Spentwash Process

DETAILED PROJECT REPORT
FOR
GOBIND SUGAR MILLS LIMITED

ESTABLISHMENT OF NEW 60 KLPD DISTILLERY MOLASSES
BASED ALONGWITH 2.2MW POWER GENERATION
AT
M/s.GOBIND SUGAR MILLS LIMITED

AIRA ESTATE, KAMARIA PANDIT, DIST. LAKHIMPUR KHERI,
UTTAR PRADESH
JUNE 2015
AVANT-GARDE ENGINEERS AND CONSULTANTS (P) LTD.

68A, PORUR KUNDRATHUR HIGH ROAD, PORUR, CHENNAI-600116.
TEL:91-44-24827843 / 24828532 FAX: 91-44-24828531

Email: agec@vsnl.com Website: http://www.avantgarde-india.com
MOLASSES BASED 60 KLPD DISTILLERY WITH SPENT WASH INCINERATION
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CONTENTS
EXECUTIVE SUMMARY
1.0 INTRODUCTION
2.0 PLANT AND EQUIPMENT DESIGN CRITERIA
3.0 PROCESS DESCRIPTION, UTILITY REQUIREMENTS AND

DESCRIPTION OF PLANT MECHANICAL EQUIPMENT FOR
THE DISTILLERY PROCESS PLANT
4.0 ENVIRONMENTAL IMPACT AND EFFLUENT DISPOSAL
5.0 SPENT WASH CONCENTRATION AND INCINERATION

SYSTEM
6.0 DESCRIPTION OF PLANT ELECTRICAL SYSTEMS AND

EQUIPMENT
7.0 INSTRUMENTATION AND CONTROL SYSTEM
8.0 PROJECT CIVIL & ARCHITECTURAL REQUIREMENTS
9.0 SITE FEATURES AND PLANT LAYOUT
10.0 OPERATION AND MAINTENANCE REQUIREMENTS
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DETAILED PROJECT REPORT AVANT-GARDE
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11.0 MANPOWER AND TRAINING
12.0 PROJECT IMPLEMENTATION AND SCHEDULE
13.0 PROJECT COST ESTIMATE
14.0 FINANCIAL ANALYSIS
15.0 DRAWING LIST
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DETAILED PROJECT REPORT AVANT-GARDE
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EXECUTIVE SUMMARY
1.0 Gobind Sugar Mills Limited (GSML), established in the year 1952,
was part of Dr.K.K.Birla group of sugar companies. The company
which is now part of the Adventz Group is one of the oldest sugar
mills in the country with almost 60 years of continuous operation.
The sugar mill at Aira Estate in Lakhimpur Kheri District of Uttar
Pradesh has a present cane crushing capacity of 7200 MT per day.
Apart from selling the finished product plantation white sugar, the
company also sells molasses, the basic raw material for ethanol
production and the surplus bagasse from the season operations.
The company is upgrading the crushing capacity of the mill to
10,000 TCD and is also adding a 500 TPD sugar refinery. The
upgraded plant with the sugar refinery will be operational for the
crushing season 2015-2016. As part of their program to utilize the
by products of the sugar mill effectively, GSML is also adding a 30
MW bagasse based Cogeneration plant which is already ready for
commissioning. After completing the sugar mill expansion and
Cogeneration projects, GSML proposes to add a ethanol distillery,
which will predominantly consume the molasses generated in-house.
2.0 The Alcohol is the generic term used for Ethyl Alcohol (C2H5OH)
which is a hydrocarbon manufactured either from petroleum or by
the fermentation of a monosaccharide like glucose or fructose. The
Extra Neutral Alcohol (ENA) which is a purified form of alcohol,
devoid of most of the commonly found impurities in the fermented
alcohol, is fit for human consumption and its consumption worldwide
is increasing annually. Apart from that, Alcohol in its anhydrous
from is touted to be the future fuel as the world’s petroleum
reserves are exhaustible. In fact automotive engines are now being
designed to accept hydrous alcohol with about 4 to 5% of moisture
which will eliminate the need for dehydrating the hydrous alcohol
for blending with gasoline. Every sugar mill is a virtual production
house for ethyl alcohol, as the molasses a by-product of sugar
manufacturing contains substantial quantity of fermentable sugar,
which can easily be fermented to alcohol by yeast.
3.0 Alcohol manufactured from sugar mills, by virtue of its renewable

nature is an eco-friendly fuel which will be a worthy substitute for
gasoline to prevent global warming. Many countries have taken up
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DETAILED PROJECT REPORT E.1 AVANT-GARDE
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aggressive usage of absolute alcohol, also commercially called as

Ethanol, to reduce the dependence on petroleum. Presently,
ethanol is blended with gasoline in varying proportions to get the
motor spirit. Brazil has done pioneering work in this direction,
followed by many countries. United States has launched an
aggressive ethanol manufacturing program and European Union is
also showing keen interest in ethanol. India also has a policy of
blending 5% ethanol with gasoline and this percentage is being
hiked to 10%. Alcohol, after limited purification, finds wide usage
in industrial applications and also in blending alcoholic drinks.
4.0 The molasses from the sugar mill with around 40% fermentable
sugar and at approximately 85 Brix is diluted with water and
fermented with Yeast grown in the distillery’s laboratory. As the
fermentation is an exothermic process, the wash (fermented
molasses) is required to be cooled by constant recycling through
coolers. As the yeast cannot survive at high temperature
approximately above 34 Deg.C, this continuous cooling of the wash
is required. Once the fermentation is complete, the wash is taken
in to the distillation section where the alcohol is stripped from the
wash in distillation columns using low pressure process steam. Also
electrical power is required for driving the various pumps and other
rotating equipment in the distillery. The alcohol production in a
distillery is an energy intensive process, which utilizes both
thermal energy from low pressure steam as well as electrical
energy. The raw alcohol thus obtained is called the “Rectified
Spirit (RS)”. RS contains about 94% to 95% ethyl alcohol by volume
and it also contains impurities such as Acetic acid, Acetaldehyde,
Ethyl acetate etc.
5.0 This RS is further purified by removing most of the impurities,

through a few more fractionating columns, to get ENA (Extra
neutral Spirit) which is used for blending potable liquor. ENA
contains about 96% ethyl alcohol. The RS could also be used for
the production of absolute alcohol, (Anhydrous Alcohol), by
dehydrating RS to reduce the moisture content to less than 0.5%.
While ENA can contain some percentage of water, the water
content in ethanol should be almost nil, and that is the reason this
ethanol is referred as anhydrous alcohol. This water removal is
carried out using molecular sieve dehydration process. This
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anhydrous form of ethanol contains a minimum of 99.5% ethyl
alcohol.
6.0 The fermented wash after the stripping of the alcohol, in the
distillation process, is called the spent wash. This Spent wash is
highly acidic, brownish black in colour, due to caramalization of
sugar in molasses and due to the bacterial action and is high on
BOD and COD. This spentwash, with the BOD and COD levels of
50,000 ppm and 1,35,000 ppm, is highly polluting in nature and that
is the reason a molasses based distillery is considered as a highly
polluting industry and the environmentalists look at the distillery
with a lot of suspicion. Environmental protection and the control of
discharge of the liquid effluents are the key elements in the design
of the distillery. Conventionally this spent wash had been disposed
of by fert-irrigation or composting or bio-methanation. As none of
these erstwhile disposal methods were very effective, the spent
wash incineration technology had been proposed and had
successfully been employed already in many molasses based
distilleries. The spent wash generated from the distillery is
generally with a solids concentration of around 14% w/w, which
after concentration could be raised to 60% w/w level. This
concentration of the spent wash will be done in a multiple effect
evaporator system using steam as the heating medium. This
concentrated spent wash with 60% solids content has a calorific
value of around 1705 kCals/kg which could sustain combustion in an
incinerator. To make the whole system energy efficient, the spent
wash incineration is done in a specially designed steam generator
which could effectively utilize the thermal energy released by the
incineration of the spent wash for the generation of high pressure
steam. As the spent wash contains a lot of alkalis, chlorides and
sulphates, fouling of the heat transfer areas and both high and low
temperatures corrosion are serious problems in using this spent
wash as a fuel. The boiler design should take care of the above
problems and ensure a longer uptime for the boiler. In India, quite
a few number of distilleries have already successfully implemented
this spent wash incineration technology. A major advantage of this
technology is that the distilleries could be designed as “Zero Liquid
Effluent Discharge” plants.
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7.0 GSML proposes to install a 60 Kilo Litres Per Day (KLPD) capacity
distillery very near to the sugar mill complex. This proposed plant
will be a multi product distillery capable of producing Rectified
Spirit, Extra Neutral Alcohol and Anhydrous Alcohol. The
distillery complex will be located in an area already owned by GSML
at a distance of about 300 meters from the sugar mill. From its
cane crushing operations GSML will produce 60,750 MT of
molasses annually with an average fermentable sugar content of
36.8%. The sugar mill already has a molasses storage capacity of
25,860 MT and additional storage facilitates will also be added in
the distillery. Apart from the in house molasses GSML is confident
of procuring a minimum of 15,000 MT of molasses from the nearby
sugar mills and it is proposed to take this 15,000 MT also into
account while calculating the total molasses availability for the
distillery operations. As the procured molasses will be from the
vicinity of the plant, it is assumed that the fermentable sugars in
the bought out molasses will also be at the same level as the in
house molasses.
8.0 The proposed 60 KLPD, multi product distillery will have installation
of the plant and equipment for the following process areas /
sections. As discussed elsewhere in this report, the distillery will
be capable of producing RS, ENA and Absolute Alcohol. The
proposed distillery could also be made to operate with grains as the
raw material with the addition of a few front end equipment for
the processing of the grains. However with minimum additions the
distillery could operate with cane juice as the raw material and
produce RS, ENA or AA as required.
 Bulk molasses
storage
 Fermentation section
 Wash to RS/ ENA/AA Distillation section
 Spent wash evaporation system
 Condensate and Spent Lees polishing section
 Alcohol daily receiver and bulk storage
 Laboratory instrument and glassware
 Water treatment plant
 Cooling towers and cooling water system
 Spent wash fired boiler
 2.2 MW back pressure turbo generator and auxiliaries
 Plant electrical system
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 DCS based instrumentation for the process plant and the co-
generation plant
9.0 This Detailed Project Report presents the details of the proposed
scheme for the Distillery, Spent wash concentration system, Spent
wash incineration boiler and co-generation power plant of the
distillery, site facilities, availability of fuel and water, features of
the main plant equipment including the co-generation power plant,
cooling water system, electrical systems, environmental aspects,
estimate of the capital cost and the schedule for the project
implementation.
10.0 With 36.8% fermentable sugar in the molasses, one Metric Tonne
of molasses could result in the production of 222.2 Litres of
alcohol. For the production of 60,000 Litres of alcohol per day, the
distillery needs 270 Metric Tonne of molasses. The annual in-
house production of 60,750 MT of molasses, with 90% capacity
utilization of the distillery plant, will meet the requirements of the
distillery for the operation of 250 days. The expected bought out
molasses quantity will enable the distillery to operate additionally
for about 50 days, thus taking the total number of days of
operation of the distillery per annum to 310. As the investment in
the distillery with spent wash incineration system is high, it is
important that the plant is operated for as many number of days as
possible in a year. If GSML could find more molasses the plant
operation could be even taken to 330 days per annum. However for
the purpose of this DPR, it is assumed that the GSML’s new
distillery will be operated for a period of 310 days per annum.
11.0 The distillation process is the separation of ethyl alcohol from

impurities like the acetaldehydes, acetones, esters and amyl
alcohols etc.. With the capacity of 60,000 Litres of total spirits
per day, the impurities will account for about 5% of the total
production and these are removed in the distillation columns and all
these impurities put together are called as technical alcohol. If
the distillery is producing Rectified Spirit, the per day production
will be 57,000 Litres. Producing ENA, where further purification of
the ethyl alcohol is involved, the plant will produce 56,320 Litres of
ENA. If the plant’s entire production is Anhydrous alcohol, where
the dehydration of the RS is involved, the daily production of AA
will be 56,000 Litres. Operating for 310 days, with the plant
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capacity utilization of 90%, the plant could produce 141.36 Lakh
Litres of RS or 139.67 Lakh Litres of ENA or 138.88 Lakh Litres of
AA. As RS has limited industrial use, for the purpose of this DPR, a
product mix of 70% of ENA and 30% of AA is assumed. Apart
from the above, the plant will also produce 8.37 Lakh Litres of
Technical Alcohol and 0.17 Lakh Litres of Fusel Oil. The
fermentation process will produces carbon-Di-Oxide as a by
product and it proposed to leave the gas to the atmosphere
downstream of the scrubber. At a later date if GSML wants to
recover the CO2 gas, it is possible to do so with the addition of a
purification plant. It is estimated that about 35 TPD of purified
CO2is recoverable from the distillery which could find usage in
beverage industry, welding process, pharmaceutical and other
chemical processing industries. Liquid CO2 is a good refrigerant
and it finds wide usage in food industry for warehouse storage and
for storage during transportation. However, this report does not
consider the carbon-di-oxide recovery and bottling plant as part of
the 60 KLPD distillery plant.
12.0 The Distillery operations produce about 718 MT of raw spent wash
per day with the solids concentration of about 14% w/w. This will
be concentrated to 60% w/w solids in a standalone multiple effect
evaporation plant using low pressure steam. The multiple effect
evaporation plant will have a minimum of five effects with the
combination of falling film and forced circulation bodies to
optimize the performance. Thus the concentrated spent wash
production in the plant will be 175 MT per day or 8 . 7 MT per
hour. The estimated Gross Calorific Value of the concentrated
spent wash is 1705 kCals/kg. This concentrated spent wash will be
fired in the boiler along with bagasse to generate the required
steam from the boiler. The 525 MT per day of condensate
generated in the concentration plant will be treated and reused in
the distillery plant.
13.0 The steam requirement for the production of RS from fermented

wash is about 5.5 TPH at 2.5 bar (a) saturated. The steam
requirement for production of ENA from fermented wash is 8 TPH
at 2.5 bar (a) saturated. The steam requirement for production of
AA from RS is 1.5 TPH at 4.5 bar (a) saturated. The steam
requirement for Spent wash concentration from approximately 14%
w/w solids to 60 % w/w solids in the stand alone evaporation
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system is 6 TPH at 2.5 bar (a) saturated. In addition to the above
the Spent wash fired boiler is provided with a deaerator which
requires steam for deaeration purposes and also for heating the
combustion air in the steam air pre-heater. Considering all the
above, the spent wash fired boiler is sized for this project to have
a MCR output of 20 TPH at 45 bar (a) 4000C. The steam produced
in the boiler will be fed to a 2.2 MW nominal capacity turbo
alternator for power generation. The extraction steam of turbine
shall be slightly superheated and shall have a pressure of about 3.5
bar (a), which will be used for meeting the distillery plant steam.
The power generation in the turbogenerator will be 2150 kW at the
MCR operation of the distillery.
14.0 The total power requirement (at 415V, 3 PH, 50 Hz level) for the
distillery and co-generation plant is given below:
 Distillery Process requirement : 775 KW

 Spentwash concentration plant : 330 KW
 Condensate/lees polishing unit : 100 KW
 Boiler and other utilities : 620 KW
 Lighting and Misc. : 25 kW
 Total (operating reqt.) : 1850 KW
With 2150 kW of generation under the MCR operation of the

distillery, there will be a surplus power of 300 kW available for
export. The spent wash fired Cogeneration plant in the distillery
will be operating in synchronization with the 30 MW Cogeneration
plant in the sugar mill, so that the surplus power could be exported
to the sugar mill and then to the grid. The actual power
requirements and the actual steam requirements will vary
depending on the output product and the sections of the distillery
that will be in operation and the total power and steam consumption
discussed earlier are the maximum consumptions. The power
generation is at 415 V level from the 2.2 MW turbo generator and
will be stepped up to 11 kV in the transformer for synchronization
with the 30 MW Cogeneration Power Plant.
15.0 The water requirements of the distillery plant is proposed to be

met by the water drawn from the bore wells. The water from the
bore wells will be stored in a water reservoir for meeting the
various uses of the distillery. The estimated raw water
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requirement is 1500 cu.m per day for the operation of the
distillery in wash to ENA mode. The water is required for the
distillery process in the fermentation section, cooling tower make
up for the distillery cooling towers. However with the usable water
recovered from the condensate and spent lees polishing plant, the
raw water required will come down to 700 cu.m/day. The DM water
requirement for the distillery and for the boiler is approximately
300 cu.m per day. The DM water requirement will be met from a
new Membrane based water treatment plant to be installed in the
distillery.
16.0 The implementation of the new distillery project is expected to be

completed within Sixteen (16) months, from the date of ordering
of the main plant and equipment i.e the distillery process section
and spent wash fired boiler. It is presumed that the ordering of
these items could be done in early December 2015. If GSML gets
the statutory clearances and the financial closure early or decides
to start the basic design and the tendering process simultaneously,
then the schedule could be advanced.
17.0 The size of the distillery project with the spent wash incineration
based Cogeneration plant, calls for proper project management and
control procedures to ensure implementation within the scheduled
program. Adequate qualified and trained manpower shall be
recruited to take care of the operation and maintenance of the
new Distillery plant with spent wash fired boiler and cogeneration
plant.
18.0 The total works cost, i.e., civil, mechanical and electrical for the
complete distillery complex, including the miscellaneous fixed
assets is estimated to be Rs.9,286.40 Lakhs. The total installed
project cost, including the pre-operative expenses, interest during
the construction, the margin money for the working capital and the
contingency provision works out to be Rs.10,738.11 Lakhs. The
total project cost of Rs.10,738.11 Lakhs will be funded with an
equity of Rs.1,654.49 Lakhs, SDF loan of Rs.3,714.56 Lakhs and an
institution term loan of Rs.5,369.05 Lakhs assuming a debt to
equity ratio of 1:1. It is assumed that the financial institution loan
for the project will be repaid in 6 years in 24 quarterly instalments
with two (2) years moratorium period from the date of loan
disbursement. It is also assumed that the interest rate on the
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term loan will be 12.5%. The SDF loan repayment will be over five
(5) years with the moratorium equal to the institution term loan
repayment period. The cost of SDF loan will be 6.5%. As the
processing of the SDF loan and the term loan may take some time
GSML will arrange for some bridge loan to tide over the project
funding requirements.
19.0 GSML proposes to use in-house generated molasses predominantly

for the production of alcohol. However the company will also
procure molasses from nearby sugar mills to run the distillery plant
for a longer period. Based on the price levels existing presently,
the average landed cost of bought out molasses is taken as
Rs.5182.50 per MT inclusive of the basic cost, Excise Duty, cess,
molasses development fund and an average transportation cost of
Rs.300 per MT. As GSML is presently selling the molasses, the cost
of the in-house molasses is also taken same as that of the bought
out molasses less the transportation cost. As the sugar mill will be
supplying the bagasse to be used as the supplementary fuel for the
operation of the distillery boiler, the bagasse cost is also
considered in the viability analysis. A value of Rs.1000 per MT is
considered for the bagasse. The cost of production will include
cost of utilities, water, chemicals, consumables, repairs and
maintenance expenses, salaries and wages for the plant operating
personnel & for contract labour, plant insurance cost,
administration expenses and selling expenses for the various
products of the distillery.
20.0 The saleable products from the distillery are the ENA, AA,
technical alcohol and the Fusel oil. In addition the 300 kW of
surplus power could be exported to the grid as the 30 MW
Cogeneration plant will be exporting power to the grid during the
season operation and part of the off-season period. In case the
Cogeneration plant is not exporting power, the 300 kW could be
used in the sugar plant for the regular off-season maintenance of
the sugar mill and for meeting the requirements of the colony.
Based on the existing price levels the selling price of ENA and AA
are taken as Rs.43.00 and Rs.40.5 per Litre. The sale price of
technical alcohol and Fusel oil is taken as Rs.20 per Litre. The
exportable electrical energy is assumed to fetch Rs.5.50 per Unit
of electricity sold.
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21.0 No escalation is considered both in the input materials cost and in

the price of saleable outputs.
22.0 The depreciation computed is on straight line basis at 6.33%% for

plant and machinery and 3.34% for buildings and civil works.
However, for income tax computation purposes, depreciation rates
of 10% for civil works, 15% for the plant and machinery are taken
on the written down value of the assets.
23.0 Income tax at the rate of 30%, with a surcharge of 5% or 10%

