29-08-2014, 03:11 PM
MIS. DHARANI SUGARS AND CHEMICALS LlMTIED - UNIT III
[attachment=67352]
1.0 INTRODUCTION
Although India is the largest producer of sugarcane and sugar, the sugar factories in India are
facing problems due to the mismatch between sugar cane price and sugar price. Sugar
factories are not viable if they produce sugar alone. It is necessary to develop the factory into
an integrated complex and use the valuable byproducts more beneficially.
Molasses is one of the important by product of the sugar industry. The profits earned by the
conversion of molasses to alcohol will be higher that that of the value realized by sale of
molasses. There is a good demand for alcohol in the country, as production and consumption
of alcohol are not quite balanced.
The target of alcohol demand as projected in the perspective plan for chemical industry,
prepared by the Govt. of India, Ministry of Industry, Dept. of chemical and petrochemicals is
around 2400 million liters per annum. It is with this view that Mis. Dharani Sugars and
Chemicals Limited has proposed to set up a green field distillery in Sankarapuram Taluk,
Villupuram District. Mis. Dharani Sugars and Chemicals Limited already have one distillery
with an annual installed capacity of 30,000 litres of Rectified spirit at Vasudevanallur factory.
The existing distillery utilizes molasses captively from this sugar factory as the main raw
material. Molasses from the other factories are presently sold to Industrial users I cattle feed.
In order to add value to molasses, it is proposed to set up a green field distillery to convert all
the available molasses to a mix of alcohol products.
The proposed new distillery will have the flexibility to produce Rectified Spirit, Extra neutral
alcohol and Anhydrous Alcohol based on the market requirement. The plant will incorporate
multi-pressure distillation over conventional steam distillation for better energy efficiency
and consistent good quality of the product.
In order to add value to molasses, it is proposed to set up a green field distillery to convert all
the available molasses to a mix of alcohol products. Kalayanallur factory has been selected
for setting up of the new distillery.
1.1 Plant Location
1.2
The Plant is located at S.F. No 47, 48(Part), 49, 50(Part), 51(Part) Kalayanallur village,
Sanka"rapuram Taluk, Villupuram District. Kalayanallur village is located about 17 km away
from Kallakurichi Town and it is in-between the road connecting Kallakurichi and
Ulundurpettai. The site is located in the Northern direction of this road. The nearest Major
railway station is Villlupuram.
1.3 Project Estimated Cost
1.4
The gross assets value of the proposed project is RS.66.81 crores. Budgetary allocation for
Environment Management alone will be RS.18 Crores
Manufacture of Rectified Spirit:
The yeast in initially propagated in the propagation vessels and then transferred to the
fermenter. Molasses diluted with water to the desired concentration is metered continuously
in to a fermenter. Spent wash from distillations re circulated to fermenter depending on solids
concentration in fermented wash and molasses composition. During fermentation process
yeast cells convert sugar in to alcohol. Fermentation is an exothermic reaction heat is evolved
during this fermentation and it is cooled by continuous cooling through plate type heat
exchanger. Temperature is maintained between 32-35°C. Small quantities of Urea and DAP
are added in the fermentor as nutrients to the yeast cells. Viable cell population of 300- 500
million cellsjml is maintained in the fermentor by continuous aeration and yeast recycling.
The fermented wash passes through series of hydrocyclones, which removes grit, iron filling
and heavy particulate matter. The material settled at the bottom of the hydrocyclone is fed to
the bottom of the analyzer column to strip the alcohol present in it. The overflow from the
hydrocyclone is fed to the yeast separators. Yeast cream is recycled back to the fermenter to
maintafn the yeast cell population. De yeasted wash is stored in prop III vessels.
The wash is preheated to 85 - 90°C in the heater, plate type mash heater and spent wash
cooler and it is fed to top of the degasifying column. Fermented wash is stripped off alcohol
by ascending vapours in Analyser column. Rectifier vapours Rrov.ide energy to analyzer
column through a Thermosyphon reboiler. Vapours of degasifying column are condensed and
taken to pre Rectifier Feed Tank. Analyser vapours are condensed in Evaporation section.
