up. High Pressure feed pumps
take suction from cartridge filters and pump water through RO trains. Permeate from RO
trains is collected in RO permeate storage tank from where it is pumped by RO permeate
transfer pump up to the specified terminal points. Reject water from RO trains along with
the CIP waste shall be collected in a RO reject tank from where it will be pumped by
means of RO reject transfer pumps. The RO system is provided with cleaning in place
(CIP) system with associated tanks, pumps etc. Chemicals such as acid, antiscalant and
dechlorination agent shall be dosed at the inlet to MCF for ensuring effective treatment.
Treated effluent quality at the out let of RO System will be are as follows:
EFFLUENT QUALITY AT OUTLET OF RO SYSTEM
pH 6.90 - 7.10
COD 20 - 50 ppm
BOD 3 - 5 ppm
TDS 200 - 350 ppm
TSS Nil
5. UV System
A portion of the water from the outlet of process water tank is pumped to a UV e purpose
of this system is to disrupt the the growth of harmful microorganisms in the treated water.
High energy UV radiations penetrate the harmful microorganisms and are absorbed by
DNA of the pathogens in the influent water. This causes the DNA to be altered rendering
the pathogen ineffective in reproducing, thereby killing them. UV system are capable of
destroying around 99.99% of all the harmful microorganisms including E. Coli,
Cryptosporidium.
6. Chemical Dosing System
Purpose of dosing system is to prepare and feed various chemicals required for RO and
post treatment systems. Chemical dosing system shall include dosing of Acid, Anti-
scalant, Anti - oxidant, Alkali, etc.
2.14 Description of Mitigation Measures

Following mitigation measures will be adopted by M/s Bajaj Hindusthan Sugar Limited,
Unit: Barkhera to minimize the impact of project on the surrounding environment.
Table-2.16: Impact of project activity on the surrounding environment
Sr No Project Activity Aspect Impact Mitigation
1. Transportation Dust ▪ Increase in ▪ Paved Road
Generation dust ▪ Speed limit in plant
concentration premises
in the ambient ▪ Control for vehicular
air movement
▪ Significant ▪ Water sprinkling
impact on ▪ Vehicles should be PUC
biotic certified
environment ▪ Greenbelt & plantation on
▪ Spread of both sides of the internal
respiratory roads & plant boundary.
diseases in
nearby
population
Increase in ▪ Congestion of ▪ Flow of vehicles to be
number of roads due to maintained
vehicles increase in ▪ Maintenance of parking
existing traffic area
load.
▪ Noise
generation due
to vehicular

movement and
increase in noise
level.
2. Fermentation Generation Increase in • CO2 generated during the
of CO2 greenhouse gases fermentation process will
be recovered by CO2
Scrubbers and sold to
beverage & packaging
industry.
Generation Odor Nuisance Yeast sludge will be mixed
of yeast with press mud and will be
sludge given to the farmers for soil
amendment.
3. Multi Pressure Generation ▪ Spent wash has During Cane Juice Syrup or
Distillation, of spent high BOD & Molasses (B heavy / C
MEE and wash COD level and heavy) based operation:
cooling tower due to this high Spent wash generated will be
concentration of concentrated in Multi-effect
pollutants it evaporator and then used as
causes negative fuel in incineration boiler.
impact on surface During Grain based
& ground water operation: Spent wash
and also affect generated will be fed into
biotic decanter for solid separation,
environment. then concentrate in MEE,
▪ Generation of concentrate from MEE will
odor causes be mixed with wet cake then
health diseases in dried in dryer and converted
nearby areas. to DDGS.
Spent Lees Reused in Process
MEE • Treated water will be
condensate recycled & reused in
& cooling process.
tower blow
down

4. Boiler Particulate ▪ Respiratory ▪ Installation of ESP with
Operation matter & disease due to adequate stack height
gaseous PM ▪ Covered storage for fuel.
emission ▪ Effect on biotic ▪ Continuous emission
environment monitoring system will be
installed at process stacks
to monitor stack
emissions
Generation ▪ Increase noise ▪ Use of earmuffs, earplugs
of noise level at work & ear defenders
zone ▪ Maintenance of
▪ Health impact equipment
such as ▪ Insulated enclosures
hearing ▪ Greenbelt development at
impairment & plant boundary
irritation
Boiler ash ▪ Water & Soil ▪ Ash generated from
(Solid waste) Contamination incineration boiler will
have potash content
approx. - 22 % - 27 %,
which will be converted to
granule and will be used
as manure.
▪ During Grain based
operation, ash generated
will be supplied to Brick
Manufacturer.
5. DG set Particulate ▪ Respiratory ▪ D.G. sets emission limits,
operation matter & disease due to ▪ Stack height (7.8 m) will
Backup gaseous PM & be as per CPCB
emission Gaseous guidelines.
pollutant.
▪ Effect on biotic
environment
6. Effluent Spent wash ▪ Water & Soil ▪ Well-designed HDPE

Treatment lagoon Contamination lined lagoon
Plant
7 Storm Water ▪ Rain water ▪ Ground water ▪ Rainwater harvesting will
losses contamination be used for conservation
▪ Soil erosion ▪ Odor Nuisance of water (collection of
storm water drainage)
▪ Industry will adopt the
pond outside the premises
for rain water harvesting.

Bajaj Hindustan Sugar - Distillery and Cogen Feasibility Report - 2024

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Establishment of new Cane Juice Syrup / Grains / B or C-Heavy Molasses Based Distillery

CHAPTER No. - 02:

2.1 Type of project

2.2 Need for the project

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Consumption of Ethanol in India:

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2.3 Proposed Distillery

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Figure-2.1: Topo sheet showing 15 Km radial distance of study area

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Figure-2.2: Google Satellite Image depicting proposed distillery

Figure-2.3: Location Map of Project site

Landuse breakup within premises

Roof Top (Building, Covered Shed)

Road and paved

33% Open Area

Figure-2.4: Land Use Breakup with in premises

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Figure-2.5: Layout Plan with Greenbelt

2.4.1 Plant setup

2.5 Other Basic Requirement

2.5.1 Raw Material Requirement and Source

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2.5.2 Water Requirement

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2.5.4 Fuel Requirement

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2.5.5 Power Requirement

2.5.6 Man Power Requirement

2.5.7 Proposed schedule and approval for implementation

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2.6 Technology and Process Description

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Figure-2.9: Schematic Flow chart of RS / ENA /AA on Mode - 1

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Figure-2.10: Process flow diagram during grain-based operation

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3) Rectified /ENA Spirit Distillation

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4) Fuel Grade Ethanol

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Figure-2.11 Molecular Sieve Technology

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Figure-2.12: Flow diagram of Molasses based distillery operation

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Figure-2.13: Process flow chart for co - generation power plant

2.8 Boiler Details

2.10 Storage Facilities

2.11 Major Equipment and Machineries

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2.13 Treatment Scheme for Spent Wash