(depending on the net taxable income being less than Rs.1000 Lakhs
or more) and a Cess of 3% is considered in the financial analysis of
the project. Minimum Alternate Tax (MAT) as per Income-Tax
Act is at the rate of 18.5% with surcharge of 5% or 10%
(depending on the book profits being less than Rs.1000 Lakhs or
more) and a Cess of 3% is also considered in the analysis.
24.0 A detailed financial analysis is made on the basis of the above given
financial assumptions. The post tax Internal Rate of Return IRR
for the proposed distillery project works out to 16.22%. The Net
Present Value (NPV), with a Weighted average cost of capital of
11.3%, works out to Rs.3,039.74 Lakhs. The simple payback
period is 5.2 years.
25.0 The return on Equity is calculated at 35.51%. The average debt

equity ratio over the fifteen year period is 1.84.
26.0 Presently GSML is selling all their molasses. With the addition of
the proposed ethanol distillery, one of the valuable by product of
the sugar mill, will be put to better use. With the proposed
distillery capable of producing both ENA and Anhydrous alcohol,
the opportunities are enormous. With ethanol considered to be the
future fuel for this planet, utilizing the molasses to produce
ethanol will make good business sense. Even if there is a sluggish
off-take of Anhydrous Alcohol for gasoline blending, the ENA will
have an ever expanding market with the ENA consumption in India
posting an average annual growth of 4 to 5%. With the advent of
the spent wash concentration and incineration technology, the
disposal of spent wash, one of the worst nightmares of the
distillery industry, has been made easy. In fact the dreaded
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effluent is now used as a fuel for powering the distillery, meeting
almost 60 % of the total energy requirements of the distillery. The
project viability analysis indicate that the proposed distillery unit
is immensely viable.
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1.0 INTRODUCTION
1.1 Ethyl Alcohol commonly known as Ethanol, with the molecular formula
of C2H5OH, is an important organic compound which has wide use, in
industrial applications, as fuel for internal combustion engines and as
an intoxicating ingredient of alcoholic beverages. In the Industrial
applications it is used as solvents and in the synthesis of varied
organic chemicals like acetaldehyde, acetic acid, benzene, PVC etc.
Eventhough the major consumption as of now is for alcoholic
beverages, Ethyl alcohol has the potential to fuel the future
relegating gasoline to a secondary place. Brazil has pioneered the
blending of Ethyl alcohol with gasoline to be used as automotive fuel,
followed by United States of America and many other countries. Many
countries, including India, have implemented policies to ensure that
the bio-fuels become important element of their transport fuel mix.
Bio-ethanol, unlike petroleum, is a form of renewable energy that can
be produced from agricultural feed stocks. Ethanol can be produced
from several raw materials like sugarcane or sugar beet molasses,
cassava, maize and other grains. Concerns about its production, from
raw materials other than sugar cane molasses, relate to increased
food prices, the large amount of arable land required for crops etc.
However the latest developments with cellulosic ethanol production
may allay some of these concerns relating to the food security.
1.2 India’s total installed ethyl alcohol production capacity is 4 billion

litres per annum in about a total of 350 Distilleries. The installed
production capacity for anhydrous alcohol is 2 billion litres per annum.
Most of the alcohol produced in India is from cane molasses and
grains contributing to only a small fraction of the production for
potable alcohol. With the cane supplies diminishing in the last two or
three years the production of alcohol had also come down. The
average annual consumption had remained at around 3 Million litres
with Industrial, potable, gasohol and other segments contributing
35%, 55%, 5% and 5% respectively. The alcohol consumption for
blending with gasoline has not taken off as expected due to various
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DETAILED PROJECT REPORT 1.1 AVANT-GARDE
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reasons. Eventhough the notification to blend 5% alcohol with gasoline
was made out in 2002; the 5% blending was made mandatory only in
2007. Later the Government of India mandated 10% blending of
alcohol with gasoline from October 2009. The Government of India
has planned to achieve 20% blending by 2017. However due the
vagaries in the price of oil, reduction in the production of alcohol due
to less cane cultivation etc., the policy of blending could not be
implemented in full. As against the consumption of about 1050 Million
Litres per annum for 5% blending and about 2100 Million Litres for
10% blending the consumption had been only around 100 Million Litres
in the last year. However this scenario will change for the better as
the whole world is now moving towards bio fuels. With Brazil and USA
showing the way, increasing concerns about the environmental
degradation and with the oil prices set to increase ultimately, we will
be left with no option other than to increase our ethanol production
and go with higher percentage of blending. In addition the potable
alcohol consumption has been steadily increasing at the rate of 5 to
7% per annum. Presently many of the organic chemicals that are
synthesized from petroleum feed stock due to the price advantage
will eventually shift to ethanol feed stock as the crude price
increases.
1.3 With the demand for ethyl alcohol set to increase, in the industrial,
alcoholic beverages and Gasohol segments the future looks very
promising for the Alcohol industry. With the possible future pressure
against the use of food grains for the production of alcohol and the
demand for alcohol increasing, the alcohol produced with molasses or
even cane juice as feed stocks will probably have a vast market.
1.4 Gobind Sugar Mills Limited (GSML), one of the oldest sugar mills in
the country, with almost 60 years of continuous operation, is part of
the Adventz Group. The company originally established in the year
1952, was part of Dr.K.K.Birla group of sugar companies. The company
is listed in the Kolkata stock exchange. The sugar mill at Aira Estate
in Lakhimpur Kheri District of Uttar Pradesh has a present cane
crushing capacity of 7200 MT per day. Under the stewardship of
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Chairman Mr.Suresh Krishnan and Managing Director
Mr.R.S.Raghavan, the company is planning for performance and
capacity enhancement, value addition to the product and utilization of
the by products to create additional revenue streams. GSML, as part
of their sugar mill modernization and capacity upgradation program is
enhancing the crushing capacity of the sugar mill to 10,000 TCD, with
50% of the juice processing taking place in a a modern and efficient
boiling house. Along with this capacity upgradation, GSML is also
setting up a sugar refinery of 500 TPD capacity and a high pressure
bagasse based Cogeneration plant of 30 MW capacity. GSML will start
this ensuing crushing season 2015-2016, with the upgraded capacity
and with both the refinery and the high pressure Cogeneration plant in
operation. Presently, apart from selling the finished product plantation
white sugar, the company also sells molasses, the basic raw material
for ethanol production, and the surplus bagasse from the season
operations. The ongoing high pressure Cogeneration project will
ensure that one of the two by products, namely the bagasse, is used
effectively and efficiently to increase the revenue generation to the
company. In order to derive the best value of the other by product,
namely the molasses, GSML would like to implement an ethanol
distillery project. It is estimated that the in-house generation of
about 60,000 MT of molasses per annum will enable the company to
implement a distillery of 60 Kilo Litres Per Day (KLPD) capacity
operating for a period of 250 days per annum. Apart from that the
company could also procure molasses from nearby sugar mills to the
extent of about 15,000 MT, to take the number of operation days to
310. The proposed distillery will be multi product plant capable of
producing Industrial grade rectified spirit, Potable Extra Neutral
Alcohol and the Anhydrous ethanol used for blending with gasoline.
1.5 The distillery will be designed as a Zero Effluent discharge plant with
the spent wash concentrated and incinerated in a specially designed
boiler. The high pressure steam generated in the boiler will enable
adequate power generation in a turbogenerator for meeting the
requirements of the distillery operations and will also provide the
process steam required for the distillery operations. The distillery
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design will employ the multi pressure technology with the distillation
columns operating under various pressures to economize on the energy
consumption in the distillation process. This distillery project will also
include a effluent treatment plant, based on anaerobic digestion,
aeration, clarification and Reverse Osmosis, to treat the condensate
generated in the spent wash concentration plant and the spent lees
generated in the distillation process. The permeate from the RO
system will be used as process water, thus reducing the dependence
on external water and the concentrated RO reject will be mixed with
the influent spent wash upstream of the concentration plant.
1.6 Having decided to implement the ethanol distillery project GSML has
retained M/s.Avant-Garde Engineers And Consultants (P) Ltd.,
Chennai-600116, a consultancy company with good experience in the
sugar and ethanol Industries, as their consultants for the preparation
of the Detailed Project Report and for the implementation of this
project.
1.7 The subsequent sections of this report furnishes the details of the
proposed distillery process plant, the spent wash concentration
system, the concentrated spent wash fired boiler system, the power
plant, site facilities etc. The report also dwells on the environment
aspects, estimate of the capital cost, financial analysis and the
schedule for the implementation of the proposed multi product
Distillery Project.
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2.0 PLANT AND EQUIPMENT DESIGN CRITERIA
2.1 General
The proposed 60 KLPD distillery facility at Coromandel Sugars

Limited will be operating almost for about 310 days in a year, with
in house molasses and about 15,000 MT of bought out molasses. It
is possible to increase the number of days of operation to 330 days
per annum, if GSML is able to buy more molasses from the market
at reasonable price. All the plant and systems shall be designed to
achieve the best possible efficiency under the specified operating
conditions. The boiler to be installed in the distillery shall be
designed to fire concentrated spent wash along with bagasse for
steam generation. The steam generated in the boiler will be
supplied to a turbogenerator for power generation and the
extracted/pass out steam will meet with all the process steam
requirements and the steam required for spent wash concentration.
The complete plant instrumentation and control system for the

distillery, spent wash concentration and incineration system and
the 2.2 MW co-generation plant shall be based on Distributed
Control System (DCS) philosophy, covering the total functioning
requirements of measuring, monitoring, alarming and controlling,
logging, sequence interlocks and equipment protection, etc.
The plant layout shall make optimum use of the land and facilities
to minimize the cost of installation. The optimum arrangement of
the equipment shall be determined by the considerations of
functional requirements, economy of piping and electrical cables,
economy of equipment supports, installation and maintenance
access requirements, ventilation requirements and equipment
generated noise and vibrations.
2.2 Plant & Machinery design criteria
This section of the report gives the basic criteria for the design
of the plant. The design parameters like the size, layout, ratings,
quantities, materials of construction, type of equipment etc.,
described in this report are tentative and approximate. Necessary
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changes could occur as the detailed engineering of the plant

progresses and such changes are permitted as long as the
detailed engineering of the plant achieves the intent of this
report.
2.3 Ambient Conditions
Plant Elevation above Mean Sea Level (MSL) : 160 meters
Temperatures :
 Maximum Temperature : 45 Deg.C

 Minimum Temperature : 3 Deg.C
 Plant Design Temperature (Dry Bulb) : 30 Deg.C
 Plant Design Wet Bulb Temperature : 28 Deg.C
 Plant Design Temperature for : 50 Deg.C
Electrical Equipment
Relative Humidity:
 Maximum :85.0 %
 Minimum :47.0 %
 Plant Design Relative Humidity :70.0 %
Precipitation:
* Total Annual Rainfall, average : 600 mm
Wind:
* Wind Direction : East - West
* Design Wind Velocity : As per IS:875
Seismic Coefficient:
* Design : As per IS:1893
Soil Bearing Capacity:
* At 2.0 m Depth : 12 MT/Sq.M

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2.4 Plant input specification
2.4.1 Molasses
Molasses is the mother liquor left after crystallizing out a major

portion of sucrose crystals from concentrated cane syrup. As one
hundred percent exhaustion of the mother liquor is not possible,
even the final molasses that leaves the sugar process house still
contains appreciable quantum of sucrose. Apart from sucrose the
molasses also contains other sugars, which are not crystallisable,
but could be used for fermentation. 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
molasses also contains some form of sugars that are not
fermentable and the total sugars in molasses, both fermentable
and non-fermentable, are called total reducing sugars (TRS). The
molasses proposed to be used is expected to have a fermentable
sugar content of 36.8%. With this FS the ethanol yield in the
distillery will be around 222 litres per MT of molasses. For the
proposed 60 KLPD distillery at GSML, the molasses requirement
with the FS of 36.8% will be 270 MT/day. In general the molasses
characteristics are dark brown in colour, viscous syrup mass,
miscible with water, pH 4.5 - 5.5 and Sp. Gravity-1.35 to 1.45.
Various components present in molasses are:- Water: 20% to 30%

w/w, Total solids: 70% to 80% w/w, Organic solids like total
sugars, non sugar substances, organic acids, vitamins, pigments.
Factors affecting the composition of molasses are variety of cane,
composition of soil, climatic conditions, harvesting practices, sugar
factory practices and efficiencies etc.
Molasses should be free from any foreign material including any

caramalisation products, known inhibitory elements of yeast
metabolism (i.e.) lead, arsenic, poly electrolytes etc., or micro
organisms producing side products. The molasses for this plant has
been taken to have the following characteristics, based on the
information furnished by the sugar factory:
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Fermentable Sugars : 36.8 % (w/w)
Brix (%) : 89.4%
Total Organics (other : Max. 6-8% w/w
than sugar)
Total inorganics : Max.13.79% w/w
Volatile Acids : Max. 500 ppm
Butyric acid : NIL
Total viable count : Max.1000 cfu/gm
Free assimilable : Min. 1300 ppm
nitrogen content
Sludge content : Max. 1.1% w/w
Caramel in terms of : Present
colour
Proper care should be taken during storage of molasses,

specifically during filling of the storage tanks. It is preferable to
cool down the molasses before it goes to molasses storage tank.
The molasses storage tank should have a suitable pump for
recirculation of molasses.
There will be a total storage of 33,360 MT for molasses. This

includes the already existing storage tank of 25,860 MT capacity
in the sugar mill. The balance of the storage will be made up by
adding one number of 7,500 MT capacity within the new distillery
complex.
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2.5 Other Distillery Chemicals
In addition to the molasses requirement, the distillery process

also requires other chemicals, the composition of which are
given below:
2.5.1 Concentrated commercial Sulphuric Acid
Composition : Value in % w/w
Purity : 97 % Min.
Lead : 0.001 Max.
Arsenic : 0.0001 Max.
Iron : 0.03 Max.
Moisture : 2 Max.
Density : 1840 kg/cu.m
Liquid form : Clear, colourless, odourless liquid
2.5.2 Antifoam agent: Turnkey Red Oil
Degree of Sulphation : 6 Min.

Total Alkali (KOH) : 4 Max.
Total fatty matter (TFM) : 60 Min.
Total Ash : 8 Min
pH : 6.5 - 7.5
State of fluid : Liquid
2.5.3 Di-ammonium Phosphate
Di-ammonium phosphate (DAP), in the form of granules, confirming

to following specifications. Values given below are in w/w %.
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Available Phosphorus as : 50% Min.

P2O5
Total Nitrogen : 20 Min
Arsenic : 0.0001 Max
Iron : 0.01 Max.
Lead : 0.001 Max
2.5.4 In addition to the above, the process requires chemicals like,

Caustic (47% w/w) for neutralisation, Phosphoric acid (1% w/w) for
membrane cleaning and Sodium Meta bisulphate (1% w/w) for
membrane storage in the condensate and spent lees treatment unit.
Caustic solution is required for CIP (Cleaning in Process) in the
fermenters and Caustic solutions and Nitric acid are required for
in process cleaning (CIP) of the distillation and evaporation
sections.
2.5.5 The Fermentation process requires yeast for the conversion of

glucose into ethanol and Carbon-di-Oxide. Yeast culture will be
supplied by the distillery supplier in the form of slant during the
plant start up. The distillery should further develop the culture
for regular use during plant operation.
2.6 Water requirement for the Distillery
The raw water supply for the plant will be from the bore wells
located within the plant. This raw water will be used as make up
for the losses in the process steam, boiler blow down, cooling tower
blow down, service water, make up water, etc. In addition water is
required for fermentation section for dilution of molasses, for the
ENA section for extractive distillation, make up water for the
process cooling towers etc.
The design of the water treatment system will be based on the

actual chemical analysis of the raw water at site. During contract
stage, the water analysis will be carried out in a detailed manner
before furnishing the same to the water treatment plant vendor.
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The raw water quality considered for this project report is

given below:
2.6.1 Physical Examination
Appearance when Analysed Clear on Settling
Appearance after Filtration Clear
Turbidity, NTU 2
Total Suspended Solids, mg/l 4
Odour (Smell) Unobjectionable
Colour, Hazen Unit <5
pH @ 25ºC 8.0
Electrical conductivity at 25ºC (µS/cm) 835
Colloidal (Molubdate Unreactive) Silica 0.7

(as SiO2), mg/l
2.6.2 Chemical Examination
Cations
Calcium (as Ca), mg/l 31
Magnesium (as Mg), mg/l 35
Sodium (as Na), mg/l 100
Potassium (as K), mg/l 3
Ammonium (as NH4), mg/l 0.33
Aluminium (as Al), mg/l < 0.02
Barium (as Ba), mg/l 0.11

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Copper (as Cu), mg/l 0.01
Ferrous Iron (as Fe 2+), mg/l < 0.1
Ferric Iron (as Fe3+), mg/l 0.16
Manganese (as Mu), mg/l 0.04
Zinc (as Zn), mg/l 0.11
Strontium (as SR), mg/l 0.28
Anions
Chlorides (as Cl), mg/l 19
Fluoride (as F), mg/l 0.5
Nitrates (as NO3), mg/l 4
Nitrate Nitrogen (as N), mg/l 0.9
Nitrite (as NO2), mg/l <0.01
Phosphate (as H2PO 42-), mg/l <0.05

(monovalent)
Phosphate (as PO 42- ), mg/l <0.05

(Divalent)
Phosphate (as PO 43-), mg/l <0.05

(Trivalent)
Sulphate (as SO4), mg/l 55
Sulphide (as S), mg/l <1
Sulphite (as SO3), mg/l <1
Lime (as CaO), mg/l (on the basis of 43

Calcium)
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Molybdate Reactive Silica (as SiO2) mg/l 21.1
Total Volatile Solids, mg/l 55
Total Fixed Solids, mg/l 465
Total Dissolved Solids 520
Total harness (as CaCO3), mg/l 221
Methyl Orange Alkalinity (as CaCO3), mg/l 359
Phenolphthalein Alkalinity (as CaCO3), mg/l Nil
2.6.3 Organic Constituents Examination
Biochemical Oxygen Demand (BOD) 8

(at 20ºC for 5 days), mg/l
Chemical Oxygen Demand (COD), mg/l 36
Oxygen absorbed in 4 hours at 27ºC 0.7

(Tide’s Test), mg/l
Dissolved Oxygen (as O2), mg/l 5.4
Total Organic Carbon, mg/l 0.9
Ammonical Nitrogen as N, mg/l 0.26
Albuminoid Nitrogen as N, mg/l 0.61
2.6.4 Toxic Substances
Lead (as Pb), mg/l <0.01
Cyanide (as CN), mg/l <0.01
Mercury (as Hg), mg/l <0.001
Total Chromium (as Cr), mg/l <0.01

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Nickel (as N), mg/l <0.01
Cadmium (as Cd), mg/l <0.01
Arsenic (as As), mg/l <0.005
Sulphide (as H2S), mg/l <1
2.6.5 Gases
Free Carbon di oxide (as CO2), mg/l 1.8
Free Ammonias (as NH 3+), mg/l 0.01
2.6.6 Microbiological Examination
Total Bacterial Count 1.5 x 104
Sulphate Reducing Bacteria/100 ml No Growth Observed
2.6.7 Additional Parameters
Bisulphate (as HSO4), mg/l 56

(on the basis of SO4)
Bisulphite (as HSO3), mg/l <1

(on the basis of SO3)
Bicarbonate (as HCO3), mg/l 438
Carbonate (as CO3, mg/l Nil
Note: BDL – Below Detectable Limit
2.7 Distillery Product Specification
The expected product output specifications shall be as given below.

The input molasses specification has a bearing on the on the exact
product specification, but however the plant shall be designed to
give broadly the following product specification. The Detailed
Project Report is based on a plant that could give the specification
requirement as given below:
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2.7.1 Rectified Spirit
Characteristics Specification
Color Colourless
Appearance Clear and transparent
Ethanol content at 200C 95% v/v minimum
Specific gravity at 15.60C 0.8178 maximum
Aldehydes (as acetaldehyde) 0.0060% w/w
Maximum (60 ppm)
Acidity (as acetic acid) 0.002% w/w maximum
(20 ppm)
Esters (as ethyl acetate) 0.020% w/w maximum
(200 ppm)
Furfural Nil
Residue on evaporation 0.0050% w/w Max.(50 ppm)
2.7.2 Extra Neutral Alcohol
Ethanol content, % v/v at 96

200 C, minimum
Relative density at 15.60 C 0.80692
Miscibility with water Miscible
Acidity, as Acetic acid ppm 15
max.
Residue on evaporation ppm 15
max
Aldehydes, as Acetaldehyde 5 - 10
ppm max.
Esters, as Ethyl acetate ppm 13
Max.
Copper, as Cu ppm max. 0.02
Lead, as Pb ppm max 1
Methanol ppm Max. 5 to 7
Higher Alcohol as Iso-amyl 15
alcohol ppm , max.
Furfural Not Detectable
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Permanganate Decolorization 45
Time, minutes, minimum
2.7.3 Anhydrous Alcohol
Ethanol content, % v/v at 99.8%

15.60C, min (excluding
denaturant)
Relative density at 15.60C 0.7961
Miscibility with water Miscible
Acidity, as Acetic acid, mg/l Max.30
Residue on evaporation, % Max.0.005
w/w
Aldehydes, as Acetaldehyde, Max.60
mg/l
Alkalinity Nil
Methanol mg/l max 300
Appearance Clear & bright
2.8 Distillery Mode of Operation
The distillation system of the Distillery shall be designed in such a

way that it will give the flexibility of running the plant in any of the
modes such as wash to RS, wash to ENA, wash to ethanol and RS to
ethanol. The distillation system shall be designed for accepting
fluctuation in the molasses quality. The plant should be capable of
producing RS of industrial quality, superior grade ENA and Fuel
ethanol. Total spirit production shall be 60,000 litres per day out
of which impure cut or technical alcohol shall not exceed 5%.
2.9 Distillery Equipment Design Criteria
2.9.1 Water usage should be as minimum as practical in the distillery.

The distillery should be designed for Zero effluent discharge.
Process condensate and spent lees, should be treated in an effluent
treatment system and reused for cooling tower and other process
requirements.
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2.9.2 All fermenters shall be provided with cleaning nozzles with ability
to ensure proper cleaning, after the completion of each batch of
fermentation.
2.9.3 The spent wash from distillery shall be concentrated to 60% w/w
solids through an independent multiple effect evaporation system.
The evaporator shall be designed to operate with 2.5 bar(a) steam.
2.9.4 TEMA Standards shall be followed for heat exchanger design. A

minimum thickness of 3mm shall be provided over the calculated
thickness towards corrosion allowance for all scantlings other than
the heat exchanger tubes. The tube shall be connected to the tube
sheets with expansion followed by welding. Vertical cut baffles
shall be provided for horizontal condensers. Vapour entry shall be
from the side for horizontal condensers. Heat exchanger tube
shall be minimum 1.6mm thick. Tube sheet thickness shall be
minimum 16mm. Vent connection shall be provided at highest point
for venting non-condensable gases.
2.9.5 MOC for water headers, bonnets and steam heated reboilers shall
be SS 304. Plate heat exchanges shall be single pass type on both
sides. The plate shall be of wide gap type and plate thickness shall
be 0.6mm.
2.9.6 All pressure vessels like distillation columns, molecular sieve drums,
evaporation vessels, condensate pot etc shall be designed as per
ASME Section VIII- Div.1. Columns and other equipment designed
for steam or vapour applications and working above atmospheric
pressure shall be designed for full vacuum as well as for the
working pressure.
2.9.7 All the Columns shall be designed considering wind and seismic load
as per applicable IS standards.
2.9.8 FRP type induced draft cross flow cooling towers shall be
considered with appropriate ∆T in the design.
2.9.9 All process pumps shall be centrifugal type with mechanical seal.
100% standby shall be provided. MOC shall be SS 304 except for
Sulphuric acid CIP pumps. Molasses pumps shall be of shuttle block
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type with MOC of cast steel. The dosing pump shall be of plunger
/ diaphragm type.
2.9.10 Fermenters, product storage tanks, receivers, molasses bulk

storage tanks shall be designed generally as per IS standards/API
standard. All tanks shall be supported on civil foundations.
2.9.11 The Molecular sieve technology based Dehydration system for the
production of Anhydrous Alcohol shall be designed to accept RS
from the distillery or RS from the bulk storage.
2.10 Design & Guarantee Fuel for the Spent wash fired boiler
The design and guarantee fuel for the distillery boiler cogeneration
plant will be concentrated spent wash (60% w/w solids) to be fired
along with in house generated bagasse from the sugar mill. The
following will be the analysis and the Gross Calorific Value (GCV) of
the various fuels. The boiler shall be designed to burn about
8 . 7 TPH of concentrated Spent wash along with approximately 5
TPH of bagasse for generating 20 TPH of steam required for the
plant. The fuel analysis of the various fuels is given below.
2.10.1 Bagasse Composition and GCV of bagasse
Carbon : 23.0%
Hydrogen : 3.25%
Oxygen : 20.75%
Moisture : 50%
Ash : 3.0%
GCV with 50% moisture : 2272 kCals/kg
2.10.2 Typical analysis of 60% w/w solids concentrated Spent wash
Carbon : 22.93%
Hydrogen : 2.21%
Oxygen : 15.22%
Moisture : 40%
Sulphur : 0.63%
Nitrogen : 1.91%
Ash : 17.11%
Gross calorific value : 1705 kClas/kg
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2.11 Steam Generator & Auxiliaries
The new steam generating system for the Cogeneration plant of

the distillery will consist of One (1) bagasse and concentrated
spent wash fired boiler with a Maximum Continuous Rating (MCR) of
20 TPH, with the outlet steam parameters at 45 bar(a) and 400
Deg.C. The tolerance on the super heater outlet temperature shall
be +50C and -00C. The 20 TPH of MCR capacity is arrived at
considering the availability of 7 TPH
‘. The combustion system of the boiler shall be travelling grate with
spreader stoker for bagasse firing and a spray burner system for
burning of concentrated spent wash. The boiler efficiency shall
be a minimum of 61% on the GCV basis while firing concentrated
Spent wash with bagasse. The boiler shall be designed to meet with
the requirements of the Indian Boiler Regulations.
The dust Concentration in the flue gases leaving the boiler shall be
a maximum of 50 mg/N.Cum and the boiler shall be provided with a
bag filter for flue gas cleaning.
The design of the boiler shall be of single drum, natural circulation;

radiant furnace with water cooled membrane walls, two stage
superheater with interstage Desuperheater and balanced draft.
The boiler shall be top supported and shall be of semi-outdoor
type. The boiler shall be capable of a peak generation of 110% of
the MCR generation for a period of One (1) Hour in a shift. The
operating excess air percentage at the outlet of the boiler shall be
an average of 40%.
Boiler Feed Water
The boiler shall be capable of operating with the following feed

water quality requirements.
- pH : 8.8 - 9.2
- Oxygen : 0.007 ppm
- Hardness : 0
- Total Iron : 0.01 ppm
- Total Copper : 0.01 ppm
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- Total Silica : 0.02 ppm

- Hydrazine : 0.01-0.02 ppm
- Specific Electrical
Conductivity at : 0.5 micro-ohms/cm
25Cmeasured after
Cation exchanger in the
H + form and after CO2
removal (max)
Steam Purity
The boiler shall be capable of supplying uninterrupted steam at the