The condensed analyzer vapours are taken to pre Rectifier Feed Tank. Rectifier Column,which operates under pressure, concentrates the condensate of analyzer column to 95% v/v
concentration. Condensing steam provides energy to pre rectifier column through a vertical
Thermosyphon reboiler. Fusels oil draws are taken from appropriate and fed to FO decanter.
An impure spirit cut of about 2 - 3 % of the Total spirit production is taken out from the top
of the pre rectifier column. Rectified spirit draw of 95% vjv is taken out from the upper trays
of pre rectifier column.
Manufacture of Extra Neutral Alcohol:
The concentrated rectified spirit from Pre-Rectifier column is fed to the Extractive
Distillation column. Dilution water is fed on the top most of the column with a dilution ratio
of 1 :9. this column serves to remove the impurities based on the principles of HydroExtraction. The water is fed to the column in such a way that it selects the higher alcohols
and other impurities to move upwards and extracts ethanol down. The top vapours of the
columns are condensed and feed to the recover column.
The purified dilute ethanol is removed from the bottom of the column and feed to the
rectification column, which concentrates ethanol to 96% v/v. Rectifier Column operates
under pressure and condensing steam provides energy to this column through a vertical
Thermosyphon reboiler. ENA draw is taken out from appropriate upper trays and fed to
Simmering Column after cooling. 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. The lees of the column are recycled as dilution water after a part of it is purged.
Lower side draw streams are taken from rectification column to avoid fusel oil build up in the
column. These streams are sent to the Recovery Column where these fusel oils are
concentrated and then sent to decanter where these streams are diluted with water band fusel
oil rich layer is separated. Washings are sent back to the column to recovery alcohol. An
impure spirit cut will be taken from top of this column.
Manufacture of Anhydrous Alcohol:
Production of anhydrous alcohol from rectified spirit (Industrial Ethanol) with molecular
sieve dehydration utilizing pre concentration column:
The rectified spirit, before sending in for dehydration process, it is heated and water is
stripped in the pre concentration column through a pre-heater. The mixture of alcohol and
little water is sent to molecular sieve in the form of vapour.
The molecular sieves are hard granular substances, cylindrical extrudates manufactured from
clay like silica gel material such as potassium alumino silicates. They are grated according to
the nominal diameter of the myriad of internal pores,
which make up the interstitial free volume found within their structure. A typical sieve used
in ethanol dehydration in Type 3A. This designation means that the average diameter of the
interstitial passageways is 3 Angstroms (One Angstroms: 1A is unit of measures equivalent
to 10-8 centi meters). Thus, the passageways in the structure have a diameter that is
molecular scale. The water molecule has a mean diameter less than 3A, while the ethanol
molecule has a mean diameter greater than 3A.
In addition, the water molecules can be absorbed on the internal surface offered by the
passageways within the molecular sieve structure. It is the physical property of the sieves,which make them useful for the separation of mixture of ethanol and water.
Water molecules can invade the inner structure of the molecular sieve beeds and be absorbed
thereon, while the ethanol molecules are too large and pass out of the vessel leaving the water
behind, Thus, dehydration of ethanol takes placer in the molecular sieve technology.
In this technology, the re-generation of beads is done by one bed under vacuum; while the
other bed is producing anhydrous ethanol vapour under pressure with an automated
operation, the feed of vapour to the molecular sieve system can be taken directly from the pre
concentration column passing through a superheated. The pre concentrated column is
operated at a pressure sufficient to economically operate a reboiler. The condensed anhydrous
alcohol vapour are cooled and passed to storage through product cooler. The recovered
ethanol and water from the regeneration phase is fed back to the pre-concentration column for
recovery. Thus, there is no generation of effluent except the condensate water from steam is
cooled and taken back process.
2.4 Power and Fuels
Total Power requirement of the Plant will be 1400 KWH. Total Power will be obtained from
its sister concern MIS. Dharani sugars and chemicals limited (cogeneration Plant).
2.5 Raw Water
The total requirement of raw water for this unit will be 600 KLD, which will be met from
wells inside the factory premises
2.6 Land
The total area allotted for this factory is 9.71 hectares.
2.7 Manpower
The total workforce including staff and workers will be 60.
3.0 POLLUTION CONTROL MEASURES
3.1 Air Emissions
In the Fermentor, the evolved traces of CO2 will be scrubbed with water and scrubbed water
will be recycled in the process. Clean air will be discharged from the scrubber to the
atmosphere. For wet scrubber, 15.0 meter height from ground level and 0.6 m diameter of
stack will be provided. The emission from boiler will be controlled by 40m height of stack
with bag filter will be provided.
3.2 Wastewater Generation
The waste water from the domestic usages (4 KLD) will be sent directly to the septic tank of
size 5 x 2 x 2 m (2 Nos) followed by the dispersion trench of size 5.0 x 2.0 x 2.5 m . 700 CU
M spent wash of 17% concentration will be generated from the process, which is further
concentrated in Evaporators to a concentration up to 55% V/V and used along with coal in
the specially designed boiler and incinerated. The condensate water coming out from
evaporators are used in Boiler as well as in Distillery process
By this way, the management proposes to achieve zero discharge system to have a better
environment not only in the factory premises and also to the surrounding environment.
PROCESS DESCRIPTION OF EVAPORATION SYSTEM
Five Effect Falling Film Evaporator
Flow = inlet - E1 - E2 - E3 - E4 - E5
The above flow pattern is specially designed for utilization of available energy. High wetting
rates are provided in falling film bodies. This will reduce scaling and the offline CIP
frequency/downtime of evaporator.
The spent wash from distillery from storage is fed to falling film Evaporator system, where it
is concentrated from 17% to 25% solids. The analyzer column vapors and exhaust steam
from Turbine are used as heating media. All the Effects are falling film type with vapour
separators.
The feed from feed tank will be introduced into the effect 1. The vapours from analyzer
column are used as heating media in Effect 1 and recovered in the form of condensate.
Partially concentrated feed is then transferred to Effect 2 and subsequently to effect 3. The
vapour from Effect 1, are given to Effect 2 as heating media. Evaporated vapours from effect
2 are used as heating media in Effect 3 and so on. Finally the vapours separated in VS 3 are
condensed in a Plate type surface. condenser.
The partially concentrated feed flows from E1 to E2, E2 to E3 and further up to E5, by means
of transfer cum recycle pumps. Final concentration is achieved in Effect 5. Level control
loops are provided for all effects to ensure trouble free operation.
INCINERATION OF CONCENTRATED SPENT WASH
The concentrated spent wash of around 55 brix from the concentration plant is then pumped
in to the specially designed boiler for incineration along with coal as supplement fuel. The
concentrated spent wash with above composition and calorific value is burnt to generate
steam at designed pressure and temperature. This steam is then taken into turbine for
generation of power and the exhaust steam is utilized for concentration and other process
requirements.
The flue gas from combustion process is vented out after removal of suspended particulate
matter in specially made bag filters and sulfur-dioxide in scrubbers. The ash collected from
the process rich in potash can be sold for fertilizer application and used in brick j cement
blocks manufacturing.
3.4 Hazardous Waste
There will be no hazardous waste generated from this proposed distillery unit.
3.5 Noise
The noise level in the inside & outside the factory is maintained at low level.
3.6 Odour Control System
Since the entire process like distillation and CO2
scrubber will be proposed with world-class
technology, the odour from the process will be of very minimum.
4.0 PRESENT ENVIRONMENT SCENARIO
4.1 Climate
The climate is generally arid with temperatures varying from 20.00C to 37.9°C. The rainfall
is maximum in the NE monsoon period and minimum in SW monsoon period.
4.2 Ecology
There is no endangered species of flora and fauna noticed in this area. The area does not
shelter any specific wildlife.
4.3 Hydrological Conditions
4.3.1 Surface Water
The run-off during monsoon period contributes to the surface water. There is no perennial
stream or river in the surrounding villages. These villages get water from open wells and bore
wells which get recharged in rainy season
4.3.2 Ground water
The ground water table varies from 68 m to 92 m. It is therefore a low to medium potential
zone for ground water.