MCR rating with the following steam purity levels.
- Total Dissolved Solids : 0.1 ppm (max)

- Silica (max) : 0.02 ppm
Performance Guarantee Tests
* Maximum Continuous Rating (MCR) of the boiler while firing

concentrated Spent wash and bagasse, with the feed water
temperature of 150Cand super heater outlet parameters of
45 ata and 400C+ 5Cand - 0C.
* Boiler Efficiency at MCR on GCV basis while firing bagasse

and concentrated spent wash.
* Auxiliary Power Consumption under MCR operating

conditions.
* Steam purity for all operating loads.
* Dust Concentration in the flue gases leaving the bag house,

while firing Bagasse and concentrated spent wash.
2.12 Turbogenerator & Auxiliaries
The TG shall be a 2.2 MW nominal capacity backpressure machine

with the exhaust at 3.5 bar(a). The following shall be the salient
design parameters. The speed of the turbine shall be preferably
less than 8000 rpm. The inlet steam parameter for the turbo
generator shall be 42 bar(a) and 3950C. Under the normal
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operating conditions, with the boiler generating 20 TPH of steam,

the power generation in the turbogenerator shall be 2.15 MW,
adequate for meeting the distillery requirements.
The generation voltage shall be 420 kV and the system shall

operate in a standalone mode and when required in synchronization
with the sugar mill Cogeneration plant as well as the start up DG
sets in the distillery. A surplus power of about 300 kW will be
exported to the sugar mill.
Performance Guarantee Tests
The performance test shall be conducted for the following

parameters as per ASME PTC 6 and DIN 1943:
Power Output at Generator Terminals with the Inlet steam

parameters of as specified.
 Auxiliary Power Consumption under Guarantee conditions.
 Maximum temperature rise in the generator windings.
2.13 Auxiliary Plant and Equipment
2.13.1 Fuel handling
The fuel for the distillery cogeneration plant operation during the
season is bagasse and concentrated spent wash from the distillery.
The bagasse shall be conveyed to the new 20 TPH boiler by belt
conveyors from the storage yard. The system shall have provision
for returning the excess bagasse/biomass to the storage yard and
also the provision for back feeding the bagasse from the storage
yard to the boiler. The bulk density of bagasse shall be 150
Kg/Cum. Allowable inclination for the belt conveyor is 18to 20 .
The Belt speed shall be approximately 1.00 meters/sec. The
maximum moisture percentage in bagasse shall be 56%.
2.13.2 Ash handling
The ash handling system envisaged for the cogeneration plant is of

two types:
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- Sub-merged scrapper conveyor system for grate ash

- Dense phase handling system for fly ash
The ash received in the grate discharge hoppers will be around

500C, with ash lumps of size 200 mm maximum. The ash from ash
riddling hopper will be dry and powdery in nature and occasionally
with hot solids. The temperature of the ash will be around 200 C
maximum.
The fly ash from bag house Hoppers will be dry and powdery in
nature and occasionally with hot solids. The temperature of ash
will be around 200Cmaximum.
All the ash will be collected in storage silo having a suitable

capacity (24 hours) & will be disposed-off by trucks / trailers.
2.13.3 Cooling Towers
The cooling tower shall be Wooden/FRP type cross flow induced

draft cooling tower of adequate capacity for the various
applications of the distillery plant. The cooling tower shall be
designed for a cooling range of 2Cfor the fermentation section,
0 0
6 C for MSDH section and 10 C for other section of the plant with
an approach of 5Cwhile operating under the atmospheric wet bulb
temperature of about 28 C.The cooling tower shall be carefully
sited such that there is no re-entrainment of the vapours into the
cooling tower. The location shall also be such that there will be no
major contamination of the cooling tower basin water with the
bagasse.
The cooling tower for the power plant shall be designed with an
approach of 5 Deg.C and a cooling range of 8 Deg.C. The cooling
tower for the power plant shall be separate from the process plant
cooling towers. This tower will meet with all the cooling water
requirements of the power plant.
2.13.4 Pumps
The head / flow characteristics of pumps will be such that the

head continuously rises with decreasing capacity until a maximum
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head is reached at zero flow. Maximum run-out flow should at

least 130% of duty point flow.
The shut off head should be at least 1.1 times the duty point head
and should not be more than 1.2 times the duty point head.
The power curve should be of non-overloading type with the

maximum power occurring at or near duty point or towards
maximum runout flow.
NPSHR curve should be a continuously rising one in the range of

operation, from the minimum flow in the range to the maximum flow
in the range. Required NPSH values shall not exceed available
values over the entire range from minimum to rated flow.
2.13.5 Condensate System
The process condensate and spent lees mixture shall be treated in

a treatment plant, based on anaerobic digestion, aeration,
clarification, ultra filtration and reverse osmosis, with recovery of
about 90%. This recovered water shall be recycled and used as
make of water for cooling towers of the plant and also for molasses
dilution in the distillery process.
Process Steam from turbine extraction shall be supplied to the

reboilers of pre rectifier cum exhaust column, rectifier cum
exhaust column and extractive distillation column in the distillery
process plant and to the evaporators in the spent wash
concentration plant. The condensate from these reboilers outlet
will not be contaminated and hence can be reused in the boiler.
The pure condensate from the process area shall be stored in a
condensate recovery tank from where it will be fed to the
deaerator of the spent wash fired boiler.
2.13.6 DM Plant
The Demineralized water quality at the outlet of the DM plant shall

be as follows:
* Hardness (ppm) : 0
* pH @ 25C : 8.8 - 9.2
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* Conductivity @ 25C : 0.5
(microsiemen / Cm)
* Oxygen (maximum) (ppm) : 0.007
* Total Iron (maximum) (ppm) : 0.01
* Total Copper (maximum) (ppm) : 0.01
* Total Silica (maximum)(ppm) : 0.02
* Residual Hydrazine (ppm) : 0.01-0.02
The DM water required for the distillery and the spent wash
incineration boiler will be supplied form a new dedicated
water treatment plant. Necessary piping, valves, fittings,
flow meters shall be installed for the clarified water to the
process and DM water to the boiler and distillery.
2.13.7 Vessels & Heat Exchangers
The design shall be as per ASME Sec.VIII, HEI and TEMA. All
heat exchangers and vessels for steam application shall be
designed for full vacuum conditions. The heat exchangers shall be
provided with start up vent connections. The design shall have
provision for complete drainage on both shell and tube sides. The
heat exchangers shall be provided with emergency drains, shell
side safety valves, and individual bypass with manual valves. A
minimum corrosion allowance of 3 mm shall be provided. The tube
bundle shall be of removable type. The tube material shall be
stainless steel, unless otherwise specified in the specifications.
2.13.8 Tanks
The distillery plant tanks should have storage capacities as

required by design of the systems, requirement from the statutory
authorities and necessity to have storage facilities built in the
plant to match with marketing of the products. Tanks will be of
the closed top type. The Tanks will be fabricated in accordance
with the guidelines established by Indian Standards, API–650, BS-
2654. The tanks shall be provided with proper feeding arrangement
of the product into the tank. Drain valves, discharge valves,
manhole, safety railing, vent, vent condensers as applicable, ladders
shall be provided for the tanks. Water spraying facility shall be
provided for the molasses tank. The AA, ENA & RS storage tank
shall strictly adhere to the safety regulations.
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The receiver tanks for RS, ENA and AA will be of 60 KL capacity

each. There will be three (3) receiver tanks for each of RS, ENA
and AA. The technical alcohol receivers will be 25 KL capacity and
there will be three such tanks. There will be two (2) bulk storage
tanks for each of RS, ENA and AA. The capacity of each such bulk
storage tanks will be 450 KL. There will be one tank each for the
bulk storage of TA and Fusel oil with the capacity of 90 KL and 2
KL respectively. Apart from these tanks, denaturant will be stored
in 3 nos. 2 KL capacity tanks, and there will be two (2) denatured
spirit blending tanks each with the capacity of 60 KL for RS and
AA.
2.13.9 Piping
All piping system shall be designed as per ASME B 31.1. In addition,

statutory requirements of the Indian Boiler regulations shall be
complied with, wherever applicable.
Stress Analysis shall be carried out for all possible operating

modes and shall be as per IBR and ASME B 31.1 requirements.
Supports, guides, Directional Anchors shall be selected to satisfy
all the operating conditions.
All piping shall be sized considering the allowable velocity and

allowable pressure drop in the system. The suggested flow
velocities of various mediums are,
* Superheated Steam : 45 to 55 M/Sec

* Saturated Steam : 15 to 30 M/Sec
* Boiler Feed Water
* Pump Suction : < 1M/Sec
* Pump Discharge : 2.5 to 4 M/Sec
* Water
* Pump Suction : < 1M/Sec
* Pump Discharge : 2.5 M/Sec
* Condensate
* Pump Suction : 0.6 to 0.7 M/Sec
* Compressed Air : 12 to 18 M/Sec
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* Lube Oil & molasses

* Pump Suction : 0.3 to 0.4 M/Sec
2.13.10 Piping Materials
The piping material selection shall be based on the following

recommendations.
 For temperature 400°C to 510°C, SA 335 Gr. P11/P12/P22

shall be used.
 For temperature 399°C & below SA 106 Gr.B/C or ASTM A-

53 seamless shall be used.
 For HP/LP chemical dosing SA 312 TP 304, Stainless Steel

shall be used.
 All pipe fittings other than those mentioned shall confirm to

ASTM A 234 standard and dimension as per ANSI B 13.9 / B
13.28 / B 13.11.
 For Cooling water, Raw water, Service Water, Safety/ Relief

valve exhaust carbon steel ERW pipes shall be used.
 For the alcohol system stainless steel AISI – 304 shall be

used.
 For Service air applications the piping shall be carbon steel

Black Medium Class.
 For instrument air applications: Galvanized pipe shall be used.
2.13.11 Insulation
All exposed portions of the plant which operate at temperatures of

60°C and above during normal operation shall be thermally
insulated so that the temperature on the outer surface of the
cladding shall not exceed by more than 20°C above ambient, based
on an ambient temperature indicated in site data. The specified
insulation thickness shall not include the thickness of wire netting,
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finishing cement or any other finishing or weatherproofing

application. Insulation shall not fill the contours of the expansion
bellows. Piping and equipment that are not insulated but having a
surface temperature exceeding 50 Deg.C shall be insulated for
personnel protection.
2.14 Civil & Structural
The reinforced concrete structures shall be designed in

accordance with the latest version of Indian Standards. The
structural steel design shall be as per Indian Standards. The
design wind speed and seismicity shall be in accordance with the
applicable Indian Standards. The structures shall be designed to
withstand the calculated Dead loads, Live loads, along with the wind
and seismic loads in appropriate combinations recommended by the
Codes. The minimum dead and live loads for the design of the
platforms and walkways shall be 500 kg/sq.m.
Structural steel shapes, plates and other structural materials shall

conform to IS, with minimum yield strength of 25 kg/sq.mm.
Welding electrodes shall be as per AWS. HYSD reinforcement
steel bars shall conform to IS standards. All structural steel and
MS members will be painted with two coats of red oxide zinc
chromate paint and two coats of synthetic enamel paint.
Most of the foundations shall be of the spread footing or mat type,

with the ones for heavily loaded equipment designed with piles. Soil
Bearing Capacity shall be 12 MT/Sqm at two meter depth and
Settlement shall be 25 mm at a depth of 2.0 m below ground level.
The above soil bearing capacity shall be verified by soil
investigation before final design. The site is assumed to be
relatively flat, requiring minimal grading & levelling (levelling &
grading upto + 0.5m). Minimum grading / levelling works are
envisaged, as the land area is presently under cane cultivation. All
excavation work shall be done by conventional manual methods or
by mechanical equipment method (wherever required). For
substructures & superstructures Ordinary Portland Cement (grade
43) will be used. Grade of Concrete for steam turbogenerator &
heavy rotating equipment foundations & chimney shall be with a
compressive strength of 25N/sq.mm for a 150mm test cube at 28
days and all other foundations / pedestals / buildings etc. shall be
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with a compressive strength of 20N/sq.mm for a 150mm test cube

at 28 days.
2.15 Electrical system
All equipment for the distillery plant cogeneration unit shall be

designed for satisfactory operation for a life time of minimum 30
years under specified site conditions. All equipment shall be
suitable for rated voltage of ±10% and frequency of 50 Hz with
±5% variation and 10% (absolute sum) combined voltage and
frequency variation.
The generator shall be of synchronous type with brushless

excitation system, and shall be designed for rated voltage
& frequency of 420 V & 50 Hz, with corresponding variations of
±10% and ±5%. The generator shall have closed circuit air-cooled
system with external water circuit (CACW cooing) and the windings
shall have class ‘F’ insulation, with temperature rise limited to class
‘B’ insulation limits, under specified cooing water & ambient air
temperatures.
One (1) no. of 2.5/3.15 MVA distribution transformer shall be

installed as a stand-by supply, which in turn receives supply from
co-generation plant at 11 kV voltage level.
The nominal voltage of main DC system for protection & control

systems and turbine emergency oil pumps shall be 110 V.
UPS system with rated voltage of 230 V AC shall be envisaged, for

meeting UPS power requirements of the plant DCS and other
instrumentation / control loads.
All equipment shall comply with the applicable provisions of

relevant IS / IEC / IEEE standards, as listed elsewhere in this
document.
Breakers for LV system shall be Air break type circuit breaker.
All interconnections at 11 kV shall be carried out through 11 kV, UE

grade, armoured, XLPE insulated cables. Connection between
secondary of the distribution transformers and the respective PCC
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/ Panels shall be through non-segregated phase busduct, with

electrolytic grade aluminium busbars and aluminium alloy enclosure.
All other LT connections (power as well as control) shall be with
PVC insulated, armoured, aluminium / copper cables.
Sizing of cables shall be as follows:
The cables shall be derated for the site ambient and ground
temperatures, grouping and soil resistivity. Cables shall be
selected to limit the maximum voltage drop at equipment terminals,
during normal operation and starting conditions, to be well within
permissible values.
Cables in circuits controlled by circuit breakers shall be capable of

withstanding the maximum system fault currents till the breaker
opens by main protection. For 11 kV grade cables, screen shall be
suitable for carrying earth fault current of 1 kA for a duration of 1
sec.
Current ratings of the cables shall be assigned considering

continuous conductor temperature of not more than 70 Deg.C for
PVC and 90 Deg.C for XLPE. Cables should also be sized to carry
system fault current for the duration specified above without
exceeding the temperature limit of 160 Deg.C for PVC and 250
Deg.C for XLPE.
For 415V system, ACBs shall be provided for rating 630A and
above, and MCCB shall be provided for lesser ratings. Motor
feeders shall have fuse MCCB / MPCB, over load relays and air-
break contactors. Motors of rating above 30 kW shall be provided
with star-delta starters, depending on application.
All motors shall be of squirrel cage type and shall have class ‘F’
insulation, with temperature rise limited to class ‘B’ limits under
specified ambient and voltage / frequency conditions.
Fault Level
All equipment shall be designed to withstand the maximum fault,

under voltage variation of ±10%, 40 kA for 3 seconds at 11 kV
system and 50 kA for 1 sec in 415 V system.
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Auxiliary transformers and all accessories shall be capable of

withstanding for two seconds without damage during any external
short circuit at the terminal.
All Switchgears, MCC & Distribution Boards shall be capable of

withstanding the maximum fault currents that may arise, duly
considering the maximum fault levels on high voltage system,
negative tolerance on transformer impedance and maximum
possible motor contribution for maximum possible fault clearing
time on ultimate backup protection but not lower than one second
in any case.
Degree of Protection
* Synchronous Generator : IP54

* LT Switchgears : IP52
* Switchgears located : IP55.
outdoor
* LT busduct Enclosure : IP52 (in the indoor
portion)
: IP55 (in the outdoor
portion)
* Control Panels : IP42 (in air-conditioned
area)
: IP52 (in other areas)
* Push Button Stations : IP54 (indoor)
: IP55 (outdoor)
* Induction Motors : IP54 (indoor)
: IP55 (outdoor)
Neutral Grounding
415V transformer neutrals shall be solidly earthed through bolted

links.
DCS Interface
The system shall be compatible for accepting / sending signals

from / to DCS. Winding, bearing and cooling circuit (where
applicable) RTDs shall be hooked up to DCS for signal processing
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and necessary tripping shall be arranged from DCS, for tripping of

the corresponding motor.
Signals from all transformers for winding temperatures, oil

temperatures, oil level gauges, Buchholz relay outputs for alarm
and tripping shall be brought to DCS.
Status (ON/OFF/TRIP) of all breakers, LT breakers in PCCs and all

motor feeders shall be brought to DCS, for plant monitoring.
Control of motor feeders, as per system requirement, shall also be
arranged for control from the DCS system.
2.16 Instrumentation & Control system
The distillery and cogeneration plant’s Instrumentation and Control

system, based on Distributed Control System philosophy, will be
designed to provide monitoring and control capabilities to ensure
safe and reliable operation, minimize operator manual actions and
alert operators on any conditions or situations requiring manual
intervention in a timely manner. The control functions shall be
backed up by interlocks and safety systems which cause pre-
planned actions like tripping or sequential shut down of equipments
during situations where unsafe conditions develop faster than the
controls or the operator’s reaction time. All I&C equipment will be
of proven design and will be selected to achieve highest level of
plant availability and facilitate equipment maintenance.
Signals of various process parameters shall be electrical signals

generated by field mounted micro processor based smart type
transmitters. The above signals will be processed in the DCS to
produce electrical signal outputs which will control the final
actuators through converters. All computation, signal conditioning
and control function generation will be done in the DCS. More
details on the Instrumentation and Control systems are furnished
in Section - 7.0 of this Detailed Project Report.
2.17 Codes & Standards
Systems and equipment will be designed in accordance with the

applicable sections of the following codes, standards and
regulations in effect at the date of this Contract. Applicable
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sections of codes, standards and regulations will be defined in

specifications.
Bureau of Indian Standards (BIS)
IS:325: 1996 Three-phase induction motors
IS:456: 2000 RCC Structures
IS 800: 2007 Code of practice for construction in Steel
IS:807: 1976 Code of Practice for Design, Manufacture,

Erection and Testing (Structural Portion of
Cranes & Hoists)
IS:875: 1987 Code of practice for Design loads for

building structures
IS:1554:1988 PVC insulated (heavy duty) electric cables
IS:1893:2002 Criteria for Earthquake Resistant - Design

of Structures
IS:2042:2002 Insulating bricks
IS:2309:1989 Practice for the protection of the buildings

and allied structures against lightning - code
of practice
IS:2429:1987 Round Steel Short link chain electric butt
welded Gr.30
IS:2544:1973 Porcelain post-insulators for systems with

Nominal voltage greater than 1000 V.
IS:2705: 1992 Current Transformers
IS:2825:1969 Code for unfired pressure vessels
IS:3043:1987 Code of practice for earthing
IS:3144:1992 Methods of test for Mineral Wool Thermal

Insulation Material
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IS:3156:1992 Voltage Transformers
IS:3177:1999 Code of Practice for design of Electric

Overhead Traveling Crane and Gantry
Cranes
IS:3646:1992 Code of practice for interior illumination
IS:3832:1986 Hand Operated Chain pulley blocks
IS:3938:1983 Specification for Electric Wire Rope Hoists
IS:4503:1967 Shell and Tube Heat Exchangers
IS:4776:1977 Troughed Belt Conveyors
IS:5422: 1996 Turbine type generators
IS:5521:1980 Steel Tanks for Storage of Molasses
IS:7098:1973 Cross linked polyethylene insulated

PVC Sheathed cables
IS:7155:1990 Code of recommended practice for Conveyor

Safety
IS:8183:1993 Specification for Bonded Mineral Wool
IS 8466 Bagasse Carrier Chains
IS:8531 Pulleys for Belt Conveyors
IS:8623: 1993 Low voltage switchgear and control gear

assemblies
IS:9921:1985 Alternating current disconnectors

(isolators) & earthing switches for
voltage above 1000V
IS:11592:2000 Code of Practice for Selection and Design of

Belt Conveyors
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IS:13118:1991 High voltage alternating current circuit

breakers
IS:13947:2004 LV switchgears and controlgear
IS:13779:1999 Static watthour meters, class 1 and 2
IS:14164:1994 Industrial application and finishing of

Thermal insulating materials at
temperatures above 80Cand upto
700 Deg.C
IS:1162:1958 Specification for cane molasses
IS:323:1959 Rectified spirit specification
IS:324:1969 Specification for ordinary denatured spirit
IS:6613:2002 Neutral spirits for alcohol drinks

specification
IS:321:1964 Specification for absolute alcohol
IS:15464:2004 Test methods for absolute alcohol
American Society of Mechanical Engineers (ASME)
ASME Section I Rules for construction of power

Boilers
ASME Section IX Welding & Brazing Qualifications
ASME section VIII Unfired Pressure Vessels Code
ASME Section IX Welding Qualification
ASME Performance Test Code
ASME PTC 4.1 Steam Generating Units
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ASME PTC 4.3 Air Heaters
ASME PTC 3.0 Guide for evaluation of Measurement

Uncertainty in Performance test of Steam
Turbine
ASME PTC 19.11 Water and Steam in the Power Cycle

(Purity and Quality, Leak detection and
Measurement)
ASME PTC 25.3 Safety and Relief Valves
American National Standards Institute
ASME B13.5 Pipe flanges and flanged fittings
ASME B 13.9 Butt welding fittings
ASME B 13.1 Socket Welding and Threaded Fittings
ASME B 31.1 Code for Power piping
IEEE Standards
IEEE:141 Recommended Practice for Electric Power

Distribution for Industrial Plants
IEEE:142 Recommended Practice for Grounding Of

Industrial and Commercial Power Systems
IEEE:241 Recommended Practice for Electric Power

Systems in Commercial Buildings
IEEE:242 Recommended Practice for Protection And

Coordination of Industrial and Commercial
Power Systems
IEEE:446 Recommended Practice for Emergency and

Standby Power for Industrial and
Commercial Applications.
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IEEE:493 Recommended Practice for the Design of

Reliable Industrial and Commercial Power
systems.
IEC Standards
IEC:34 Rotating Electric machines
IEC:44 Instrument Transformers
IEC:56 HVAC circuit breakers
IEC:71 Coordination of Insulation
IEC:85 Thermal evaluation and classification of

Electrical insulations
IEC:99 Lightning Arrestors
IEC:129 Alternating current disconnectors

(isolators) and earthing switches
IEC:144 Degrees of protection of enclosures for low

Voltage switchgear & controlgear
IEC:137 Bushings for Alternating Voltages above

1000 V
IEC:183 Guide for selection of HV Cables
IEC:185 Current Transformers
IEC:186 Potential Transformers
IEC:214 On load tap changers
IEC:227 PVC insulated electric cables
IEC:255 Electrical relays
IEC:269 LV Fuses
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IEC:270 Partial discharge requirements
IEC:296 Insulating oils
IEC:298 AC metal enclosed switchgear and

controlgear for rated voltages above 1 kV
and upto and including 52 Kv
IEC:376 Specification and acceptance of new sulphur

hexafluoride
IEC:439 LV switch gears and controlgear assembly
IEC:502 Extruded solid dielectric insulated power

for rated voltages from 1 kV upto 30 kV
IEC:529 Classification of degree of Protection
IEC:542 Application guide for on load tap changers
IEC:694 Degrees of protection provided by

enclosure (IP code)
IEC:885 Electric test methods for electric cables
IEC:909 Short-circuit current calculation in three

phase AC systems
IEC:947 LV switch gears and control gear
IEC:1036 Static meters
Industry Standards
American Gear Manufacturers Association (AGMA)
American Petroleum Institute (API)
American Society for Heating, Refrigeration and Air-conditioning

Engineers (ASHRAE) Handbook
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American Society for Testing and Materials (ASTM)
American Water Works Association (AWWA)
American Welding Society (AWS) Structural Welding Code (AWS

D1.1)
Conveyor Equipment Manufacturers Association (CEMA)
Cooling Tower Institute (CTI)
Heat Exchange Institute (HEI)
Hydraulic Institute (HI)
Institute of Electrical and Electronics Engineers (IEEE)
Instrument Society of America (ISA)
Manufacturers Standardization Society (MSS) of the Valve and

Fitting Industry
National Electrical Manufacturers Association (NEMA)
National Fire Protection Association (NFPA)
Pipe Fabrication Institute (PFI)
Tubular Exchanger Manufacturers Association (TEMA)
Turbine:
IEC Recommendation Publication No: 45
CSN 080030
DIN 1943
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British Standards
BS 4592 Industrial type metal floors, walkways and

Stair treads
BS 5395 Stairs, ladders and walkways
BS:2573 Permissible Stresses in Cranes
BS:466 EOT Cranes for general use in factories,

workshops and Ware houses.
BS:5316 Performance Testing of Pumps Part-I

Class C
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3.0 PROCESS DESCRIPTION, UTILITY REQUIREMENTS

AND DESCRIPTION OF PLANT MECHANICAL EQUIPMENT
FOR THE DISTILLERY PROCESS PLANT
3.1 Process & Technology
The various sections involved in the process of Manufacture of

Alcohol in a multi product zero effluent discharge distillery are:
 Molasses receiving, Storage and Handling Section
 Feed stock weighing, distribution and Fermentation Section.
 Distillation for production of Extra Neutral Alcohol.
 Absolute alcohol production section
 AA, ENA, RS and Technical Alcohol Daily Receiver & Bulk

Storage Section
 Spent wash concentration plant
 Utilities comprising of Boiler, TG, DM water plant, Cooling

towers, compressed air system and Electrical Section
 Laboratory, stores
 Fire fighting and alarm systems for the plant
 Civil and structural work for the complete plant
3.2 Manufacturing Process
The production of alcohol from molasses is based on the property

of some specific micro organisms in metabolizing the sugar content
of molasses into alcohol. The activity is generally termed as
Fermentation. This practice of molasses fermentation into alcohol
is widely prevalent all over the world in both the cane sugar and
beet sugar industries. Being a biological and renewable source
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molasses continues to occupy a predominant position as a feed

stock of alcohol production in the world, though other sources like
food grains, dilute cane juice etc. are also widely used for this
purpose.
In the current scenario, sugar manufacture is not seen in isolation,

but as a vibrant sugar complex with facilities for production of
rectified spirit, ENA, Fuel Ethanol, cogeneration, bio fertilizer,
alco chemicals, CO2 etc. The different products of a sugar
complex complement each other in improving efficiencies, reducing
costs and earning higher revenues.
3.3 Different plant sections of the Ethanol distillery
 Molasses Bulk Storage Tanks.
 Fermentation Section –: Consisting of fermenter system

which can operate on batch or continuous mode. This section
shall also include molasses weighing, yeast propagation and
activation, tank for fermented wash holding etc.
 Multi Pressure Wash to ENA Distillation Section: Consisting

of seven column distillation unit with columns operating on
different pressures. Flexibility to draw Rectified Spirit
(RS) and Extra Neutral Alcohol (ENA) as per requirement.
This will be an automated plant with DCS based
instrumentation.
 Molecular Sieve Dehydration Section: Two bed molecular

sieve dehydration units for the production of Fuel ethanol
plant, based on pressure swing adsorption principle.
 Raw Spent Wash Evaporation Section: Consisting of an

independent falling film and forced circulation or only forced
circulation evaporation system. This will achieve spent wash
concentration of up to 55 – 60% w/w solids.
 Condensate Treatment Section – Based on UASB, aeration,

clarification and cross flow membrane technology to recover
re usable water which can be used in process.
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 Concentrated spent wash incineration boiler and a matching

turbogenerator.
 Utilities for the above sections including cooling towers,

cooling water recirculation pumps, water treatment plant and
instrument air compressor etc.
 Product Storage Section – Consisting of alcohol daily

receivers, bulk storage, alcohol transfer pumps, delivery
meters etc.
3.4 Raw material for alcohol production
3.4.1 Molasses
Molasses produced from the sugar process operations of GSML is

the primary raw material that will be used for the production of
alcohol. Molasses to be used for this project contains about 36.8%
fermentable sugars, which include the sucrose and other
fermentable monosaccharide like glucose. During the
fermentation, yeast strains of the species Saccharomyces
cerevisieae or Pombe are used as alcohol producing micro organism.
This living micro-organism belonging to class fungi converts the
monosaccharide sugars such as glucose into alcohol and carbon-di-
oxide. The sucrose in molasses will be hydrolysed into glucose with
water.
3.4.2 Yeast
Each yeast cell by itself is an independently existing living entity.

Of the different types of yeast, Saccharomyces cerevisiae is the
industrially important yeast for alcohol fermentation.
Saccharomyces cerevisiae consists of different strains and
varieties.
Criteria for Selection of yeast for molasses Fermentation:
 Fast fermenting
 High alcohol tolerance
 High sugar tolerance
 High salt tolerance
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 High temperature tolerance

 Produce less amount of by-products
 Resistance to contamination
Yeast can grow aerobically as well as anaerobically. Aerobic

conditions favours yeast cell production, which is not of interest to
ethanol producers. However, growth during anaerobic condition is
very marginal and major reaction is conversion of sugar to ethanol
for energy production. For growth and multiplication, yeast
requires utilizable organic carbon (sugars), nitrogen source, and
various organic and inorganic trace growth factors. Proper
nutrition, like for any other living organism, is the key to making
yeast thrive and to obtain optimum performance. The two most
important nutrients for growth are nitrogen and oxygen. In
addition to this, optimum environmental parameter i.e. temperature
is also required. The ethanol production process from glucose is an
exothermic reaction and this heat is to be removed to maintain the
optimum temperature for high yeast activity. At lower
temperatures the yeast becomes dormant and at higher
temperatures the yeast loses its ability to produce alcohol and
dies.
Propagation of yeast culture
Culture yeast is grown in the laboratory during the plant start up.
Yeast propagation section has hygienically engineered yeast culture
vessel equipped with heating, cooling and air sparging facilities. The
Purpose of propagation is:
 For Cultivation of yeast culture in pure form

 To obtain yeast culture in required amount
 Required to reduce the time for fermentation
 To have Maximum viability & vitality of yeast
 To Improve ethanol tolerance of yeast.
Yeast propagation method:
Initially yeast is developed in the laboratory from the single cell

yeast culture. Laboratory propagated cell mass is scaled up in a
series of culture vessels. Sterile air from air blower is sparged in
pasteurised and cooled media in the Culture Vessels for optimum
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growth of culture yeast. Temperature is maintained at 300C-320C

by cooling water. Yeast development in laboratory is as follows. –
Single cell 10 ml media in 100 ml media 1 lit. media in

test tube in conical flask conical flask
Flask contains the sterilized molasses media solution. It is

necessary to adjust the pH of the molasses solution in the range of
4.5 to 5.0, add nutrients such as ammonium sulphate or urea, DI-
ammonium phosphate etc. Each stage of development of yeast from
10 ml to 500 ml and 500 ml to 5000 ml requires 8-12 hours in the
laboratory. On the plant side, there are again 3 stages of
propagation viz., 100 litres, 500 litres and 5000 litres, boiling
molasses solution in order to sterilize it and cool to bring it to the
0
32 C. Heating and cooling of the molasses and introducing culture
etc. is done in aseptic manner. Further stages of yeast propagation
are done in tanks. i.e. in the pre-fermenter which requires about 8
hours in order to build up necessary concentration of yeast in
them.
3.5 Distillery Fermentation Area
3.5.1 Molasses storage weighment and distribution
Based on the daily requirement of molasses for the plant, molasses

is received from bulk storage tanks to the day storage tank. From
the molasses storage tank the molasses is transferred to the
molasses receiving tank using transfer pumps through load cell type
molasses weighing scale. Weighed molasses is collected in the
weighed molasses tank and then distributed to cell mass
propagation, yeast activation and fermentation section using
weighed molasses pumps.
3.5.2 Plant Fermentation Section
As the yeast cannot survive in the high sucrose molasses, the

molasses needs to be diluted with water to give a sugar
concentration of 14% to 18%. Yeast will find this sugar
concentration conducive for ethanol production. This molasses is
usually not sterilized, although in certain cases it has been
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pasteurised with a resultant slight increase in efficiency. The mash

is adjusted to a pH of 4 to 5 with Sulphuric acid, if required.
Although the optimum pH for maximum efficiency varies with the
molasses used, an initial pH of 4.8 to 5.0 is usually considered the
best.
The fermentation process converts the fermentable sugars in feed

stock into alcohol using yeast. During fermentation, sugar molecules
are broken down into alcohol and carbon-di-oxide. Significant heat
release takes place during fermentation. However, the
fermentation temperature is maintained at around 320C by forced
recirculation flow of mash through mash coolers using fermented
mash recirculation pumps.
The enclosed Drawing No.1-15003-800-0001, titled “Process Flow

Diagram for Fermentation Section” gives the Fermentation scheme
proposed for the project.
Fermentation time:
Fermentation begins promptly after the fermenter is filled and

usually active after 2 to 4 hours. Fermentation time vary with the
molasses used, but blackstrap fermentation is usually complete in
36 hours while some molasses require 48 hours and 72 hours,
respectively. After fermentation is complete the fermented mash
known as “beer” and containing 8% to 9% alcohol is pumped to a
temporary storage tank or also known as wash holding tank prior to
distillation.
Contamination:
The mash in molasses fermentation is usually not sterilized, the

chief defence against contaminants being the adjustment of the
acidity to pH 5.0 or slightly below. Many contaminants will not grow
readily at such pH levels. The fermentation is usually so vigorous
that anaerobic conditions are quickly established and the alcohol
produced tends to inhibit those lactic and butyric organisms that
do develop. Molasses itself usually contains a relatively small flora
consisting of spores of moulds, bacteria, and yeasts. Many common
species of bacteria will not multiply to any extent in molasses
mashes containing 15% sugars.
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When spent wash recirculation is employed, care must be taken to

avoid contamination of the mash with bacteria from spent wash
lines and coolers, incrustations on values’, dead ends etc, since
these parts of the equipment can build up residues and thus act as
foci of infection, harbouring bacteria acclimatized to and capable
of growing in molasses mashes. Good practice consists of daily
washing and steaming of all mash and spent wash lines and coolers.
When not in use these lines are preferably held under steam
pressure.
Spent wash recycling
The spent wash recycle to the fermentation is a function of

molasses quality and the operating parameters maintained in the
fermentation. This recycle helps reduce the spent wash generation
from the distillery process, as a percentage of the spent wash will
be recirculated to the fermentation section for molasses dilution.
The parameters like volatile acidity, butyric acid content are
important parameters of molasses quality which are crucial for
fermentation and hence the percentage recycling of spent wash to
the fermentation section. Spentwash received from analyser
column is cooled using spent wash recycle cooler and fed to
fermenters so as to reduce the usage of fresh water for molasses
dilution in the fermentation process. As this aspect of spent wash
circulation is to be determined, looking at the molasses, during the
operation, this report, for the present, assumes that there will be
no spent wash recirculation.
3.6 Alcohol Production from sucrose
Yeast consumes fermentable sugar present in molasses and

converts it into alcohol. Alcohol so produced in the yeast cells
diffuses out of its body cell wall and get accumulated in fermenter.
Alcohol yield varies with yeast strain and type of molasses. The
biochemical reaction occurring in yeast cell and total amount of
alcohol synthesized in process per metric ton of molasses is as
follows:
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Biochemical reaction:
I) C12H22O11 + H2O Invertase 2C6H12O6

Sucrose Glucose + Fructose
II) C6H12O6 Zymase 2C2H5OH + 2CO2

180 2 x 46 + 2 x 44
GLUCOSE /FRUCTOSE Ethyl alcohol + Carbon di-oxide
Thus 180 gm. of sugars on reaction gives 92 gms of alcohol.

Therefore, 1 mt of sugar gives 511.1 kgs of alcohol. The specific
gravity of alcohol is 0.7934, therefore, 511.1 kg. of alcohol is
equivalent to 511.1 / 0.7934 = 644.19 litres of alcohol. During
fermentation, other by-products like amyl alcohols, glycerine,
succinic acids etc. also are formed from sugars. In addition some of
the sugar is consumed by yeast and hence the efficiency of
fermentation in producing ethyl alcohol is taken only at about 90%.
Therefore, actually 90% total fermentable sugars are available for
alcohol conversion. Thus theoretically, one MT of sugar will give
only 644 x 0.9 = 579.6 litres of alcohol, under ideal conditions.
Depending on the quantity of fermentable sugars in molasses the
alcohol production per MT of molasses will vary and with 36.8%
fermentable sugars the alcohol production will be 222 Litres per
MT of molasses.
The process of conversion of sugar into alcohol, as seen above, is an

exothermic process. The amount of heat liberated during the
fermentation of a gram mole of glucose is given by the following
formula.
C6H12O6 2C2H5OH +2CO2+ 26 Kilo Calories
The heat produced from a fermentation involving 100kg of glucose

(monosaccharide) is 14,000 kilo cals.
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3.7 Various by products of alcoholic fermentation
Fusel Oil:
The high boiling fraction (100 to 150oC) obtained in the distillation

of fermented wash is known as fusel oil. It is generally 0.2-0.4
percent of spirit production. Fusel oil from molasses is a mixture of
isopropyl and n-propyl, isobutyl and n-butyl, isoamyl and d-amyl
alcohols. Over 50% of the total fusel oil consists of isoamyl and d-
amyl alcohols. The ammonium salts depress the yield of fusel oil,
since yeast preferentially uses the ammonium ion directly rather
than delaminating amino acids. The use of acid to adjust the pH of
the mash likewise decreases the fusel oil yield.
Carbon Dioxide:
Carbon dioxide will be available in large quantities as a by-product

of the fermentation industry. From every 100 kg of
monosaccharide fermented, approximately 51.1 kg of alcohol and
48.9 kg of Carbon-di-oxide are produced. Thus, from a
fermentation process large amount of Carbon-di-oxide is formed.
About 70% of the produced carbon di oxide can be recovered.
Depending on the market conditions and seasonal demand for
carbon dioxide the carbon di oxide could be sold in the solid form
(dry ice) or in cylinders for carbonating beverages. Carbon-di-
oxide is collected from closed fermenters after a vigorous
fermentation has set in and the dissolved gases and air have been
purged from the fermenter. The CO2 is taken to a scrubber where
it is washed with water to recover the entrained alcohol. The
scrubbed CO2 can be taken to either a CO2 plant or vented to
atmosphere. The scrubbed water is transferred to mash holding
tank. The gas at this stage while relatively pure (99.5%) contains
traces of entrained molasses solids, aldehydes, alcohol and minute
amounts of other impurities These are responsible for an odour
which must be removed before the gas can be utilized to carbonate
beverages or be processed into solid Carbon-di-oxide. Of the total
Carbon-di-oxide produced in the fermenter only 70% to 75% can
be recovered as liquid or solid Carbon-di-oxide.
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3.8 Distillation Section
When we consider distillation system employed in distillery on the

basis of steam consumption and quality of spirit, multi pressure
vacuum distillation will be the preferred choice. In multi pressure
vacuum distillation best quality of Extra Neutral Alcohol at
affordable steam consumption is possible to be produced. The
potassium permanganate test time for Extra Neutral Alcohol
produced by vacuum distillation easily achieved up to 45 minutes. In
case of atmospheric distillation unit, steam and energy consumption
will be at higher side & at the same time quality of Extra Neutral
Alcohol produced is on the inferior side as compared to that
produced by vacuum distillation.
One of the important reasons for selection of vacuum distillation is

not only Quality but also great improvement in plant cleaning
period. In case of atmospheric distillation, there arise a need to
clean the analyzer column frequently . In vacuum distillation as
boiling of fermented wash is carried out at low temperatures,
calcium induced hard scale deposition is low and the cleaning
requirements get reduced greatly.
3.9 Distillation Technologies
Distillation is a the process of separation of a multi product liquid

into its components, by using the difference in the boiling points of
the various constituents. This is achieved by boiling the liquid and
condensing the various constituents at appropriate locations
depending on the boiling temperatures and hence is an energy
intensive process.
3.9.1 Multi pressure vacuum distillation:
After fermentation the next stage in the manufacture of alcohol is

to separate alcohol from fermented wash and to concentrate it to
95% alcohol called as rectified spirit. For this purpose, distillation
process is employed.
Distillation consumes a considerable amount of energy and is also a

deciding factor in the quality of ethanol produced. Hence, in line
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with the demand of the industry, efforts have always been made to
minimize requirement of energy and to improve the basic quality of
alcohol produced. Ease of operation, reliability, lower down time
and flexibility of operations are other parameters considered
during the design.
Three basic types of plant are designed:
 One is to produce primary or the industrial quality of alcohol,

usually referred to as 'Rectified Spirit' (R.S.) from the
fermented wash. Such plants are also referred to as ‘Primary
distillation’ plants.
 Second is to produce a fine quality of spirit usually referred

to as 'Extra Neutral Alcohol' (ENA) starting from R.S. Such
plants are also referred to as 'secondary distillation' plants.
 Third is to directly produce fine quality alcohol (ENA) from

fermented wash. Such plants are referred to as 'wash
(mash) to ENA' plants, where the two steps of primary and
secondary distillation are combined. Such plants usually have
lower consumption of energy than two separate plants.
 Multi-pressure vacuum distillation system for production of

Rectified Spirit / ENA consists of following distillation
columns namely
o Degasifying cum analyzer column – Operation under

vacuum
o Pre-rectification column – Operation under vacuum
o Rectification cum Exhaust Column - Operated under
pressure
o Recovery column - Operated under atmospheric
o Extractive distillation column – Operated under
vacuum
o Simmering column – Operated under atmospheric
In the proposed 60 KLPD project, ENA could be produced directly

from wash. The concentrated vapours from the rectifier cum
exhaust column will be fed directly to the ENA section of
distillation columns (Extractive distillation and simmering column).
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For ENA-distillation, columns will work on multi-pressure principle

so that maximum heat economy can be achieved with improved
quality of ENA.
3.9.2 Benefits of Multi Pressure Vacuum Distillation
Following are the advantages of pressure vacuum distillation.
 Since the columns operate under different pressures, the

vapours from one column could provide the energy required
for driving the other column. As the system operates to
some extent like a multiple effect evaporator system, good
steam economy is achieved.
 Since the analyzer column operates under vacuum, the

formation of by-products such as acetal may be minimized
there by improvement in quality of alcohol.
 Pre-rectification column ensure removal of sulfur

compounds/mercaptans and also reduces load of lower boiling
volatile compounds passing on to Rectifier cum exhaust
column.
 The chances of scaling due to invert solubility of certain

precipitating inorganic salts are minimized in vacuum
distillation.
 Vacuum distillation requires low steam consumption with

reboiler
3.9.3 Integrated Multi-products Concept
It is now possible to install a distillation system, which can produce

different products. In the proposed scheme; the production of
Rectified spirit, ENA & Absolute alcohol have been considered.
This allows flexibility of operation and various products can be
manufactured depending on the market demand. This integrated
multi-product system involves less capital investment as compared
to independent system.
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In this type of system, switching over from one product to another

is quite easy and there is no chance of contamination of one
product with another. The system can work under multi-pressure
principle with few columns operating under vacuum and few under
pressure/atmospheric. The process for wash to RS mode and wash
to ENA mode is described below:
The Drawing No.1-15003-800-0002, titled “Process Slow Diagram

for Distillation Section” gives the distillation scheme proposed for
the distillery project.
Wash to RS Mode
The following distillation columns will be under operation
 Analyser Column (Under Partial Vacuum)

 Degasifying Column (Under Partial Vacuum)
 Recovery Column (Atmospheric Pressure)
 Rectifier cum Exhaust Column (Under Pressure)
Pre-heated fermented wash will be fed to Degasifying column.

Fermented wash is stripped off alcohol by ascending vapors in
Analyser column. Vapours of Degasifying column are condensed and
appropriate TA cut is taken out from this column. The DG
condensate is fed to the Recovery column. Analyser vapours are
condensed and taken to Rectifier Feed Tank (which acts as Pre-
Rectifier Column Feed Tank in Wash to ENA mode). Rectifier
column, which operates under pressure, concentrates the
condensate of Analyser column to 95% v/v concentration. Fusel Oil
Draws are taken from appropriate trays and fed to Recovery
Column. Recovery Column concentrates the fusel oil streams. A
suitable impure spirit cut is taken out from this column. Rectified
Spirit draw of 95% v/v is taken out from the upper trays of
Rectifier Column and taken to storage after passing it through a
cooler. RS produced in this mode of operation can be taken to
storage and later be fed to the MSDH unit or directly be fed to
the MSDH unit.
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Wash to ENA Mode:
The following distillation Columns will be under operation
 Analyser & Degasifier Column: Operates under partial

vacuum.
 Pre-Rectifier cum Exhaust Column: Operates under pressure.
 Extractive Distillation (ED / Purifier) Column: Operates
under partial vacuum.
 Rectifier cum Exhaust Column: Operates under pressure.
 Recovery Column: Operates at atmospheric pressure.
 Simmering Column: Operates at atmospheric pressure.
Pre-heated fermented wash is fed at the top of the Degasifier

column. Analyser Column is provided with re-boiler. Top vapours of
Analyser column containing all the alcohol in the wash are sent to
Pre-rectifier column after condensation. Rest of the fermented
wash flows down the Analyser column and is taken out as spent
wash 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 is further sent
to Extractive Distillation (Purifier) column.
Dilution water in the ratio of 1:8 to 1:9 is fed to this column. The
Extractive Column operates on the principle of inversion of relative
volatility. Low boiling impurities are separated in the purifier
column & bottom is sent to Rectifier cum Exhaust column. The
Rectifier / Exhaust column concentrates the alcohol to 96% v/v.
The high grade spirit is drawn from the upper trays of the
rectification column. Fusel oil build up is avoided in the Rectifier
cum exhaust column by with drawing side streams (fusel oils).
Purifier condensates, Degasifier condensates & fusel oil draw from
R/E column are sent to Recovery column where these fusel oils are
concentrated and then sent to decanter where these streams are
diluted with water and fusel oil rich layer is separated. Washing
are sent back to the column to recover alcohol.
The High Spirit Draw from the Rectifier Column is sent to the
Simmering Column where methanol is separated in the form of a
cut from the top and ENA is taken out from the bottom. ENA
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drawn from the Simmering Column is taken to the receiver after

cooling in ENA cooler.
3.10 Manufacture of absolute/anhydrous alcohol
Anhydrous alcohol is an important product required by industry.