4.4 Water Quality
Water samples were collected from different locations, and the following parameters will be
monitored for Ph, Colour (Visual), Odour, Turbidity (NTU), Electrical Conductivity, Total
Suspended Solids, Total Dissolved Solids, Chlorides (as CI), Sulphates (asSO4
), Calcium (as
Ca), Magnesium (as Mg), Total Hardness(as Caco3), Phenolphthalein Alkalinity(as CaCO3
),
Total Alkalinity (as CaCO3
), Iron (as Fe)
4.5 Ambient Air Quality and Noise Levels
The ambient air quality will be conducted as per the SPCS Norms. The following parameters
will measured as follows, SPM, RPM, SO2
, NOx.
4.6 Land Use Pattern
The entire area is a patta land owned by the company and it is in the form of shrub land. The
buffer zone has no forests.
4.7 Socio-Economic Conditions
There is no habitation or settlement in the industrial area. The nearest village of Kalayanallur
is having a population of 1739 with 940 males and 799 females as per 2001 census data. The
workers constitute 56.6%. The major source of income of the local population is from these
types of industries and agriculture only.
5.0 ENVIRONMENTAL IMPACT ANALYSIS
5.1 Air Quality
In the Fermentor, the evolved traces of CO2 will be scrubbed with water and
scrubbed water will be recycled in the process. Clean air will be discharged from the scrubber
to the atmosphere. For wet scrubber, 15.0 meter height from ground level and 0.6 m diameter
of stack will be provided. The emission from boiler will be controlled by 40m height of stack
with bag filter will be provided.
5.2 Water Resource
This proposed unit is depending on bore well for its different water requirements and the
quantity will be 600 KLD.
6.0 ENVIRONMENTS, SAFETY AND HEALTH MANAGEMENT
6.1 Organization Structure
The Senior General Manager is responsible for the factory operations. There are several
executives for various sections such as Production, Human Resource, Purchase, Store,
Accounts, Environmental & Safety, Maintenance, and Quality Control etc.
6.3 Air Quality Management
Proper control measures will be provided in all process area in order to control all emissions
if any to maintain a safe and healthy work place environment. The vent air will be passed
through pollution control equipments before it is released into the atmosphere.
6.4 Wastewater Management
The domestic sewage will be disposed by means of septic tank of size 5.0 x 2.0 x 2.0 m (2
[attachment=67352]
1.0 INTRODUCTION
Although India is the largest producer of sugarcane and sugar, the sugar factories in India are
facing problems due to the mismatch between sugar cane price and sugar price. Sugar
factories are not viable if they produce sugar alone. It is necessary to develop the factory into
an integrated complex and use the valuable byproducts more beneficially.
Molasses is one of the important by product of the sugar industry. The profits earned by the
conversion of molasses to alcohol will be higher that that of the value realized by sale of
molasses. There is a good demand for alcohol in the country, as production and consumption
of alcohol are not quite balanced.
The target of alcohol demand as projected in the perspective plan for chemical industry,
prepared by the Govt. of India, Ministry of Industry, Dept. of chemical and petrochemicals is
around 2400 million liters per annum. It is with this view that Mis. Dharani Sugars and
Chemicals Limited has proposed to set up a green field distillery in Sankarapuram Taluk,
Villupuram District. Mis. Dharani Sugars and Chemicals Limited already have one distillery
with an annual installed capacity of 30,000 litres of Rectified spirit at Vasudevanallur factory.
The existing distillery utilizes molasses captively from this sugar factory as the main raw
material. Molasses from the other factories are presently sold to Industrial users I cattle feed.
In order to add value to molasses, it is proposed to set up a green field distillery to convert all
the available molasses to a mix of alcohol products.
The proposed new distillery will have the flexibility to produce Rectified Spirit, Extra neutral
alcohol and Anhydrous Alcohol based on the market requirement. The plant will incorporate
multi-pressure distillation over conventional steam distillation for better energy efficiency
and consistent good quality of the product.
In order to add value to molasses, it is proposed to set up a green field distillery to convert all
the available molasses to a mix of alcohol products. Kalayanallur factory has been selected
for setting up of the new distillery.
1.1 Plant Location
1.2
The Plant is located at S.F. No 47, 48(Part), 49, 50(Part), 51(Part) Kalayanallur village,
Sanka"rapuram Taluk, Villupuram District. Kalayanallur village is located about 17 km away
from Kallakurichi Town and it is in-between the road connecting Kallakurichi and
Ulundurpettai. The site is located in the Northern direction of this road. The nearest Major
railway station is Villlupuram.