Alcohol as manufactured by distilleries is rectified spirit, which is
94.68 % alcohol, and rest is water. 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.
 Azeotropic Distillation
 Molecular Sieves
As azeotropic distillation calls for an entrainer like cyclohexane or

Benzene and needs some make up and also the steam requirement
for this process is comparatively high, this process is not as widely
used as the molecular sieve dehydration. It is proposed to go with
molecular sieve dehydration for the proposed distillery project.
3.10.1 Dehydration with Molecular Sieve Process
Molecular sieve dehydration technology is commonly used in Indian

distilleries for dehydration of rectified spirit to produce fuel
ethanol because of easy operation and low steam requirement.
The Drawing No. 3-15003-800-0003 titled “Process Flow Diagram

For Molecular Sieve De-hydration Section” gives the proposed
Anhydrous Alcohol production scheme for the proposed Distillery.
Rectified spirit containing 94.68% to 95% v/v alcohol is pumped

from RS collection tank to dehydration section. Rectified spirit is
preheated in feed pre heater with the help of product vapours and
fed to top tray of evaporator column. The objective of evaporator
column is to evaporate the rectified spirit. Evaporator column
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operates under pressure. Energy is supplied to evaporator column

by evaporator column re boiler with steam condensing on the shell
side. Overhead alcohol feed vapours from evaporator column are
pass through super heaters where the alcohol vapour is
superheated. Energy for super heating is supplied by steam
condensation on the shell side of the super heater.
Superheated hydrous alcohol vapours are sent to twin Adsorbent

Beds. The twin Adsorbent Beds operate in cyclic manner. Twin
beds are provided to allow for bed regeneration in continuous
operation. While one bed is in dehydration mode, the other is in
regeneration mode. Depending on feed and product specification,
dehydration regeneration exchange takes place approximately
every few minutes. The feed alcohol vapours are passed through
the bed under dehydration mode. The Adsorbent Bed will absorb
moisture present in feed vapours and dehydrated product alcohol
vapours are obtained from bottom of the bed. The dehydration is
done by adsorption by the desiccants which has pore sizes of 3
Angstrom units. The water molecules having a size of 2.5 Angstrom
units are adsorbed in the pores and the alcohol molecules with the
size of 4 Angstrom units go through the desiccant bed in a
dehydrated condition.
The product alcohol vapours are then passed through Regeneration

pre heater for heat recovery. The Product alcohol vapours are
then passed through Product Condenser where product vapours are
condensed with the help of cooling water. Condensed product
alcohol is collected in product receiver. The Product alcohol from
Product Receiver is pumped to Product Cooler where it is cooled
with the help of cooling water and then sent for anhydrous alcohol
storage. The life of molecular sieve may be around five to seven
years. However, the operating cost is considerably less than
azeotropic distillation.
3.11 Raw material and utilities requirement for the 60 KLPD multi
product distillery
3.11.1 Molasses
Molasses requirement (36.8% F.S.) for proposed 60 KLPD distillery

will be 270 MT/day (222 litres of alcohol can be obtained from 1
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ton of molasses). Proper care should be taken during storage to

cool down molasses before it goes to molasses storage tank. The
molasses storage tank should have a suitable pump for recirculation
of molasses. The molasses tank should also be equipped with water
spraying circumferential header on top of the tank. Higher
molasses temperature could lead to internal combustion of
molasses and will result in the loss of the entire quantum of
molasses stored in the tank. The molasses specification is given in
Section 2 of this report under clause 2.4.1.
Assuming that both the sugar mill and the distillery start operation
simultaneously, the in house molasses storage shall be adequate to
meet with the number of operation days of the distillery after the
closure of the cane crushing. It is estimated that the requirement
could come to about 32000 MT of Molasses. There will be a total
storage of 33,360 MT for molasses. This includes the already
existing storage tank of 25,860 MT capacity in the sugar mill. The
balance of the storage will be made up by adding one number of
7,500 MT capacity within the new distillery complex. .
3.11.2 Raw Water
The raw water requirement is 1500 cu.m per day for the operation
of the distillery in wash to ENA mode. The water is required for
the distillery process in the fermentation section, cooling tower
make up for the distillery cooling towers. The raw water
specification is given in Section-2 under Clause 2.6. The above
quantities are based on the usage of fresh raw water for meeting
all the needs without any consideration for the condensate recycle.
If water recycling from the condensate treatment and polishing
plant is considered, the raw water required will be 700 cu.m/day.
To optimize the water usage the 60 KLPD distillery section will

have a process condensate and spent lees treatment and polishing
unit, the recovered water of which will be used for process make
up or cooling tower make up. The DM water requirement for the
distillery and for the boiler is approximately 300 cu.m per day.
In another section of this report, the condensate and spent lees

treatment and polishing unit is dealt with in detail.
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The drawing No.1-15003-800-0010 titled “process flow diagram for

cooling water system” gives the proposed cooling water scheme for
the distillery.
The drawing No.3-15003-800-0011 titled “Process Flow Diagram

for Raw water & DM Water system” gives the proposed raw water
and DM water scheme for proposed distillery.
3.11.3 Steam Requirement
The steam requirement for production of RS from fermented wash

is about 5.5 TPH at 2.5 bar (a) saturated. The steam requirement
for production of ENA from fermented wash is 8 TPH at 2.5 bar
(a) saturated. The steam requirement for production of AA from
RS is 1.5 TPH at 4.5 bar (a) saturated. The steam requirement for
Spentwash concentration from approximately 14% w/w solids to 60
% w/w solids in the stand alone evaporation system is 6 TPH at 2.5
bar (a) saturated. In addition to the above the Spentwash fired
boiler is provided with deaerator which requires steam for
deaeration purposes and also for heating the combustion air in the
steam air pre-heater.
Considering all the above, the spent wash fired boiler is sized for
this project to have a MCR output of 20 TPH at 45 bar (a) 4000C.
The steam produced in the boiler will be fed to the turbo
alternator for power generation. The extraction steam of turbine
shall be slightly superheated and shall have a pressure of about 3.5
bar (a), which will be used for meeting the distillery plant steam
requirements.
3.11.4 Power Requirement
The total power requirement (at 415V, 3 PH, 50 Hz level) for the
distillery and co-generation plant is given below:
 Distillery Process requirement : 775 KW

 Spentwash concentration plant : 330 KW
 Condensate/lees polishing unit : 100 KW
 Boiler and other utilities : 620 KW
 Lighting and Misc. : 25 kW
 Total (operating reqt.) : 1850 KW
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The connected power will be higher than operating requirement.

The distillery power requirement will be generated by a 2.2 MW
backpressure type which will be supplied with steam from the
Spent wash fired boiler. However the boiler and turbogenerator
will be operating in synchronization with the Cogeneration plant
operating in the sugar mill, so that the surplus power could be
exported to the sugar mill and then to the grid. The actual power
requirements and the actual steam requirements will vary
depending on the output product and the sections of the distillery
that will be in operation and the total power and steam consumption
discussed earlier are the maximum consumptions. The power
generation is at 415 V level from the 2.2 MW turbo generator.
3.11.5 Chemical Requirement
The distillery fermentation section requires Sulphuric acid, anti

foaming agent, nutrients and yeast for the process. In addition, the
condensate and spent lees polishing unit requires chemicals for
neutralization, membrane cleaning etc. The following is the daily
tentative requirements of major chemicals when the distillery is
operating at its rated capacity.
 Sulphuric acid : 400 Kg/day

 Nutrients (DAP/ Urea) : 170 kg/day
 Anti foaming agent : 60 kg/ day
 Caustic (47% w/w) : 800 kg/ day
The composition of the above chemicals is given under clause 2.5 in

section - 2 of this report. In addition, the process requires in
process cleaning chemical like caustic, sodium meta bisulphite,
Nitric Acid, cooling water treatment chemicals etc., for the
process cooling towers, cleaning of the columns and RO membranes
etc. However, the usage of these chemicals is not on a continuous
basis and the quantity requirements is also much less.
3.12 Output from the Distillery
The proposed distillery will be designed to give a total output of 60

KLPD of total spirit. As finished product the plant will produce 47
KLPD of rectified Spirit or 56.32 KLPD of Extra Neutral Alcohol or
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56 KLPD Anhydrous Alcohol (fuel ethanol). In addition the impure

spirit production will be 3 KLPD. The recoverable Carbon-di-oxide
production will be 35 TPD from the fermentation section of the
distillery.
3.13 Effluent production from the distillery
The proposed 60 KLPD distillery is designed as a “Zero Effluent

discharge” unit. The spent wash generated in the distillery is
concentrated in an independent evaporator station with the 2.5
bar(a) heating steam supplied from the turbine extraction. The
concentrated Spent wash will be fired in a boiler of 20 TPH
capacity to be installed in the distillery which along with the 2.2
MW co-generation power plant supplies steam and power to the
distillery.
About 600 TPD of Spent wash at a concentration level of 14% to

15% w/w will be concentrated to 175 TPD of 60% w/w
concentration in an independent evaporator station. This quantity
of about 175 TPD (8.7 TPH) concentrated spent wash along with 5
TPH of bagasse, as the auxiliary fuel, will be used in the boiler for
steam generation.
The general characteristic of raw spent wash indicates that it is

dark brown in colour with low pH and high BOD and COD, total
solids, volatile solids etc. The tentative composition of spent wash
is given below.
ELEMENT PARAMETER
Volume, lit. /LIT. of Alcohol 11-12
Colour Dark brown
PH 4.0-4.3
COD PPM 1,10,000-1,30,000
BOD PPM 55,000-65,000
SOLIDS -
Total (mg/l) 1,30,000-1,60,000
Total Volatile (mg/l) 60,000-75,000
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Inorganic dissolved (mg/l) 35,000-45,000

Chlorides (MG/L) 6,000-7,500
Sulphates (MG/L) 4,500-8,500
Total Nitrogen (MG/L) 1,000-1,400
Potassium (MG/L) 10,000-14,000
Phosphorus (MG/L) 300-500
Sodium (MG/L) 1,400-1,500
CALCIUM (MG/L) 4,500-6,000
The details of the effluent treatment, condensate polishing, spent

wash fired boiler and the 2.2 MW Turbogenerator etc., are
furnished under Section – 4 and Section – 5 of this report.
3.14 List of equipment
The following gives the typical list of plant and machinery in each
section of the distillery process. It is possible that depending on
the supplier, there could be some marginal changes in the list of
equipments.
3.14.1 Fermentation Section
 Molasses Bulk Storage Tanks.

 Molasses Bulk Storage Tank Transfer Pump with motor
 Molasses Day Storage Tank Transfer Pump with motor
 Molasses Strainers
 Molasses Weighing System
 Weighed Molasses Pump with motor
 Molasses Diluter
 Culture
Vessels
 Air Sparger for Culture Vessel
 Cell Mass transfer Pump

Fermenters
 CO2 Scrubber
 Mash Cooler for Fermentor
 Fermented Mash Recirculation / Transfer Pump with Motor
 Mash Transfer Pump with Motor
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 Safety System for Fermentors
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 Molasses Broth Mixer for Fermentors

 Cooler for Prefermentor
 Recirculation cum Transfer Pump
 Air Sparger for Prefermentor
 Molasses Broth Mixer for Prefermentor
 Agitator for Nutrient Dosing Tank with motor
 Air Blower with Motor
 Air Filter
 Liquid separator for Air Blower
 Antifoam Dosing Pump with Motor
 Acid Dosing Pump with Motor
 Nutrient Dosing Pump with Motor
 Nutrient Dosing Tank
 Spentwash Recycle Cooler
 Spentwash Recycle Pump with Motor
 Piping, Valves, Fittings, supports etc
 Field Instruments for Fermentation Section
 Electrical Equipment MCC / Cables etc., lighting, earthing,
for fermentation section
3.14.2 Distillation Section
 Mash / Analyzer Column

 Degasifying (DG) Column
 Pre-Rectifier Column
 Rectifier cum Exhaust Column
 Extractive Distillation (ED) Column
 Recovery Column
 Simmering Column
 Alcohol scrubber
 Fermented Mash Preheater
 Mash Column Reboiler
 Pre-Rectifier Column Reboiler
 ED Column reboiler
 Rectifier cum Exhaust Column Reboiler
 Simmering Column Reboiler
 DG Condensers
 Impure Spirit Cooler
 Mash Column Vent Condenser
 ED Column Condensers
 Recovery Column Condensers
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 Simmering Column Condensers

 Vent Condensers for Simmering Column Reboiler
 Pre-Rectifier PCV Condenser
 Rectifier PCT Condenser
 Simmering Feed Cooler
 Product Cooler
 Rectifier LFO / HFO Cooler
 Pre-Rectifier LFO / HFO Cooler
 Recovery LFO / HFO Cooler
 TA Mixing Bottle
 ED Mixing Bottle
 Rectifier Feed Preheater
 Pre-Rectifier Feed Preheater
 DM Water Feed Preheater
 Pre-Rectifier Feed Tank
 Pre-Rectifier Feed Pump with motor
 CIP Pump with motor
 Mash column Bottom transfer Pump with motor
 Pre-Rectifier Reflux Tank
 Pre-Rectifier reflux Pump with motor
 Rectifier Reflux Tank
 Rectifier Reflux Pump with motor
 Pre-Rectifier Spent Lees transfer Pump with motor
 Steam Condensate Pump with motor
 Rectifier Spent lees Transfer pump with motor
 ED Column bottom transfer pump with motor
 Fusel oil washing tank
 Fusel oil washing pump with motor
 Recovery Feed Tank
 Recovery Feed Pump with motor
 Vacuum Pump with motor
 Fusel Oil Decanter
 Flash tank for Mash Column Reboiler System
 Vapour bottles
 Piping, Valves, Fitting & Supports
 Field instruments and Cabling
 Plant electrical, MCC, Cables, plant lighting, earthing, etc.
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3.14.3 MSDH Section
 Feed Pump.
 Feed Filters.
 Evaporator Columns.
 Superheater
 Molecular Sieve beds.
 Regeneration condenser
 Regeneration Preheater.
 Feed Preheater.
 Regeneration Receiver.
 Regeneration Pump
 Vacuum Eductor.
 Regeneration Cooler.
 Product Condenser.
 Product Receiver.
 Product Pump with motor.
 Product Cooler.
 Product filter.
3.14.4 Standalone Evaporation
 Falling Film Type / forced circulation Evaporators &

finishers
 Vapour Liquid Separators
 Process Condensate Pot
 Spentwash Feed Tank
 Spentwash Feed Pump with motor
 Recirculation Pumps with motors
 Product Transfer Pump with motor
 Process Condensate Pump with motor
 Steam Condensate Pump with motor
 CIP Pump with motor
 Vacuum Pump with motor
 Piping, Valves, Fittings & Instrumentation
 MCC and other Electricals
3.14.5 Product storage tanks with pumps, valves and piping
3.14.6 Day tanks & issue tanks with pumps, valves and piping
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3.14.7 Air compressors & compressed air system
3.14.8 Cooling towers for the various sections of the distillery
3.14.9 DCS system for the plant control
3.15 Laboratory Instruments & Glassware
The distillery should have a laboratory with testing instruments,

glass wares etc. The co-generation plant water treatment plant
laboratory could also be integrated with the distillery laboratory.
The suggested list of distillery laboratory equipment is given below.
 Anton Paar densitometer

 BOD incubator
 Constant temperature water bath
 Hand Refractometer
 Hot Air Oven
 Karl Fischer Moisture Titrate
 Lab Centrifuge (Table Top Model)
 Magnetic Stirrer
 Muffle furnace
 pH Meter
 UV Visible spectrophotometer
 Vacuum Oven Attached with Vacuum Pump
 Weighing Balance

Autoclave
 Laminar Air - Flow unit
 Microscope

Refrigerator
 Vortex
Mixer
 Nichrome Wire – Loop
 Petri Plate holder
 Test Tube Rack
 Dispenser with Plastic disposable tips
 Distillation Assembly (Glass Ware)
 Necessary Glassware
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3.16 Fire Fighting System for the distillery
The fire fighting system for the distillery shall comprise of the
following.
 Fire hydrant system for the entire distillery plant

 Foam system for Alcohol & Ethanol storage tanks
 Automatic fire detection and alarm system for MCC rooms
 Portable fire extinguishers for the entire distillery plant
3.16.1 The alcohol & ethanol storage tanks shall be protected with water
spray system in the form of a ring along the top edge of the
vertical face of the tank. The foam system shall be designed as
per latest edition of NFPA 11 & water spray system shall be
designed as per Regulations. The water required for foam system
shall be taken from the nearest hydrant main. If the water
requirement for foam system exceeds 410 cum/hr, then the fire
hydrant pump capacity shall be revised accordingly.
3.16.2 The MCC room for the fermentation plant, distillation plant and
effluent treatment plant shall be provided with automatic fire
alarm and protection system. The automatic fire detection & alarm
system for MCC rooms shall be designed as per existing
regulations.
3.16.3 Two Nos. of pumps (one working & one standby) shall be envisaged
for fire hydrant system. Main pump shall be electrical motor driven
and standby pump shall be diesel engine driven. In addition to the
above, jockey pump shall also be envisaged to maintain the pressure
in the system. The pump and electric motor shall be mounted on a
common base frame with ‘tyre’ type coupling, coupling guard,
foundation bolts and nuts.
3.16.4 The under ground piping shall be applied with PYPKOTE tar based
polymeric corrosion protection tape of 4 mm thk. for the
protection of external surface of the pipes.
3.17 Product Storage
3.17.1 The distillery products will be stored in the tanks to be located in

the product storage yard. As the storage and distribution will
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come under the control of the Government authorities, there will

be strict control on the quantity of alcohol produced, stored and
distributed. Based on the practice elsewhere the scheme given in
Drawing No. 1-15003-800-0007 is proposed. The produced alcohol
will be received in the daily receiver tanks and after certification
will be transferred to the bulk storage tanks. There will be
receiver and bulk storage for the RS, EN and AA There will be
receiver and bulk storage for the technical alcohol but only a bulk
storage is proposed for the fusel oil. The issue will be from the
bulk storage tanks through certified flow meters to the trucks. If
found necessary, the bulk storage of RS, ENA, and AA could be
interchanged after rinsing with appropriate alcohol.
3.18 DM Water Plant
To cater to the DM water requirements of the distillery and the

power, a water treatment plant (WTP) based on the Reverse
Osmosis (RO) is proposed. The WTP will be provided with a pre-
treatment system, the RO based water treatment system and DM
plant (downstream of Ro) for ensuring the quality of the DM water.
As the source of raw water is bore well, the pre-treatment system
will be just a Multi Grade Filter. The capacity of the water
treatment plant will be 20 Cu.m/hr.
The raw water from the water reservoir will be pumped by the raw
water pumps to the Multigrade Filter. The outlet water from the
MGF will be taken to reverse osmosis skid & DM plant, through the
Micron Cartridge Filters, and then stored in a DM water storage
tank.
The Drawing No.3-15003-800-0011 gives the Process Slow Diagram

for raw water and DM water system.
The treated and de-mineralized water will be stored in a rubber

lined or epoxy coated 1 no. Of 200 Cu.m capacity storage tank.
3.19 Compressed Air System
The requirement of compressed air for instruments and the control

systems of the proposed distillery complex will be supplied by
three (3) instrument air compressors with two (2) working and the
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other standby. Each of the compressor shall be rated for 750

N.Cu.m/ hr at 7 kg/sq.cm (g). All the compressed and service air
requirements of the distillery process plant, spent wash
concentration plant, the effluent treatment and polishing plant and
the power plant will be met by these compressors.
The air compressor shall be provided with accessories like Inter

cooler, After cooler, Moisture separators, Air driers, Air receivers
and control panel.
The service air requirement of the plant, being very low will also be
met by the instrument air compressors. However the service air
will be directly tapped off from the air receiver bypassing the
dryer units.
3.20 Air Conditioning System
The main plant control rooms housing the controls for the
Distillery, concentration plant and the power plant shall be air
conditioned with ductable package air-conditioners, which will be
located in a plant A.C. room, adjacent to the control room. The
condensers will be located above the plant A.C. room and the
conditioned air will be distributed by means of ducting in the
control room. Suitable humidity control devices shall be provided.
A temperature of 22.2C+ 1.1Cand a relative humidity of 55 + 5%
will be maintained in the control rooms.
3.21 Ventilation System
The ventilation requirement for various area in the TG building and

Electrical panel room in TG building, Panel rooms in the
Fermentation section of the can be broadly classified under two
sections:
- Area which need positive pressure to avoid outside air

infiltration, which is to be achieved by continuous fresh
supply.
- Area which need exhaust ventilation and have adjacent

sufficiently large wall to fix exhaust fans.
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The areas which require to maintain the positive pressure are the
Electrical panel room. The temperature inside shall not increase
considerably (not more than 4-5Cunder maximum load conditions)
due to the equipment load inside; further area where infiltration is
to be avoided shall be maintained at slight positive pressure to
ensure the same. Frequency of door opening in these areas can be
considered to be minimum.
The areas which require to maintain the exhaust ventilation system

are the TG hall at various levels and toilets. Exhaust fan of
sufficient size and numbers shall be installed in these areas which
need exhaust by propeller fans. These areas shall have sufficient
air intake opening in the opposite wall where fans are to be fixed.
These opening will enable drawing air from the TG bay.
3.22 Green Belt Development
Green belt development for the project shall be considered with

ecological perspectives taking into consideration the nature of
pollutants, availability of space and dominant wind directions. The
inter-spaces within the plant are to be laid with shrubs/grass bed.
The green belt or tree plantation around the proposed project will
help to arrest the particulate, matter in the area and hence
attenuate the pollution to a great extent. The following
characteristics would be taken into consideration while selecting
plant species for green belt development and tree plantation.
 They should be perennial and evergreen.

 Fast growing and tall trees
 They should have thick canopy cover.
 They should have large leaf area index. They should
not have any noticeable effect on the plant yield due
to gaseous pollutants.
 The planting should be in appropriate alternate rows
around the proposed site to prevent lateral pollution
dispersion.
 The trees should maintain regional ecological balance
and conform to soil and hydrological conditions.
Indigenous species would be preferred.
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4.0 ENVIRONMENTAL IMPACT AND EFFLUENT DISPOSAL
4.1 General
4.1.1 A molasses based distillery is considered as a highly polluting industry

and the environmentalists look at the distillery with a lot of suspicion.
Environmental protection and the control of discharge of the solid,
liquid and gaseous effluents are the key elements in the design of the
distillery. The emissions from the industries are tightly regulated by
Governments and applicable specific rules and requirements
controlling the emissions are constantly changing. At present, the
most significant of these emissions, concerning the distillery are,
spent wash and waste water effluents with high BOD and COD, oxides
of sulphur (SOx), fine airborne particulate, and sludge from
Fermentation.
4.1.2 Environmental control is primarily driven by Government legislation

and the resulting regulations at the local and National levels. These
have evolved out of a public consensus that the real costs of
environmental protection are worth the tangible and intangible
benefits now and in the future.
4.1.3 A molasses based distillery conventionally has three major sections,

which let out pollutants. One is the fermentation section, the second
is the Distillery Section and the third is the power plant section which
generates the steam and power required for the distillery operations.
The emissions discharged from the distillery fall under the three
categories of atmospheric air borne emissions, aqueous emissions and
solid emissions.
4.1.4 Atmospheric air borne emissions arise primarily from the by-products
of the combustion of the fuels in the boiler like SO2, NOx, particulate
fly ash, volatile organic compounds (VOC) and some trace quantities of
other materials and are exhausted from the stack. A second source
of particulate is fugitive dust from fuel handling equipment. A third
source of air emissions is the cooling tower and the associated
thermal rise plume which contains heat and some trace materials along
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with the water vapour. Another pollutant, under today’s context of

reduction of green house gases is the carbon-di-oxide emissions from
the fermentation section of the distillery.
4.1.5 Aqueous discharges from the distillery are the most worrisome of all
the pollutants. Primary of these emissions is the spent wash generated
in the fermentation process and separated in the distillation process.
A second source of aqueous emission is the discharges from the
distillation column bottoms, called spent lees. The third source include
other waste water and these include cooling tower blow down, sluice
water from the bottom ash handling system, boiler chemical cleaning
solutions, CIP waste solutions, as well as a variety of low volume
wastes including ion exchange regeneration solutions from the
Demineralized Water Plants, boiler blowdown, sewerage system
discharges from buildings and plant floor drains.
4.1.6 The solid effluents generated in the distillery are the sludge from the
fermentation section, yeast spent residue and the boiler ash.
4.2 GSML’s Distillery Effluents and Disposal
4.2.1 GSML’s 60 KLPD distillery is designed on the “Zero Effluent

Discharge” concept. The design philosophy being that the effluents
will be used within the distillery or treated and let out as a non-
polluting discharge. The new concept of spent wash concentration
and incineration is adopted in the design which ensures that the
discharge from the distillery is devoid of the dark, acidic high BOD
and COD effluent. Even the streams with lesser pollutants are
properly treated and let out.
4.2.2 The enclosed Drawing No.4-15003-800-0006, titled “Block Diagram

for Effluent Generation and Treatment”, summarizes the various
effluent generation and the proposed treatment in the distillery.
4.2.3 Fermentation Section:
4.2.3.1 The fermentation section is where the molasses is fermented by

yeast to alcohol. As a by product of this fermentation process carbon-
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di-oxide is produced. After the completion of every batch of

fermentation, the fermenters are cleaned and the water used for
cleaning is taken to spent wash lagoon through effluent collection pit.
There will be no wash water generation from the fermentation section
under the normal operation. Whenever any infection occurs, the
fermenters are washed with caustic solution and the washed caustic
solution is taken to the CIP tank for reuse. After a few cycles of re-
use, the pH of the caustic solution comes down and the same is taken
to spent wash lagoon through effluent collection pit. The Caron-di-
oxide generated in the process will be let out to the atmosphere. At a
later date, GSML may add a CO2 bottling plant to capture and sell the
CO2 in the market. However the CO2 emission is only a fraction of the
CO2 sequestered by the sugar cane during its growth. Hence the
emission of CO2 from the distillery will not add any net green house
gases to the atmosphere. In the proposed batch fermentation section
there will be no yeast separation and the wash along with the yeast
will be taken to the distillation section for processing. Similarly there
will be no sludge separated in the proposed batch fermentation
section. Everything from wash goes into the distillation section and is
later taken out as spent wash and concentrated for incineration.
4.2.4 Distillation Section:
4.2.4.1 The distillation section is where the alcohol is separated from the
fermented wash. The fermentation in addition to ethanol, also
produces, depending on the fermentation process and impurities,
higher alcohols and other organic compounds. These organic
compounds and higher alcohols are separated out in the distillation
section along with traces of ethanol and sold off as Technical spirit
and Fusel oil. The two major aqueous effluents from the distillation
section are the spent wash and the spent lees. Spent wash is the
fermented wash devoid of the alcohol.
4.2.4.2 In some cases, where the spent wash recycling is employed, some
percentage of the spent wash generated in the process will be
recirculated to the fermentation section for the dilution of the
molasses. This recirculation depends on the quality of the molasses
and hence could be decided only at the time of plant operation. Hence
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the distillery is designed with no recirculation of spent wash to the

fermentation section and the entire quantity of about 600 MT of
spent wash generated with the solid concentration of 14% will be
available for disposal. It is proposed to concentrate the spent wash to
60% w/w solids in the evaporation plant and then incinerate the same
in the specially designed boiler. Firing some supplementary fuel like
bagasse with concentrated spent wash, this boiler will meet with the
entire steam and power requirements of the distillery. The spent wash
concentration and incineration system proposed for this project is
dealt with in greater detail in the Section-5 of this report.
4.2.4.3 The spent lees are the bottoms collected from the various
distillation columns and this is essentially water with small traces of
alcohol and other organic compounds. All these spent lees streams will
be collected from the distillery for disposal. The Molecular Sieve De-
Hydration (MSDH) system for the dehydration of the industrial
alcohol to produce Anhydrous Alcohol will also generate some spent
lees and this also will be treated with the spent lees generated in the
distillation section. It is estimated that the total spent lees to be
treated will be about 2.25 Cu.m/hour.
4.2.4.4 The multiple effect evaporator system used for the concentration
of the spent wash generates a lot of condensate which will be
contaminated with organic elements. In the independent evaporator
systems proposed for the concentration of the spent wash, it is
expected that there will be a generation of 480 Cu.m/day of
condensate with organic loading. As this will be polluting in nature this
cannot be discharged out and hence is to be treated internally. The
multiple effect evaporator system of the spent wash is susceptible
for scaling and CIP using caustic will be made depending on the scaling.
The caustic solution after a few cycles of usage will be taken to spent
wash lagoon through effluent collection pit.
4.2.4.5 Two streams of liquid discharges from the distillery, with the spent
wash evaporation system are the evaporator condensate and the spent
lees from the distillation section. These two streams are proposed to
be treated in a system with the combination of UASB, extended
aeration system, membrane bio reactor (MBR) and Reverse osmosis
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(RO) system and is designed for removal of organic acids, COD and
BOD. The condensate treated by such system can be reused in the
alcohol manufacturing process as process water or cooling water
make-up thereby reducing the requirement of fresh water as well as
solving the problem of waste disposal to a great extent.
The proposed treatment methodology is based on following principle

operating systems:
1. Up flow Anaerobic Sludge Blanket Reactor

2. Extended Aeration
3. Membrane bio reactor (MBR)
4. Reverse Osmosis (RO)
Up flow Anaerobic Sludge Blanket (UASB) reactor is provided for the

primary anaerobic treatment of Condensate & Spent lees effluent.
The UASB reactor shall be constructed in MS with suitable epoxy
coating inside the tank. The reactor consists of three zones viz.
Influent distribution zone, Reaction zone, Gas solid liquid separation
zone. The liquid to be treated enters into the bottom through influent
distribution zone and uniformly distributed in the tank. In the
reaction zone the anaerobic bacteria are maintained in the form of
sludge blanket. When the upward rising waste water penetrates
through the sludge blanket, the organic matter in the waste water
comes in contact with the bacterial population and is degraded
anaerobically to methane rich biogas, the end product of anaerobic
digestion. The biogas so produced is bubbled through the effluent and
is separated out in the third section i.e. Gas-Solid-Liquid separation
zone. The suspended solids, rich in bio-mass, are also separated to
prevent escape of solids from the reactor. In gas solid liquid
separation a hood fabricated in Mild Steel and duly painted with
corrosion resistant paint is provided. The hood separates the solid
from the overflowing reactor content. Gas collectors are provided for
collection and conveyance of gas. The treated effluent overflows
through a launder and will be taken to a secondary treatment system.
4.2.4.6 The secondary treatment consists of extended aeration, membrane

bio reactor (MBR) and Reverse osmosis (RO) system. The permeate of
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the RO system, will be collected in a tank and used as the process

water or make up water for the process cooling towers. The sludge
generated from UASB, extended aeration and MBR system will be
collected in the sludge pit and taken to decantation system for
separation of solids and the separated solids will be disposed off
suitably. The filtrate from the decantation system will be recycled to
equalisation tank/clarifier. The drawing No. 3-15003-800-0005 gives
the process flow diagram for the above described effluent treatment
plant.
4.2.5 Boiler Section:
The proposed boiler for the distillery will be firing the concentrated
spent wash and bagasse. The entire concentrated spent wash quantity
of about 175 TPD generated will be consumed in the boiler. However,
for the expected steam generation of 20 TPH from the boiler, the
spent wash quantity alone is not sufficient and hence the spent wash
needs to be supplemented with an auxiliary fuel which in this case will
be bagasse.
4.2.5.1 The air borne pollutants that are discharged from the proposed
boiler unit are,
- Dust particulate from fly ash in flue gas

- Sulfur-di-Oxide in the flue gas.
4.2.5.2 Bag (Fabric) Filters are proposed as the gas cleaning equipment for
the boiler, to contain the dust emissions from plant to a level of 50
Mg/Ncum under all the fuel firing conditions. While firing 8.7 TPH of
spentwash and 5 TPH of bagasse, the ash quantity generated will be
equal to 37 TPD and out of that 80% will be go out of the boiler
furnace as fly ash. Balance of 20% will be discharged as grate ash.
The grate ash will fall on the water impounded belt conveyor and will
be discharged into a trailer for disposal. Some amount of this fly ash
will be captured in the hoppers of the horizontal pass of the boiler
and the balance will be captured in the fabric filter. A suitably
designed dense phase ash handling system will be provided for the
collection and transportation of the fly ash to the fly ash silo. The
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ash collected from the boiler is very rich in potash and hence will be a
good fertilizer. Out of 1.2 TPH of ash in the 37 TPD of spent wash
fired+Baggase, 0.55 TPH will be potassium Oxide. Both the grate
bottom ash and the fly ash could be disposed off as fertilizer to the
farmers. Depending on the demand, at a later date, the ash could be
bagged and marketed. The height of the stack for the 20 TPH
boiler, which disburses the pollutants, has been fixed at 55 meters,
based on the sulphur-di-oxide emissions from the chimney.
4.2.6 Cooling Tower Blow Down water
The Distillery will be designed with a few cooling towers for meeting
specific requirements. The fermentation section, Distillation Section,
MSDH section, the spent wash evaporation and the Cogeneration plant
will have individual cooling towers. The blow down water will be let
into the neutralizing pit of the DM plant and will be pumped after
neutralization for gardening.
4.2.7 Steam generator blow down
The salient characteristics of blow down water from the point of view
of pollution are, the pH and temperature of water since suspended
solids are negligible. The pH would be in the range of 9.8 to 10.3 and
the temperature of blow down water will be 100 Deg.C The quantity
of blow down is only about 2% of the boiler capacity (0.4 TPH) and it
is proposed to put the blow down into the DM plant neutralizing pit,
after running it through the open drains, for disposal.
4.2.8 Sewage from various buildings in the plant
Sewage from various buildings in the power plant area will be conveyed
through separate drains to the septic tank. The effluent from the
septic tank will be disposed in soil by providing disposing trenches.
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There will be no ground pollution because of leaching due to this.

Sludge will be removed occasionally and disposed-off as land fill at
suitable places.
4.3 Thermal Pollution
A close circuit cooling water system with cooling towers has been
proposed for various applications in the Distillery. This eliminates
letting out of warm water into the canals and prevents thermal
pollution. Blow down from the cooling tower will be trenched out to the
existing DM plant neutralizing pit and disposed off the sugar mill
effluent treatment plant. The water evaporated form the cooling
tower will be discharged through the fan stack as water vapour. As
this vapour quantity is small and also it is let out at a higher
temperature there will be no thermal pollution on account of this.
4.4 Noise Pollution
The rotating equipment in the Distillery and the Cogeneration plant

will be designed to operate with a total noise level of not exceeding 85
to 90 db(A) as per the requirement of Occupational Safety and
Health Administration (OSHA) Standards. The rotating equipment is
provided with silencers wherever required to meet the noise pollution.
The frequently blowing safety valves will also be provided with
silencers to meet with the norms for the noise levels.
4.5 Monitoring of Effluents
The characteristics of the effluents from the proposed distillery

plant will be maintained so as to meet the requirements of Pollution
Control authorities and the minimum national standards for effluent
from Distillery. Air quality monitoring will also be undertaken to
ensure that the dust pollution level is within limits.
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4.5.1 Monitoring Programme
The purpose of air quality monitoring is the acquisition of data for

comparison against the prescribed minimum standards and thereby,
assures that the air quality is maintained within the prescribed levels.
The following will be monitored from the stack emissions.
 Suspended Particulate Matter.

 Sulfur-Di-Oxide.
The Laboratory attached to the Power plant will be equipped with the
necessary instruments for carrying out air quality monitoring. It is
also proposed to monitor the particulate emission at the stack to keep
a continuous check on the performance of the bag filter. Adequate
sampling openings will be provided in the stack.
Also the aqueous samples will be collected and tested periodically in

the laboratory, to ensure that there is no pollutant discharged outside
the plant.
4.6 Impact of the Pollution on the Environment
The GSML’s distillery is designed such that there will be no pollutant

discharged from the distillery. As discussed above all the pollutants
normally expected out of the distillery will be adequately treated and
used internally within the distillery. Only the aqueous discharges
from the DM plant, cooling tower blowdown and the boiler blowdown
which are neutralized are discharged out for gardening and dust
suppression. Any way these are not pollutants and they are let out only
after neutralization. The only solid waste will be the ash which has
enormous value as a fertilizer and hence cannot be treated as an
effluent. On the whole the Distillery at GSML will not affect the
environment and ecology of the surroundings.
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5.0 SPENT WASH CONCENTRATION AND INCINERATION

SYSTEM
5.1 General
5.1.1 The fermentation of the sugar in the molasses results in the

production of a large quantity of wastewater containing all the
inorganic substances, other than the fermentable sugars, that were
contained in the molasses. This waste water also contains some organic
compounds not fermented. This wastewater separated in the
analyser/stripper column of the distillation process is called the
Spent Wash. This is also called as slop or vinasse. The fermented
molasses leaving the fermenter, for distillation, is called the wash and
the wash after all the alcohol is stripped off is called the spent wash.
Spent Wash is a dark brown acidic liquid with the pH of 3.5 to 4.5 and
with a high BOD and COD content of 55,000 and 130,000 respectively.
Spent Wash derives its darker colour from the caramels developed
during the sugar production and contains chlorides, sulphates and
calcium salts apart from other dissolved solids and minerals. The
expected solids concentration in the Spent Wash from the distillation
process of the fermented molasses for this project will be 14% w/w.
The expected quantity of raw Spent Wash produced with the design
molasses will be approximately 11 to 12 Litres per Litre of Total spirit
produced.
Any favourable F/N (Fermentable solids to Non Fermentable solids

ratio) in the design molasses gives the advantage of recycling some of
the spent wash to the fermentation vessels, which reduces the
addition of the dilution water to the molasses. This reduces the actual
Spent Wash quantity to be disposed off, but however for this project
it is proposed that no spent wash will be recirculated for molasses
dilution.
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With the concentration and incineration technology proposed, the
Spent Wash hitherto considered as the worst of the pollutants,
with a dark brown colour with acidic characteristics and high BOD
and COD, will be looked upon as a fuel that could meet a
substantial part of the steam and power requirements of the
distillery. Other than the ash generated, there will be no
pollutant left, but even the ash with its high potash content will
be sought after as a good fertilizer.
5.2 Spent Wash Characteristics and Disposal
5.2.1 Spent Wash derives its characteristics from the molasses, used for
fermentation. The molasses is expected to be with 36.8% fermentable
sugars, with a total solids content of about 90 % w/w and with the
total in-organics at 11 w/w. The raw Spent Wash is expected to be
with the total solids of about 14% w/w with the above molasses, as
the feed stock. The high BOD and COD content in the Spent Wash
along with the dark brown colour makes the liquid to be feared as one
of the worst pollutants and the disposal becomes a major problem in
the distilleries. Discharging of the Spent Wash into rivers and lakes
results in eutrophication of the water bodies and results in the
elimination of the aquatic lives. The Spent Wash produced contains
residual sugar in the form of glucose and ploysaccahrides and alcohol.
These organic matters start putrefying if the spent wash is left in
the open. In addition the presence of sulphur reducing bacteria
results in the generation of hydrogen sulphide gas and the foul
smelling gases released in the process affects the environment.
5.2.2 To ensure a sustainable development it is imperative that the Spent

Wash generated in the distillery is disposed off in an appropriate
manner. Based on what had been done so far, the world over, the
following are the disposal methods available and out of these the
incineration method appears to be the most effective of disposal of
this effluent.
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a. Fertirrigation
b. Composting as Fertilizer
c. Anaerobic Digestion to produce Bio-gas and subsequent

composting.
d. Spent Wash concentration and Incineration
Fertirrigation is not an option for this project as this method of

disposal is prohibited. GSML’s Distillery project is being designed to
consume part of the in house molasses generated in the sugar mill.
There will always be a large mismatch between the press mud quantity
available and the spent wash to be consumed. Because of this
mismatch the composting option cannot be used here. Even bio-
methanation is not a viable option as the effluent from the anaerobic
reactor cannot be disposed off through the composting route and a
lot of filter mud is required for this purpose. Bio-methanation could
be considered as an option if it is decided to go with the
concentration and incineration of the effluent discharged from the
anaerobic reactor. Going through Bio-methanation and then
incineration is neither technically superior nor economically attractive
compared to raw Spent Wash concentration and incineration and
hence for the GSML project the option of raw Spent Wash
concentration and incineration is proposed. Apart from the above
discussions on the suitability of the various methods of disposal, due
to Government of India’s Clean Ganga Mission, the pollution control
authorities are very particular about the use of concentration and
incineration as the only method of disposal of the spent wash from
the distilleries.
5.3 Concentrated Spent Wash and its Analysis
5.3.1 The raw Spent Wash as extracted from the analyser/stripper column
of the distillery with the solids concentration of 14% w/w will
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approximately have combustible content of around 6.5 to 7% carbon
and about 0.6% hydrogen. The estimated gross calorific value of the
raw spent wash is hardly 500 kclas/kg. With the water content of
almost 85% and with this low gross calorific value there is no
possibility of any sustained combustion. However, when the Spent
Wash is concentrated to a solids content of 60% w/w, the carbon and
hydrogen percentages in the Spent Wash increase to 22.93% and
2.21% respectively. With these combustible products the gross
calorific value of 60% w/w solids Spent Wash increases to around
1705 kCal/kG, which can support combustion. The following gives the
ultimate analysis of the Spent Wash concentred to a solid content of
60% w/w.
Constituent % by Weight
Carbon : 22.93%
Hydrogen : 2.21%
Oxygen : 15.22%
Nitrogen : 1.91%
Sulphur : 0.63%
Moisture : 40%
Mineral Matter : 17.11%
Gross Calorific Value : 1705 kCals/kG
One of the serious problems in firing the Spent Wash is the high
fouling and corrosive tendency of the fuel ash due to the presence of
alkalies like Potassium and the presence of Sulphates and Chlorides.
These form complex compounds on the high temperature components
of the boiler like the superheater and results in corrosion. Unless
adequate precaution is taken in the design of the boiler, the boiler
could face serious fouling and corrosion, resulting in the failure of the
superheater within a few months of operation. The following gives the
analysis of the ash in the Spent Wash. It may be seen that the extent
of potassium is 47% in the mineral matter in Spent Wash. The
presence of Sulphates to the extent of 20% and Chlorides to the
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extent of 6% is the main reasons for the corrosive tendency of the
ash. In addition the presence of calcium and sulphates could cause
hard scales on the heat exchanger areas in the evaporator system
used for the concentration of the Spent Wash.
Ash Analysis
Constituent % by Weight
Silica as SiO2 : Nil

Iron Oxide as FeO3 : 2%
Calcium Oxide as CaO : 14.0%
Magnesium Oxide as MgO : 6.5%
Sulphate as SO3 : 20.0%
Phosphate as P2O5 : 10.0%
Potassium Oxide as K2O : 47.0%
Sodium Oxide as Na2O : 0.5%
Chlorides : 6.0%
5.4 Proposed Scheme of Spent Wash Concentration and Incineration
GSML’s multi product distillery will be based on the batch

fermentation of in-house and bought out molasses with Saccharomyces
Cerevisiae yeast. Based on the molasses quality specifically from the
point of view of the ratio of the Fermentable solids to the Non
fermentable solids, it is possible that the fermentation process could
allow recycling of the Spent Wash from the distillation section.
Recycling the Spent Wash to fermentation increases the non
fermentable solids in the fermenter and the limit of the quantity of
spent wash recirculated is decided from the ability of the yeast to
withstand the higher osmatic pressure. The estimated quantity of
Spent Wash produced in distillation is about 600 MT per day. It is
proposed that there will be no recirculation of the spent wash in the
system and all the spent wash generated will be sent for concentration
prior to incineration.
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This quantity of 600 TPD will be with the solids concentration of

14% w/w and this will be concentrated to a solids concentration of
60% w/w. This concentration is proposed to be done in a single
stage multiple effect evaporation plant using low pressure steam as
the heating medium. The above quantity of Spent Wash will be
concentrated to a quantity of 175 TPD with the solids concentration
of 60% w/w and this concentrated Spent Wash will be fired in a
specially designed boiler along with bagasse to generate all the steam
required for the distillery process and Spent Wash concentration.
Thus all the Spent Wash produced in the distillery will be incinerated
to generate part of the process steam required by the process. The
details of concentration system and the incineration boiler proposed
for this project are furnished in the subsequent sections.
5.5 Spent Wash Concentration System
5.5.1 The high organic loading makes the Spent Wash a possible fuel for
firing in the boiler. However the gross calorific value of the raw
Spent Wash as produced in the distillery is not adequate to sustain
combustion and hence the Spent Wash need to be concentrated to
give an acceptable gross calorific value. It has been found that the
Spent Wash concentrated to 60% w/w solids will have a GCV of
around 1705 kCals/kG is capable of sustained combustion in a boiler.
It is proposed to concentrate the Spent Wash in a multiple effect
evaporation system, which will optimize on the heat energy
requirements for the concentration.
The inorganic loading in the Spent Wash is also quite high and one of
the major problems faced in the concentration of the Spent Wash is
the rapid scales formed on the heat transfer tubes of the
evaporators. Here again the scaling tendency of the Spent Wash
depends on the quality and the inorganic salt content in molasses. The
higher quantity of calcium used in the sugar making process leaves a
lot of calcium in the molasses and that gets carried to the Spent
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Wash. Some of the calcium salts precipitate inside the tubes during
the evaporation process and leaves a hard scale in the tubes. In case
the scales are very hard and are difficult to remove with CIP, it may
be necessary to resort to mechanical cleaning of the tubes. In order
to limit the scale formation, the evaporation temperatures are kept
low as some of the calcium salts like calcium sulphates have lower
solubility at higher temperatures and hence tend to precipitate.
Another important point in evaporation is to go in for forced
circulation and flash evaporation in order limit the chances of scaling
inside the heat transfer tubes.
5.5.2 As seen elsewhere in this report, the raw Spent Wash generation,
without Spent Wash recirculation for fermentation, is 600 TPD. The
solids concentration in the raw Spent Wash is expected to be 14%
w/w. When concentrated to 60% w/w, the quantity of Spent Wash
that will be available comes down to 175 TPD. This concentration
involves the evaporation of almost 480 MT of water per day (22.92
MT of water per hour) in the concentration plant. The energy
generally available for concentration will be in the form of heat and
steam will be medium that supplies this heat energy. Indirect heating
of the Spent Wash to evaporate this quantity of water in a single
effect evaporator will call for the supply of around 20 TPH of steam
at low pressure of around 2.5 ata. In order to effect economy on the
steam consumption, the concentration is proposed to be done in a
multiple effect evaporation system.
5.5.3 The evaporation system will be an independent evaporation system for

the final concentration of the Spent Wash to 60 % and to achieve this
concentration saturated steam at a pressure of 2.5 bar(a), will be
used.
5.5.4 The drawing No. 1-15003-800-0004 titled “Process Flow Diagram for
Spent Wash Evaporation System” gives the scheme of the Spent
Wash evaporation system. The raw Spent Wash with the
concentration of 14% w/w from the analyser/stripper column bottom
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will be used to heat the incoming fermented wash coming to the
analyser column. The Spent Wash from the outlet of the wash pre-
heater will be sent to the raw spent wash storage lagoons to ensure
the settlement of part of the sludge. The partly decanted spent
wash, with the solids concentration of 14% w/w, will be pumped to the
evaporator station.
5.5.5 The independent evaporator system consists of five / six evaporator

bodies with the first few effects being falling film evaporator bodies
followed by forced circulation evaporator bodies. The driving force in
the independent evaporator is provided by the heat energy in the low
pressure steam supplied to the first effect. The falling film
evaporator will be designed with a vapour separators. The
recirculation pumps provided with the falling film bodies ensure that
the wetting rates inside the falling film body tubes are maintained at
the required levels. The Spent Wash will be heated in a plate type
heat exchanger before admission into the falling film evaporator. The
spent wash could be fed through a mixed flow arrangement which
judiciously optimizes on the heat energy input to the system.
The forced circulation evaporators use high fluid velocities through