1.3 Project Estimated Cost
1.4
The gross assets value of the proposed project is RS.66.81 crores. Budgetary allocation for
Environment Management alone will be RS.18 Crores
Manufacture of Rectified Spirit:
The yeast in initially propagated in the propagation vessels and then transferred to the
fermenter. Molasses diluted with water to the desired concentration is metered continuously
in to a fermenter. Spent wash from distillations re circulated to fermenter depending on solids
concentration in fermented wash and molasses composition. During fermentation process
yeast cells convert sugar in to alcohol. Fermentation is an exothermic reaction heat is evolved
during this fermentation and it is cooled by continuous cooling through plate type heat
exchanger. Temperature is maintained between 32-35°C. Small quantities of Urea and DAP
are added in the fermentor as nutrients to the yeast cells. Viable cell population of 300- 500
million cellsjml is maintained in the fermentor by continuous aeration and yeast recycling.
The fermented wash passes through series of hydrocyclones, which removes grit, iron filling
and heavy particulate matter. The material settled at the bottom of the hydrocyclone is fed to
the bottom of the analyzer column to strip the alcohol present in it. The overflow from the
hydrocyclone is fed to the yeast separators. Yeast cream is recycled back to the fermenter to
maintafn the yeast cell population. De yeasted wash is stored in prop III vessels.
The wash is preheated to 85 - 90°C in the heater, plate type mash heater and spent wash
cooler and it is fed to top of the degasifying column. Fermented wash is stripped off alcohol
by ascending vapours in Analyser column. Rectifier vapours Rrov.ide energy to analyzer
column through a Thermosyphon reboiler. Vapours of degasifying column are condensed and
taken to pre Rectifier Feed Tank. Analyser vapours are condensed in Evaporation section.
The condensed analyzer vapours are taken to pre Rectifier Feed Tank. Rectifier Column,which operates under pressure, concentrates the condensate of analyzer column to 95% v/v
concentration. Condensing steam provides energy to pre rectifier column through a vertical
Thermosyphon reboiler. Fusels oil draws are taken from appropriate and fed to FO decanter.
An impure spirit cut of about 2 - 3 % of the Total spirit production is taken out from the top
of the pre rectifier column. Rectified spirit draw of 95% vjv is taken out from the upper trays
of pre rectifier column.
Manufacture of Extra Neutral Alcohol:
The concentrated rectified spirit from Pre-Rectifier column is fed to the Extractive
Distillation column. Dilution water is fed on the top most of the column with a dilution ratio
of 1 :9. this column serves to remove the impurities based on the principles of HydroExtraction. The water is fed to the column in such a way that it selects the higher alcohols
and other impurities to move upwards and extracts ethanol down. The top vapours of the
columns are condensed and feed to the recover column.
The purified dilute ethanol is removed from the bottom of the column and feed to the
rectification column, which concentrates ethanol to 96% v/v. Rectifier Column operates
under pressure and condensing steam provides energy to this column through a vertical
Thermosyphon reboiler. ENA draw is taken out from appropriate upper trays and fed to
Simmering Column after cooling. 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. The lees of the column are recycled as dilution water after a part of it is purged.
Lower side draw streams are taken from rectification column to avoid fusel oil build up in the
column. These streams are sent to the Recovery Column where these fusel oils are
concentrated and then sent to decanter where these streams are diluted with water band fusel
oil rich layer is separated. Washings are sent back to the column to recovery alcohol. An
impure spirit cut will be taken from top of this column.
Manufacture of Anhydrous Alcohol:
Production of anhydrous alcohol from rectified spirit (Industrial Ethanol) with molecular
sieve dehydration utilizing pre concentration column:
The rectified spirit, before sending in for dehydration process, it is heated and water is
stripped in the pre concentration column through a pre-heater. The mixture of alcohol and
little water is sent to molecular sieve in the form of vapour.