the tubes and it is ensured that there will be no evaporation within
the heat transfer tubes. The Spent Wash circulated through the
tubes, with the slight increase in the temperature is flashed in the
flash vessel attached to each of the evaporators. The high circulation
of the Spent Wash is effected by the recirculation pumps taking
suction from the bottom of the flash vessels. The condensate in the
evaporator bodies is cascaded to use the flash steam effectively. The
vapours from the last effect are condensed in the surface condenser.
The non-condensable gases along with some vapours from the surface
condenser are again condensed in a vent condenser. Both the
condenser and the vent condenser are supplied with adequate quantity
of cooling water. The condenser and the vent condenser operate under
vacuum created by the mechanical vacuum pumps. The condensate
from the system is finally pumped by the condensate pumps from the
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condenser to the effluent treatment plant. The final draw off of the
60% w/w solids concentrated Spent Wash is made from the delivery
side of the recirculation pumps of the last effect. In order to limit
the head requirements of the recirculation pumps of the final effect
a separate booster pump is used to pump the Spent Wash to the
product storage in the boiler area.
5.5.6 For the GSML’s project, the Spent Wash leaving the independent
evaporator system will have a solids concentration of 60% w/w and
the quantity of the concentrated Spent Wash leaving the evaporation
plant will be approximately 175 TPD. Steam will be supplied to
independent evaporator system at the first body of the falling film
evaporator calendria and the quantity of steam thus to be supplied is
estimated to be 6.0 TPH at a pressure of 2.5 ata at the calendria. The
vapour generated in the various bodies is judiciously used in the next
bodies of the evaporator system, except for the vapour from the last
body is sent to the condenser.
5.5.7 The Spent Wash concentrated to 60% w/w solids will be stored in a
stainless steel tank of 100 Cu.m capacity. The Spent Wash feed
pumps will pump the concentrated Spent Wash to the spray guns in
the boiler for combustion.
5.6 Spent Wash Incineration and Steam and Power Generation
It is proposed to dispose of the concentrated Spent Wash by

incinerating the same in a boiler along with imported coal or bagasse.
The steam generated in the boiler will meet with the steam
requirements of the distillery and the evaporation plant. As the steam
required by the distillation process and the evaporation plant is at a
lower pressure of 2.5 bar(a), the potential for possible Cogeneration
is exploited and electrical power for meeting with the distillery and
the evaporation plant will also be generated using the steam generated
in the boiler. Thus an effluent, hitherto regarded as a highly polluting,
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has been converted to a fuel for meeting the energy requirements, at
least partly, of the distillery complex.
Section 5.3 above gives the analysis of the concentrated Spent Wash.
With 60% concentration, the gross calorific value of the 60% w/w
concentrated Spent Wash will be 1705 kCals/kg and this GCV is
adequate for sustaining the combustion of the Spent Wash. However
as the concentration could vary, depending on the distillery plant and
the evaporation plant performance, the GCV also could vary and this
could affect the combustion of the Spent Wash. In order to ward off
such difficulties, it is always recommended that the Spent Wash is
fired with a supporting fuel.
The concentrated Spent Wash has about 17% mineral matter and the
composition of the mineral matter is also furnished under Section 5.3.
Because of the presence of high alkalies (potassium and sodium) the
Spent Wash ash will exhibit a higher fouling tendency and there could
be problems of ash build up in the superheaters of the boiler. With
the presence of sulphates and chlorides the ash will also cause serious
corrosion problems in the superheaters and it is essential that the
steam and gas temperatures at the superheater are limited to ensure
that there is no corrosion of the superheater tubes. Based on the
extensive analysis made on such fuels, it is recommended to go with
the final steam temperature of 400 +5, -0 Deg.C from the boiler and
ensure that the gas temperature entering the superheater section is
limited to a value lower than 550 Deg.C..
The presence of sulphur compounds and chlorates could also cause

serious low temperature corrosion in the economizer and the air
heater. To eliminate such low temperature corrosion in the
economizer, we need to increase the feed water temperature entering
the economizer to a value higher than the dew point temperature. As
air heater will be susceptible to corrosion it is proposed to eliminate
the air heater altogether and go with a steam heated air heater to
increase the under grate air temperature suitable for high moisture
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fuel firing. Alternatively an air heater could be provided, if the air is
heated in a steam air-preheater to a temperature of 130 Deg.C at the
inlet of the air heater. The final choice between the use or
elimination of the air heater could be decided at the time of detailed
engineering of the boiler, depending on the confidence level and
experience of the boiler contractor.
The ash generated from the combustion of the Spent Wash will be
fine and a suitable ash collection arrangement shall be provided to
limit the particulate emission from the plant to less than 50
mg/N.Cu.m of gas leaving the chimney. Considering the fineness of
the ash and the high ash resistivity, it is proposed to employ a fabric
filter as the dust collection equipment for the boiler. The ash
generation by the combustion of the bagasse will be a small quantity
and the proposed fabric filter is well suited for the collection of the
bagasse ash. With the presence of almost 47% potassium Oxide in
the ash, the ash makes a very good fertilizer. At a later date it may
even be worth putting up a bagging plant to bag the ash generated in
the boiler and sell the same as fertilizer for field applications.
5.6.1 Spent Wash fired Boiler
The proposed boiler shall be of the travelling grate type and most of
the bagasse and part of the dried spent wash will burn on the grate.
The concentrated Spent Wash will be sprayed inside the furnace at a
height of about 8 to 10 meters above the travelling grate to ensure
that the Spent Wash particles are flash dried in the furnace
environment and a substantial part of the spent wash particles burn in
suspension. Depending on the boiler design and if required, a
refractory lining will be provided at the location of the Spent Wash
spraying point such that the temperature of the furnace in the
location is high and the Spent Wash particles get heated up and get
incinerated within a short period, from the time the particles leave
the spray guns. The boiler will be a balanced draft design with
adequate Effective Projected Radiant Surface (EPRS) to cool the
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gases to the required level before the gases enter the superheater
region.
The Drawing No. 1-15003-800-0008 titled “General Arrangement of

Boiler (Elevation)” enclosed to this report gives the side elevation view
of a typical boiler. This drawing indicates the arrangement of the
pressure parts and all the major equipment of the boiler.
The proposed boiler will be of 20 TPH MCR capacity with the steam
outlet parameters of 45 ata and 400 Deg.C at the superheater outlet.
The following are the basic technical requirements for the steam
generator:
- The steam generator, all associated piping and systems shall be

designed, manufactured, inspected, tested, erected and
commissioned to well established engineering practices and
safety codes.
- Basically the boiler shall be a radiant furnace, single drum,

natural circulation, outdoor type with two stage superheater.
The boiler shall be designed with water cooled membrane / fin
welded walls. The refractory work as required for the efficient
combustion of the fuel shall be provided and the design and
application shall be with adequate reinforcement to ensure that
premature spalling of the refractory work is eliminated. The
material of the refractory shall be suitable for the application.
- The boilers shall be top supported with adequate provisions for

the thermal expansion of the boiler in all directions. The
supports and thermal expansion guides (could be common for
wind and seismic load transfers) shall be suitably located so as
to direct the thermal expansion in the pre-determined
directions.
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- The complete pressure parts tubing, piping and headers shall be
of seamless construction, as per reputed international material
specifications and bought from renowned Suppliers. The
Circulating system essentially comprising of the drums, water
walls, furnace tubes, evaporator banks, down comers and relief
tubes shall be designed to provide an adequate circulation ratio
in the system and to prevent DNB. The downcomers and the
relief tubes shall be sized and routed to offer minimum
pressure drop and to help in improving the circulation ratio.
- The steam drum shall be provided with internals of proven

design, shall be bolted type, and of size that will enable removal
through the manways. The system of internals consisting of the
primary and secondary separators shall ensure steam of highest
purity with dissolved silica carry over limited to a maximum of
0.02 ppm, at all loads of the boiler. All the components of the
internals, except the dryer screens, shall be carbon steel and
the dryer shall be of 304 stainless steel.
- The Furnace envelope shall be constructed of fully water cooled

membrane / fin welded walls and adequately supported. The
design shall be such as to prevent distortion of steel work due
to thermal expansion. The construction shall be fully gas
pressure tight, and the furnace shall be strengthened by
providing buckstays and tie-bar system. The buckstay system
shall be adequately designed to stiffen the furnace walls
against the internal and external pressures and also to transfer
the wind and seismic loading from the boiler envelope to the
boiler structures through suitably designed guides. The
minimum design pressure for the buckstay system shall be +
400 mm WC, with the buckstay members reaching 60% of the
yield strength.
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- The furnace EPRS should be so selected to give acceptable
furnace outlet temperatures, not exceeding 600 Deg.C, while
firing Spent Wash or Spent Wash with other fuels.
- The superheater (SH) system shall be of Two (2) stage

design with inter stage desuperheating to achieve the rated
steam temperature over 60 to 100% load range. The
superheater shall be of convection type arranged to give a
minimum metal temperature. The superheater pressure drop,
the inlet and outlet header sizing, arrangement and sizing of
their respective inlet and take off connections shall be so as to
give minimum unbalance and the tube element material selection
shall be based on the actual metal temperature calculations.
- The inter stage attemperator system of the variable orifice

type to control the temperature of the final superheater outlet
steam temperature within the specified value shall be provided
in between the two stages of the superheater.
- The Economiser shall be located downstream of the convection

heat transfer section. The design shall be of bare tube
construction with inline, counter flow, and drainable
arrangement. The economiser shall be designed for an inlet
feed water temperature of 150 Deg.C. The economiser shall be
arranged such that there is space for the future addition of
about 10% of the installed heating surface area without
disturbing the existing economiser coils and headers. The coil
arrangement shall take care of proper calculated end gaps to
avert gas bypassing and the consequent erosion of the element
tubes. No gas side or waterside bypass arrangement shall be
provided. The number of parallel paths shall be so chosen to
give a water side velocity of a minimum of 0.6 meter per
Sec.
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- The flue gas velocity over the economiser tubes shall be limited
to a maximum of 10 metres/sec. Suitable number of soot
blowers shall be located in the economiser for effective
cleaning of the heat transfer areas.
- A steam coil air heater to heat the combustion air to the

required level shall be added in the air outlet ducting upstream
of the air-heater. If the design does not incorporate the air
heater, the steam air pre heater shall be designed to give an air
temperature required for the combustion. This steam coil
heater will be operated continuously to prevent the corrosion of
the main air heater. Sufficient straight length shall be provided
in the air duct for installing Steam coil air pre heater at the
airheater air inlet side. The condensate from the steam coil
heaters will be taken to the deaerator.
- The steam coil airheater shall be of finned tube construction

with the steam on the tube side and air flowing over the tubes.
The tubes shall be of carbon steel material with carbon steel
fins/aluminium LL fins. In case of carbon steel tubes with
carbon steel fins the tube and fins shall be hot dip galvanized
to eliminate the possibility of corrosion of the tube/fins. In
case of LL fin construction the LL fins shall have sufficient
overlap to cover the tubes completely and thus prevent any
corrosion of the tubes. The tubes shall be expanded and
welded to tubes sheets on either side. Semi circular headers
with end covers will be welded to the tube sheets to form the
inlet and outlet headers. The headers will be provided with
nozzles for supplying steam and draining the condensate. The
finned tube bundle shall be covered with casing and end flanges
shall be provided for connecting to the ducting.
- The boiler shall be provided with a complete system of soot

blowers and wall blowers, to effectively dislodge deposits from
the heat transfer areas. The soot blowers could be of type
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using steam as the blowing medium. The blowers shall be
provided with sealing and purge air to prevent the gases
entering the idle lance tubes and causing corrosion damage.
- The fuel firing system for the boiler shall be of the travelling
grate type. The boiler is to be designed for firing the
individual fuels and fuel combinations as specified earlier. The
layout of the fuel feeding systems shall be such that each
system is easily approachable and maintainable. All nozzles,
feeders and distributors shall have independent drive
arrangement. The distillery slop at an average of 60% solids
concentration will be made available for firing in the boiler. The
spent wash will be pumped by the feed pumps to the spray gun
located in the furnace through a suitable flow meter. The flow
to the spray guns shall be manually adjusted and the excess
spent wash pumped to the nozzles shall be returned through
the return line to the storage tank.
- For the Bagasse feeding suitable silos, extraction feeders and

screw conveyors and distributors shall be furnished. There
shall be a minimum storage of the fuel in the bunkers/silos and
the fuel shall be fed through appropriately designed feeders
and distributors.
- The draft system for the boiler shall be suitable of producing a

balanced draft with sub-atmospheric pressure conditions in the
furnace. There shall be, One x 100% capacity Induced Draft
Fans, One x 100% capacity Forced Draft Fans and One x 100%
capacity Secondary Air Fans making up the complete draft
system for the boiler.
- All The fans shall be suitable for outdoor installation. The fan
impellers shall be dynamically balanced at the fan
manufacturer's works. The first critical speed of the fans shall
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be at least 30% above the normal running speed of the
respective fans.
- The fans shall be basically sized using the following margins

over the calculated values of the flow volume and the pressure
using the maximum continuous rating condition with bagasse.
- Required Fan Margins:
Fan Margin on Margin on

Volume Pressure
Secondary air fan 10 % 15 %
Forced draft fan 15 % 20 %
Induced draft fan 25 % 30 %
- All ducts shall be rectangular in cross section and will be of

welded construction, properly stiffened and reinforced. All the
air ducts shall be fabricated from steel plates of minimum 5 mm
thick, and all flue ducts shall be of minimum 6 mm thick. The
duct plate material shall conform to ASTM A 53 or equivalent.
Carbon steel plates shall not be used for ducting system if the
operating temperature of flue gas exceeds 427C. The duct
corners shall be stitch welded internally and full welded on the
outside.
- All ducts, exceeding 600 mm width or depth, shall be suitably

stiffened and reinforced on the outside and designed to
withstand the pressures encountered, but however the minimum
design pressure for the ducts shall be + 400 mm wc. The
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stiffening shall be with Indian standard section conforming to
the applicable Bureau of Indian standards.
- The ducting expansion joints are provided to take care of the

duct expansions and all expansion joints in the flue gas and
air ducting shall be of stainless steel (SS 304). The
thickness of the sheets used for the fabrication of the
expansion bellows shall be 1.6 mm. The ducts shall be
supported adequately, either from the ground or from the
boiler structural steel works depending on the location of the
ducting support. The ducting system, consisting of the ducts,
dampers and expansion joints shall be analysed as a single unit
and the locations of the expansion joints, supports and
restraints shall be finalized based on the ducting flexibility
analysis calculations.
- One (1) Deaerator of deaerating capacity equal to Twenty

percent (20 %) higher than the gross MCR steam generation
capacity of the boiler with a deaerated water storage tank of
net useful capacity (normal water level to Low water level)
equivalent to twenty minutes (20 minutes) of MCR generation
capacity of the boiler shall be provided. The deaerator shall
be mounted on the structure in front of the boiler. The
material of the deaerator, deaerated water storage tank shall
be SA 515 Gr.70 or equivalent. The Deaerator and the
Deaerated water storage tanks shall be designed with a
minimum corrosion allowance of 3 mm.
- The deaerator shall be of either spray-cum-tray type or spray

type with counter current flow of steam and water. The
material of trays shall be stainless steel, conforming to a
minimum of AISI 316. The deaerator and the storage tank
shall be complete with all the fittings and mountings like vents,
controlled vent, drains, gauge glasses, pressure indicators,
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relief valve, steam and water inlet and outlet nozzles, overflow
nozzle etc.
- Two (2) Nos. Of 100 % capacity boiler feed water pumps with
LT motor suitable for the application shall be provided to supply
feed water to the boiler.
- The design margin for the calculation of the rated pump

capacity shall be 10 % of the feed water requirements (inclusive
of the boiler blow down of 3%) for the peak load operation of
the boiler.
- The design margin for the calculation of the rated head of the
pumps shall be 5% of its maximum discharge pressure require-
ments, to be calculated, as given below.
- The boiler integral piping consists of all the interconnecting

piping between the economiser inlet stop valve and the main
steam stop valve on the superheater outlet piping. The number
off, size and the arrangement of these integral piping shall be
based on the permissible pressure drops in these pipes and the
distribution required in the respective headers of the various
sections of the boiler. These piping shall be properly supported
and provided with the required tapping, stubs and thermowells
for measurements.
- Air pollution control system comprising of One No. Bag (Fabric)

Filter with all its accessories shall be provided. The Bag Filter
shall be designed to provide an outlet dust concentration level
of 50 mg/Ncum with the boiler operating with both Spent Wash
and bagasse as a fuel.
- Steam generator shall be provided with High pressure (HP)

dosing and Low Pressure (LP) dosing system. The HP dosing
system shall be based on ‘trisodium phosphate’ dosing and this
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shall be dosed in boiler water to take care of the ingress of the
hardness salts and to increase the boiler water pH. The LP
dosing system shall be based on ‘hydro quinine’ dosing and this is
dosed in the feed water to scavenge the last traces of oxygen
and to increase the feed water pH.
- Boiler refractory, insulation and inner and outer casing with all
fixing material for boiler, ducting, piping, valves, fittings and
equipments, etc.
- Handling system including mono rails, lifting tackles, support

structure for monorails, etc. for handling ID fan, SA fan, FD
fan, Feed pumps and drive motors, etc.
- Supporting structures, steel work, platform, ladders, galleries,

and staircases with fabricated floor grating including complete
roof, side cladding above the drum operating floor level along
with cladding structures for protection against rain and other
climatic conditions.
- The boiler instrumentation and control system shall be based on

the Distributed control system philosophy as discussed in
another section of this report. All the control, monitoring and
interlock functions will be taken care of by the DCS system.
5.6.2 Steam Turbines and Auxiliary System
The Turbogenerator proposed will be of extraction backpressure type

with the generation capacity of 2.2 MW with the inlet steam
parameters of 42 ata and 395 Deg.C. The steam Turbine shall be a
reliable and efficient system with state-of-the-art proven design with
good performance over a long period. The Turbine shall have the
following design and engineering features:
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- Highest possible thermal and energy efficiency.
- State-of-the-art technology and well proven in actual operation

over a long period.
- Rugged, conservatively designed, proven components and

systems.
- Minimum outage for field maintenance and routine inspection.
- Better operability at various load conditions.
- Advanced instrumentation, control systems, shut-down and

protection system, very reliable online supervisory and
surveillance system, with diagnostics.
- Minimum requirement of operating and maintenance man-power

and amenability to unattended automatic operation.
- Suitability for harsh tropical ambient conditions prevailing at

site.
- Simple design and ease of installation.
The turbine shall be horizontal, single cylinder, back pressure type.

The extraction shall be controlled and the extraction steam pressure
at the port will be at 3.5 bar(a).
All casings and stator blade carriers shall be horizontally split or

otherwise and the design shall be such as to permit examination of
the blading without disturbing shaft alignment or causing damage to
the blades. The design of the casing and the supports shall be such as
to permit free thermal expansion in all directions. The casing shall
also permit the inspection of the bearings without dismantling of the
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casing. The exhaust ducting shall be located on the lower half of the
casing.
The turbine shall have solidly forged and machined rotor with integral
disks. The rotor after fully machined and bladed shall be dynamic
balanced accurately in the shop and shall be given an over speed test
under vacuum. None of the critical speeds of the rotor shall fall
within the range of 20% above and 20% below the normal running
speed of the rotor. The material of construction shall be consistent
with proven practices and standards.
The blading shall be designed to withstand all vibrations, thermal

shocks, and other loading that may be experienced during service and
system disturbances. The blades shall be machined from forged bars
or die forged and the materials used shall be chromium steels suitable
for the temperatures encountered, resistant against corrosion and
erosion and consistent with proven experience and standards. In the
low pressure stages, if warranted where the moisture percentage is
higher, additional protection against erosion shall be provided.
The blading depending on the staging shall be adequately fastened,

with proven methods of fixing. The rotating blades are either
shrouded or tied with lacing wires depending on the stresses and the
excitation frequencies.
The glands shall preferably be of labyrinth type and sealed with

steam. The gland packing shall be of 13% chromium stainless steel.
The labyrinths shall be of multi-section spring backed type which
would allow for any temporary deformation of the rotor shaft without
overheating the rotor due to friction. The complete piping, valves,
pressure gauges, regulators etc. required for the end seals shall be
provided.
The Turbine shall be provided with liberally rated hydrodynamic radial

and thrust bearings. The radial bearings shall be split for ease of
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assembly, and of the sleeve or pad type, with steel shell backed,
babbitted replaceable pads. These bearings shall be equipped with
anti rotation pins and shall be positively secured in the axial direction.
The thrust bearings shall be of, Mitchell tilting pad type, the steel
backed babbitted multiple segment, designed for equal thrust
capacity in both directions. A liberal flow of lube oil under pressure
shall be supplied to all the bearings for lubrication and cooling.
All bearings shall be accessible without having to remove cylinder

covers. The metal temperatures of all the bearings shall be monitored
by thermocouples with extension right into the white metal layer.
Provision shall be made for measuring the temperature of the oil
leaving the bearings.
A pressure lubrication and control oil system shall be furnished for

the turbo generator unit to supply oil at the required pressure to the
steam turbine, gear box, generator and governing system. The
lubrication oil system shall supply oil to the turbine generator under
all the load conditions, including the turning gear operation. The oil
system of the turbogenerator shall be designed with adequate
redundancy and emergency provisions such that a failure of a single
active component will not prevent the safe operation or a safe
shutdown of the turbogenerator. Oil in the reservoir shall be main-
tained at an appropriate temperature when the TG set is idle by
providing suitable electric heaters and temperature controls if
required.
- One hundred percent (100%) capacity centrifugal/gear type,

Main oil pump shall be driven by A.C electric motor driven main
oil pump.
- One (1) No. of one hundred (100%) capacity A.C motor driven
auxiliary oil pump of centrifugal type, arranged to cut in
automatically if the oil pressure falls to a preset value. This
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pump shall also meet the requirements during the start up and
shutdown.
- One (1) D.C motor driven, centrifugal type, emergency oil pump
of adequate capacity to provide adequate lubrication in the
event of a failure of the A.C motor driven pump(s). This pump
also shall cut in automatically at a pre set value of the oil
pressure. The minimum capacity of this pump shall be to ensure
a safe shutdown of the turbogenerator.
- All the above pumps shall be provided with mechanical seals.
- Two 100 % capacity (one working and one standby) water cooled
oil coolers.
- Two 100 % duty oil filters arranged in such a way that it is

possible to clean one oil filter while the other is in service. The
filters and the coolers shall be arranged with continuous flow
transfer valves.
- Oil storage and settling tank with adequate reservoir capacity,

strainers, level indicators with float switches and alarm
contacts, vent and oil mist eliminators and 2x100% capacity
vapour exhaust fans.
- Flow and temperature indication for oil from every bearing.
- Centrifugal oil purifier with drives, interconnecting piping and

valves.
- Emergency gravity lubricating oil system
If the system envisages separate control oil circuit from the lube oil
system, there shall be independent two nos. of control oil pumps and 2
x 100 % duplex oil filters for the control oil circuit.
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The auxiliary oil pumps and the emergency oil pumps shall be arranged
to have flooded suction.
The oil coolers shall be water cooled with a duplex arrangement and
changeover valves. The coolers shall be of shell and tube type with
removable tube bundle. The coolers shall be constructed in accordance
with TEMA class C. The provided surface area shall be adequate to
cool the oil with the inlet cooling water temperature indicated in the
design basis, even with 20 % of the tubes plugged. The cooler shall be
of vertical type.
The sizing of the coolers shall consider a tube side (water side)
fouling factor of 0.0002 Hr.Sq.M.Deg.C/Kcal. The water velocity shall
be not less than 1.5 M/sec. A corrosion allowance of a minimum of 3
mm shall be applied to the design thickness of each of the component,
other than the tubes.
Full flow twin oil filters shall be used, for the lube oil, downstream of
the coolers and shall be piped in a parallel arrangement with a
continuous flow transfer valve with necessary two way change over
valves. Filter size shall be 40 microns nominal for the lube oil. Filter
cartridges shall have a minimum collapsing differential pressure of 3.5
Kg/Sq.cm. The minimum design pressure for the filters shall be the
maximum discharge pressure of the oil pumps. Differential pressure
gauge with alarm shall be provided across the filters.
The filters shall be either common or separate for the lube and
control oil circuits. The filter grade for the control oil shall be 10
Microns nominal. If a common filter is used for lube and control oil,
the filter grade shall be 10 microns nominal.
A centrifugal type oil purifier shall be provided for the removal of

water, sediments and other oxidation products from the Lube oil
system on a continuous basis. The purifier shall be a separate
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complete package, mounted on a skid, complete by itself with drive
motor, piping, valves and fittings. The capacity of the purifier shall be
at least two (2) percent of the rate of normal flow through the
reservoir. Feed to the purifier shall be from the drain end of the
reservoir and its operation shall be independent of the oil system.
Emergency gravity lubricating system shall be provided to assure the

lubrication at the time of an emergency due to the failure of the DC
operated lube oil pump. This system shall draw lube oil from an
overhead tank, under gravity, and shall be designed to supply oil for
the coasting down period of the machine. The overhead tank shall be
SS lined and the complete piping to and from the tank, shall be of SS
304 material. The tank elevation shall be finalised based on the oil
pressure requirements at the bearings.
The turbine governing system shall be electro-hydraulic designed for

high accuracy, speed and sensitivity of response. The
electrical/electronic and hydraulic components of the control system
shall be selected on the basis of reliability over a wide range of
operating conditions. All components used shall be well proven to
assure overall system reliability and shall be designed for easy and
quick replacement when necessary. The governor shall be configurable
in the field.
The governor shall ensure controlled acceleration of the turbo

generator and shall prevent over speed without tripping the unit under
any operating condition or in the event of maximum load rejection. The
governor shall have linear droop characteristics with a suitable range
for stable operation and shall have provision for adjusting the droop in
fine steps.
The governing system shall have the following important functions:
- Speed control
- Over speed control
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- Load control
- Inlet Steam pressure control
- Backpressure steam Control
The turbine control shall be through the centrally located Distributed