The molecular sieves are hard granular substances, cylindrical extrudates manufactured from
clay like silica gel material such as potassium alumino silicates. They are grated according to
the nominal diameter of the myriad of internal pores,
which make up the interstitial free volume found within their structure. A typical sieve used
in ethanol dehydration in Type 3A. This designation means that the average diameter of the
interstitial passageways is 3 Angstroms (One Angstroms: 1A is unit of measures equivalent
to 10-8 centi meters). Thus, the passageways in the structure have a diameter that is
molecular scale. The water molecule has a mean diameter less than 3A, while the ethanol
molecule has a mean diameter greater than 3A.
In addition, the water molecules can be absorbed on the internal surface offered by the
passageways within the molecular sieve structure. It is the physical property of the sieves,which make them useful for the separation of mixture of ethanol and water.
Water molecules can invade the inner structure of the molecular sieve beeds and be absorbed
thereon, while the ethanol molecules are too large and pass out of the vessel leaving the water
behind, Thus, dehydration of ethanol takes placer in the molecular sieve technology.
In this technology, the re-generation of beads is done by one bed under vacuum; while the
other bed is producing anhydrous ethanol vapour under pressure with an automated
operation, the feed of vapour to the molecular sieve system can be taken directly from the pre
concentration column passing through a superheated. The pre concentrated column is
operated at a pressure sufficient to economically operate a reboiler. The condensed anhydrous
alcohol vapour are cooled and passed to storage through product cooler. The recovered
ethanol and water from the regeneration phase is fed back to the pre-concentration column for
recovery. Thus, there is no generation of effluent except the condensate water from steam is
cooled and taken back process.
2.4 Power and Fuels
Total Power requirement of the Plant will be 1400 KWH. Total Power will be obtained from
its sister concern MIS. Dharani sugars and chemicals limited (cogeneration Plant).
2.5 Raw Water
The total requirement of raw water for this unit will be 600 KLD, which will be met from
wells inside the factory premises
2.6 Land
The total area allotted for this factory is 9.71 hectares.
2.7 Manpower
The total workforce including staff and workers will be 60.
3.0 POLLUTION CONTROL MEASURES
3.1 Air Emissions
In the Fermentor, the evolved traces of CO2 will be scrubbed with water and scrubbed water
will be recycled in the process. Clean air will be discharged from the scrubber to the
atmosphere. For wet scrubber, 15.0 meter height from ground level and 0.6 m diameter of
stack will be provided. The emission from boiler will be controlled by 40m height of stack
with bag filter will be provided.
3.2 Wastewater Generation
The waste water from the domestic usages (4 KLD) will be sent directly to the septic tank of
size 5 x 2 x 2 m (2 Nos) followed by the dispersion trench of size 5.0 x 2.0 x 2.5 m . 700 CU
M spent wash of 17% concentration will be generated from the process, which is further
concentrated in Evaporators to a concentration up to 55% V/V and used along with coal in
the specially designed boiler and incinerated. The condensate water coming out from
evaporators are used in Boiler as well as in Distillery process
By this way, the management proposes to achieve zero discharge system to have a better
environment not only in the factory premises and also to the surrounding environment.
PROCESS DESCRIPTION OF EVAPORATION SYSTEM
Five Effect Falling Film Evaporator
Flow = inlet - E1 - E2 - E3 - E4 - E5
The above flow pattern is specially designed for utilization of available energy. High wetting
rates are provided in falling film bodies. This will reduce scaling and the offline CIP
frequency/downtime of evaporator.
The spent wash from distillery from storage is fed to falling film Evaporator system, where it
is concentrated from 17% to 25% solids. The analyzer column vapors and exhaust steam
from Turbine are used as heating media. All the Effects are falling film type with vapour
separators.
The feed from feed tank will be introduced into the effect 1. The vapours from analyzer
column are used as heating media in Effect 1 and recovered in the form of condensate.
Partially concentrated feed is then transferred to Effect 2 and subsequently to effect 3. The
vapour from Effect 1, are given to Effect 2 as heating media. Evaporated vapours from effect
2 are used as heating media in Effect 3 and so on. Finally the vapours separated in VS 3 are
condensed in a Plate type surface. condenser.
The partially concentrated feed flows from E1 to E2, E2 to E3 and further up to E5, by means
of transfer cum recycle pumps. Final concentration is achieved in Effect 5. Level control
loops are provided for all effects to ensure trouble free operation.
INCINERATION OF CONCENTRATED SPENT WASH
The concentrated spent wash of around 55 brix from the concentration plant is then pumped
in to the specially designed boiler for incineration along with coal as supplement fuel. The
concentrated spent wash with above composition and calorific value is burnt to generate
steam at designed pressure and temperature. This steam is then taken into turbine for
generation of power and the exhaust steam is utilized for concentration and other process
requirements.
The flue gas from combustion process is vented out after removal of suspended particulate
matter in specially made bag filters and sulfur-dioxide in scrubbers. The ash collected from
the process rich in potash can be sold for fertilizer application and used in brick j cement
blocks manufacturing.
3.4 Hazardous Waste
There will be no hazardous waste generated from this proposed distillery unit.
3.5 Noise
The noise level in the inside & outside the factory is maintained at low level.
3.6 Odour Control System
Since the entire process like distillation and CO2
scrubber will be proposed with world-class
technology, the odour from the process will be of very minimum.
4.0 PRESENT ENVIRONMENT SCENARIO
4.1 Climate
The climate is generally arid with temperatures varying from 20.00C to 37.9°C. The rainfall
is maximum in the NE monsoon period and minimum in SW monsoon period.
4.2 Ecology
There is no endangered species of flora and fauna noticed in this area. The area does not
shelter any specific wildlife.
4.3 Hydrological Conditions
4.3.1 Surface Water
The run-off during monsoon period contributes to the surface water. There is no perennial
stream or river in the surrounding villages. These villages get water from open wells and bore
wells which get recharged in rainy season
4.3.2 Ground water
The ground water table varies from 68 m to 92 m. It is therefore a low to medium potential
zone for ground water.
4.4 Water Quality
Water samples were collected from different locations, and the following parameters will be
monitored for Ph, Colour (Visual), Odour, Turbidity (NTU), Electrical Conductivity, Total
Suspended Solids, Total Dissolved Solids, Chlorides (as CI), Sulphates (asSO4
), Calcium (as
Ca), Magnesium (as Mg), Total Hardness(as Caco3), Phenolphthalein Alkalinity(as CaCO3
),
Total Alkalinity (as CaCO3
), Iron (as Fe)
4.5 Ambient Air Quality and Noise Levels
The ambient air quality will be conducted as per the SPCS Norms. The following parameters
will measured as follows, SPM, RPM, SO2
, NOx.
4.6 Land Use Pattern
The entire area is a patta land owned by the company and it is in the form of shrub land. The
buffer zone has no forests.
4.7 Socio-Economic Conditions
There is no habitation or settlement in the industrial area. The nearest village of Kalayanallur
is having a population of 1739 with 940 males and 799 females as per 2001 census data. The
workers constitute 56.6%. The major source of income of the local population is from these
types of industries and agriculture only.
5.0 ENVIRONMENTAL IMPACT ANALYSIS
5.1 Air Quality
In the Fermentor, the evolved traces of CO2 will be scrubbed with water and
scrubbed water will be recycled in the process. Clean air will be discharged from the scrubber
to the atmosphere. For wet scrubber, 15.0 meter height from ground level and 0.6 m diameter
of stack will be provided. The emission from boiler will be controlled by 40m height of stack
with bag filter will be provided.
5.2 Water Resource
This proposed unit is depending on bore well for its different water requirements and the
quantity will be 600 KLD.
6.0 ENVIRONMENTS, SAFETY AND HEALTH MANAGEMENT
6.1 Organization Structure
The Senior General Manager is responsible for the factory operations. There are several
executives for various sections such as Production, Human Resource, Purchase, Store,
Accounts, Environmental & Safety, Maintenance, and Quality Control etc.
6.3 Air Quality Management
Proper control measures will be provided in all process area in order to control all emissions
if any to maintain a safe and healthy work place environment. The vent air will be passed
through pollution control equipments before it is released into the atmosphere.
6.4 Wastewater Management
The domestic sewage will be disposed by means of septic tank of size 5.0 x 2.0 x 2.0 m (2