Control System, described in another section of this Report. The
control system shall provide redundancy for key functions by use of
separate sensors and monitors. The control system shall include all
the standard control monitoring and alarming. Only proven equipment
that has been used in similar systems before shall be provided.
Control panels shall be supplied fully wired and complete with all
necessary special wiring for interconnection of panels. Vibration
detectors/ proximity meters/ axial position detectors monitors shall
be provided for all bearings including the bearings of the generator.
Solid state annunciation units wherever located shall be of the first
out type. Individual alarm windows shall be provided for all critical
points parameters. The alarm sequence shall be as per international
standards. Separate windows shall be provided for pre-alarm and
shutdown with simultaneous alarm.
The steam turbine and the other high temperature parts, including
piping supplied, shall be insulated with low conductivity inert material,
where required, reinforced by stainless steel wire net between
applied layers. The insulation shall be so arranged that it can be
removed for access to the flange bolting, control valves and other
parts that require periodic maintenance. The insulation shall be de-
signed, such that the outer surface temperature of the insulation
does not exceed 20 Deg.C above the ambient temperature.
All the electrical equipment of the plant including the generator is

described under the section on “Plant Electrical Systems”.
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5.7 Cogeneration Scheme at the Distillery
The enclosed Fig.1.0 gives the scheme of the Cogeneration plant

proposed at GSML’s Distillery. The boiler with the MCR capacity of 20
TPH at 45 ata and 400 +5, -0 Deg.C, firing the concentrated Spent
Wash and imported coal/bagasse. The boiler will be designed for
firing 7.0 TPH of spent wash along with 5 TPH of bagasse to
generate 20 TPH of steam. The entire steam will be fed to the 2.2
MW extraction backpressure Turbogenerator. The extraction will be
a at a pressure of 5.5 bar(a)just for meeting the requirements of the
deaerator and the steam air preheater of the boiler. While the plant
is producing anhydrous alcohol, the requirement of the 4.5 bar(a) will
also be taken from the extraction. The turbine will be operating with
a back pressure of 3.5 bar(a). With 20 TPH of input steam The
Turbogenerator generates a gross power generation of 2150 kW. Out
of the steam quantity exhausted from the turbine, 8.0 TPH will be
supplied to the distillery process, 7.0 TPH will be supplied to the
evaporation plant and the balance to the AA plant. From the
extraction 1.3 TPH will be supplied to the steam air heater and 3.01
TPH will be supplied to the deaerator. About 80% of the condensate
of the steam supplied to the distillery process and the evaporation
system returns back to the Cogeneration plant at 60 Deg.C. A make
up of 3.7 TPH is added to the deaerator at 30 Deg.C. The deaerated
water temperature is maintained at 150 Deg.C, to eliminate the
possibility of low temperature corrosion in the economizer. A steam
air-preheater is proposed and the steam consumption in the same will
be 1.3 TPH and the steam is drawn from the turbine extraction. The
condensate from the steam air-preheater returns to the deaerator.
The drawing No.3-15003-800-0009 gives the Process Flow Diagram

for the Plant Steam System at the Distillery.
The Fig.2.0 gives the power balance for the plant. Out of the 2150 kW
of power generated 1230 kW is supplied to the distillery including the
evaporation plant, process cooling towers, utilities, condensate and
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lees polishing system etc. And the balance of 620 kW is supplied to
the Cogeneration plant including the boiler, TG, cooling tower and
other auxiliary systems of the Cogeneration plant. There will be a
surplus of about 300 kW which could be exported to the grid through
the sugar mill.
5.8 Bagasse handling system
The bagasse handling system will consist of the conveyors, boiler front
bagasse silos, extraction feeders, screw conveyors and
pneumatic distributors.
5.9 Ash Handling System
As the boiler is a travelling grate fired boiler, the ash from the
boilers will be collected at the grate discharge point as coarse ash and
as fly ash at the various hoppers provided in the economizer, air-
heater and the fabric filter. It is proposed to handle the grate
discharge ash from the submerged conveyor outlet through wheel
carts as this ash will be wet. The fly ash will be collected in a silo. All
the ash collected at various hoppers will be transported through
dense phase ash handling system to a storage silo. As seen elsewhere
in this report, all the ash collected in the boiler could be used as
fertilizer, because of its high potassium oxide presence. The collected
ash from the silos could be carted away to be applied as fertilizer in
the fields.
5.10 Balance of Plant Systems
All the balance of plant systems like the DM water system,

compressed air system are common for the distillery and the
Cogeneration plant and hence are covered under Section-3 describing
the “distillery process and the mechanical systems”.
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COROMANDEL SUGARS LIMITED
45 KLPD DISTILLERY WITH SPENT WASH BASED INCINERATION PROJECT
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6.0 DESCRIPTION OF PLANT ELECTRICAL SYSTEMS

AND EQUIPMENT
6.1 Proposed System
6.1.1 The distillery shall be planned with its own generating plant to
meet with the power requirements of the plant auxiliaries. The
boiler of 20 TPH, 45 ata, 385 deg. C and TG of 2.15 MW shall be
installed to meet the plant’s power requirements. The plant’s
auxiliary load shall be around 1450 kW. The electrical scheme of
the distillery plant will consist of one no. 415 V, 50 Hz, 3 Phase, 0.8
pf synchronous generator having nominal capacity of 2.15 MW. The
generator will operate in parallel with the 30 MW co-generation
plant. One (1) no. of 2.5/3.15 MVA, 11/0.415 kV distribution
transformer shall be installed as a stand-by supply, which in turn
receives supply from co-generation plant at 11 kV voltage level.
The drawing titled “Protection, Metering & Control Schematic
Diagram” (Drg. No. 1-15003-900-0453, Rev-0) attached to this
report, depicts the electrical scheme planned for the proposed
2.15 MW Cogeneration plant at the Distillery.
6.1.2 The power generated by the turbogenerator will meet the auxiliary
power requirements of the co-generation plant and the distillery
plant. The surplus power, if any after meeting the plant auxiliaries
shall be exported to the 11 kV switchboard of the 30 MW co-
generation plant.
6.2 Generator
6.2.1 The generator will have nominal rating of 2.15 MW with the
generation voltage of 420 V, three phase, 50 Hz, at a rated
power factor of 0.8 (lag). The saturated rated direct axis sub
transient reactance of generator should not be less than 18% and
not more than 22%. The machine will run at 1500 rpm, and will
operate with the voltage and frequency variation of ±10 % and ±5 %
respectively, with a combined voltage and frequency variation of ±
10%. The enclosure will be of dust, vermin and water proof. The
generator will meet other requirements as stipulated in IEC:60034.
The generator will be complete with base frame, closed air circuit
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water cooled (CACW) cooling system, brushless exciter,

automatic voltage regulator, relay, metering and control panels,
instrumentation control and safety devices and other accessories,
spares and special tools that will be required for satisfactory
erection and efficient operation of the station. The generator
coupled to the steam turbine will be suitable in all aspects for
operating in parallel with grid. The generator will match with the
turbine in respect of speed, over speed, moment of inertia,
overload capacities, coupling and other relevant requirements.
6.2.2 The stator and the rotor of the generator will have class 'F'
insulation but the temperature rise will not exceed the limits
specified for class 'B' insulation. The generator will be fitted with
RTDs, space heaters and temperature indicators. RTDs as
mentioned below shall be provided:
a. Coil sides : 4 Nos. per phase

b. Stator core : 4 Nos.
c. Bearings : 2 nos. each for DE and NDE
d. Cold & Hot air : 2 Nos. per stream
streams
6.2.3 The generator terminals will be suitable for connecting to

switchgear panel (PCC) through busduct. The current transformers
for metering and protection will be housed in the main switchgear
panel and busduct. The drawing enclosed to this report gives the
protection scheme for the generator.
6.3 Excitation System & Synchronizing Panels
6.3.1 The excitation system will be of brushless type and will be

provided with the following features:
a. Generator voltage control

b. Excitation current control
c. Excitation build up during start up and field suppression on
shutdown
d. Limiter for the under excited range and delayed limiter for
overexcited range
e. PT fuse failure detection and auto changeover
f. Auto power factor control
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6.3.2 The system will have double auto and manual channels, with bump
less changeover facilities. Alarms will be arranged for AVR fault,
AVR automatic changeover to second auto channel / manual mode
and for diode failure.
6.3.3 Synchronising panel complete with running and incoming voltmeters,

running and incoming frequency meters, synchroscope,
synchronizing check and guard relays, no volt relays, synchronizing
cut off switch, lamps etc. will be provided. Automatic synchronizing
with inputs to governor and AVR control will be made possible.
6.4 Unit Control Panel
6.4.1 The unit control panel will comprise of control and metering
system, synchronising system, protective relays, start / stop
system, alarm / annunciation and temperature measurement
system. The control panel will have provision for closing /
synchronising through the generator breaker and tie breaker.
Dead bus closing arrangement will also be provided in the control
panel. The panels may be split up into control panel, metering panel
and relay panel for convenience.
6.4.2 Each panel will have digital / electronic PQM, ammeters,

voltmeters, frequency meter, power factor meter, kW and kVA
meters. The following minimum protections will be provided for the
generators:
a. Over voltage, under voltage relay

b. Voltage restrained over-current relay
c. Field failure relay
d. Reverse power (active & reactive) relay
e. Differential protective relay
f. Stator earth fault relay
g. DC failure trip relay
h. Under/Over frequency relay
i. Stator and rotor winding temperature trip relay for
alternator.
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6.5 Standby Power Distribution
6.5.1 It is proposed to add one (1) number of 2.5/3.15 MVA, 11/0.415 kV

distribution transformer to receive stand-by supply from co-
generation plant and the same transformer shall be used to
evacuate surplus power from distillery plant to co-generation plant.
The transformer will be of the following rating:
Rating : 2.5/3.15 MVA

Cooling : ONAN/ONAF
Voltage Ratio : 11/0.415 kV
Highest system Voltage : 12 kV
Power frequency Voltage : 28 kV rms
Impulse Withstand : 75 kV peak
Voltage
Taps and Range : On load tap changer,
±12.5% in steps of 2.5%
(suitable for bi-directional
power flow)
Voltage Vector : Dyn11
Impedance : 18% @ 2.5 MVA base
(without negative
tolerance)
Neutral Earthing : Solid Earthing
6.5.2 11 kV XLPE Power Cable shall be considered for connecting the HV

side of the transformer to 11 kV switchgear of co-generation plant.
1.1 kV grade, LT XLPE cable shall be used to connect the LV side of
the transformer to PCC.
6.5.3 The transformer will be protected by Restricted Earth Fault (REF)

relay. The neutral bushing CT before bifurcation of neutral will be
provided for REF protection of secondary winding of the
distribution transformers. The drawing enclosed to this report
gives the protection scheme for the generator.
6.6 LT Distribution System and Interconnection
6.6.1 The LT distribution panels conforming to the latest revision of

IEC:439 will be of dust & vermin proof construction, sheet steel
clad, totally enclosed, floor mounted, self standing single front
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type, with both front and rear access for PCCs and front access
for MCCs. All panels will be of single bus bar type with bottom
cable entries. The MCCs shall be of compartmentalised design with
cable alleys at the sides. PCCs shall have the cable chambers at
the rear. The busbars shall be of electrolytic grade aluminium
alloy, designed for 85Cend temperature with an ambient of 45 C.
All panels shall have neutral bus, sized to carry half the phase
current. All panels shall be designed for 50 kA for 1 sec.
6.6.2 PCCs shall have ACBs for ratings of 630A and above. All breakers
shall be of draw-out type with spring charged motor operated
closing mechanism for incomer feeders and manual draw out type
breaker for motor and other outgoing feeders. For ratings less
than 630A, MCCB shall be provided.
6.6.3 MCC feeders shall be envisaged with MPCB and contactor for
motors of rating up to 30 kW. For ratings beyond 30 kW, MCCB,
contactor and microprocessor based Overload relay shall be
provided. Ammeters of suppressed scale (above 5.5 kW) and
indication lamps, suitable for remote operation shall be envisaged.
6.6.4 Motors feeders of rating less than 37 kW will be provided with

DOL starter in MCC. Higher sized motors may be provided with
star / delta starter depending on application.
6.6.5 Busduct of rating 5000A, 50 kA for 1 sec. shall be provided for

connection between the generator terminals and the PCC. The
busduct shall be with aluminium enclosure and aluminium alloy
conductors. The busduct shall be of non-segregated phase busduct
type interleaved design and shall be complete with flexible,
bellows, vertical & horizontal bends, seal-off bushing, outdoor
hoods, etc.
6.7 Motors
6.7.1 All motors shall be of squirrel cage type conforming to IEC:34,

totally enclosed and fan cooled. Motors shall be of ‘premium
energy efficient (IE3)’ type as per IS 12615 – 2011. The windings
will be insulated by class `F' insulation material and maximum
temperature rise shall be limited to class ‘B’ insulation limit over an
ambient of 50 Deg. C.
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6.7.2 Motors to be located in hazardous area shall be of flame proof,

Ex(d) type suitable for zone – 2 area of classification.
6.8 Plant Start-up
6.8.1 The plant shall be started with power from co-generation plant
through the distribution transformer will be provided at distillery
plant
6.9 Earthing System
6.9.1 Neutral point of the distribution transformers and neutral of the

TG set generators shall be effectively connected to individual
earth pits and shall be interconnected, as per IEEE:80
recommendations. The neutral of LV of side of transformer shall
be kept open, when the TG is running in parallel with co-generation
plant.
6.9.2 Non-current carrying parts of all electrical equipments viz.

generator, PCCs, MCCs, distribution boards, control panels, and
motors shall be earthed rigidly, to ensure safety. The armour of
the cables, steel structures cable supports and all lighting fittings
shall also be earthed.
6.10 Cables
6.10.1 The outer sheath of all cables in the hazardous area shall be of
FRLS type.
6.10.2 All cables shall be selected to carry the load current under site
conditions, with permissible voltage drop. In addition, high voltage
cables shall be sized to withstand the short circuit current. The
following types of cables shall be used.
6.10.2.1 Power cables for 11 kV system will be with three core aluminium
conductor, XLPE insulated, screened, armoured and overall PVC
sheathed confirming to IEC:502.
6.10.2.2 The power cables of 1.1 kV grade will be XLPE insulated, aluminium
conductor, inner sheath PVC taped strip / wire armoured with
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outer sheath of PVC compound conforming to latest version of IEC:

227.
6.10.2.3 The control cables for control / protection / indication circuit of

the various equipment will be of 1.1 kV grade, PVC insulated
annealed high conductivity stranded copper conductor, inner sheath
PVC taped, flat/round wire armoured with outer sheath of PVC
compound conforming to latest version of IEC:227.
6.11 DC supply system
6.11.1 Battery, battery charger and DC distribution board unit will be

provided in common for the power house DC load requirements (viz.
turbine emergency oil pumps, control & protection).
6.11.2 Valve regulated lead acid battery (110V) with 2V cells along with
accessories shall be provided.
6.11.3 The battery sizing will be on the basis of the following type of
loads:
- Momentary load for 1 min.

- Emergency load for 2 Hrs
- Continuous load for 10 Hrs.
6.11.4 The battery charger will be of SCR controlled with dual float cum
boost charging (FCBC) equipment housed in a free standing, floor
mounting cubicle having hinged half doors made out of 14 SWG
CRCA sheets.
6.12 AC Auxiliary Supplies
6.12.1 AC supplies of single and three phase, needed for internal use for
several functions such as Illumination, Battery charging, UPS,
Excitation supply, communication equipment and generators space
heater shall be arranged from minimum two supply sources one
from the main switchboard of the distillery and other from LT
distribution of the existing sugar plant. For extremely critical AC
loads, UPS supply system will be envisaged.
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6.13 Lighting System
6.13.1 Good lighting in the distillery plant will be ensured to facilitate

normal operation and maintenance activities and at the same time
to ensure safety of the working personnel. The lighting system
would comprise of normal and emergency power supplies. Main
lighting system shall receive supply from reliable supply sources
and the emergency lighting system will be supplied from battery
units. Emergency lighting will be provided at strategic points in the
power station, switchyard area and in control rooms.
6.13.2 Light fittings provided in the hazardous area shall be of flame

proof type suitable for zone-0 with class duty of IIA/IIB.
6.14 Lightning Protection
6.14.1 Building lightning protection system will be provided as per IS:

2309. The protections consisting of roof conductors, air terminals
and down conductors will be provided for the power house.
6.14.2 All tall structures of the distillery plant including tanks shall be
protected against direct lighting strokes, by providing air finials /
horizontal conductors and down conductors up to the earth
electrodes, as per IEC standards.
6.15 Plant Communication system
6.15.1 Existing communication facility at sugar plant shall be extended for

the Distillery plant.
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7.0 INSTRUMENTATION AND CONTROL SYSTEM
This Section of the Report gives the general philosophy of the

Instrumentation and Control system proposed for the 60 KLPD
multi product distillery plant and 2.15 MW cogeneration power
plant.
7.1 The plant will be complete with the basic instrumentation and
control system necessary for its safe and efficient operation.
7.2 Comprehensive instrumentation and control equipment will be

provided for each major area of the plant.
7.3 The control system shall be based on the State-Of-The-Art

DISTRIBUTED CONTROL SYSTEM (DCS) technology with Data
Acquisition and control for controlling / monitoring the different
sections of the distillery plant and the concentrated spent wash
fired boiler & 2.15 MW co-generation plant. The Data Acquisition
and control of the entire plant shall be achieved by a popular DCS
package.
7.4 The centralized control / monitoring of the plant shall be from a

Remote Central Control Room where the DCS and its sub-systems
including the operator console shall be located.
7.5 The Instrumentation and control system of the distillery plant and
co-generation power plant shall be realized as given below and the
drawing “Overview of the control system” for the plant is given in
Drg. No: 3-15003-800-0013.
7.6 Distillery section and its auxiliaries control
The control of the total Distillery section operation start up /

shutdown / trip shall be realized directly through DCS. The
distillery controls will be for the manufacture of RS, AA and ENA
products.
Flow measurement for remote monitoring includes Process steam

flow, Inlet molasses flow, cooling water flow, Condensate flow,
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Products output flow from the process and Flow of products outlet
from the plant. In addition to the above flow measurement,
Mechanical weighing system (Tip measurement) shall also be
considered for Inlet molasses to the process.
The major controls of Distillery plant include the following:
 Fermented wash Flow Control

 Level control for analyser column
 Level Control for Rectifier column and its reflux tank
 Level Control for Pre Rectifier column and its reflux tank
 Level Control for Fuse oil reflux tank
 Level Control for extractive column
 Level Control for Simmering column and its reflux Tank
 Level Control for recovery column and its reflux tank
 Steam flow Control for Simmering
 DM water flow Control of Purifier Column
 Soft water flow Control for Flash tank
 Flow control for pre-rectifier RS draw control
 Flow control for rectifier RS draw control
7.7 Boiler and its auxiliaries control
The control of the entire boiler operation / Start-up / Shut-down

/ Trip shall be realized directly from the DCS. All the signals
required for controlling the boiler operation shall be processed by
the DCS and necessary actuating signals or the various final control
elements shall be driven from the DCS.
The Major control of the boiler includes the following as a

minimum:
 Drum level ( 3 element ) control
 Combustion control
 Deaerator level control
 Deaerator pressure control
 Furnace Draft pressure control
 Superheated Steam Temperature Control (2 element )
Signals from the following shall be taken to the DCS for monitoring
/ interlocking purpose.
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 Boiler Feed Pumps


Deaerator
 Chemical dosing
 Boiler safety and protection interlocks
7.8 Turbine and its Auxiliaries control
Turbine control shall be performed by the DCS. Turbine Protection

and safety interlocks shall be performed by DCS. Signals from the
following major equipments shall be taken to DCS for monitoring /
Interlock purpose.
 Lube oil system

 Control oil system
 Generator cooling system
 Turbo supervisory system
Dedicated independent micro processor based systems shall be

considered for the following systems of the TG and shall be
interfaced with the DCS through serial communication for
monitoring / interlocking purpose:
 Turbine Vibration Monitoring system

 Turbine Governing system
The turbine shall be provided with and electro-hydraulic

governing system. The system shall be designed such that the
governing of the turbine shall be automatic and provides for safe
operation.
The information of the following shall be monitored by the DCS for

Data logging / Interlocking purpose:
 Power generation details

 MOP/ AOP / EOP status
 Temperature of turbine bearings
 Temperature of windings / Bearings of Generator
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The following details on the electrical signals shall be processed /

monitored by the DCS for interlock / data acquisition purpose:
 Safety Relay status

 Breaker status
 Generated Voltage, Current, Kilowatt, KVAR, Power factor,
Frequency
 Line Voltage, Current, Kilowatt, KVAR, Power factor,
Frequency
7.9 Various electrical inputs from the transducers and the digital
signals from MCC panels shall be processed in the DCS system for
monitoring and achieving the necessary interlocks / controls.
7.10 The control and monitoring of the Instrument Air Compressor shall
be realized directly from the DCS.
7.11 The operation and control of Ash Handling System shall be from
DCS only.
7.12 The operation and control of Fuel Handling System shall be from
DCS only.
7.13 The PRDS functions shall be directly processed by the DCS.
7.14 The control and monitoring of auxiliary cooling water System shall
be realized directly from the DCS.
7.15 The operation and control of water treatment system shall also be
directly processed by the DCS. Dedicated operator station and
respective IO panel shall be envisaged for the same.
7.16 The design of the total control system will be such that the
following sub-system's functions will be handled by the respective
equipment:
a. Data acquisition, Display and logging sub-system for

monitoring, display, logging and printing of process
parameters like flow, temperature, pressure, level, current,
voltage, analytical and status will be performed by the
operator station
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b. Start / Stop Sequence & Interlock sub-systems consisting

of the safety interlocks, Sequence of starting and stopping
of the distillery plant and alarm generation will be achieved
through the DCS.
c. Closed loop control sub-system consisting of the continuous

monitoring of the operational parameters like Level,
Pressure, Flow etc., and controlling of the same using the
PID functions will be achieved by DCS.
d. Engineer / Operator interface sub-system consisting of

setting / changing the operational parameters based on the
experience of the operator and as a reaction to emergency
situations will be achieved by the computers used as the
operator station.
e. Communication sub-system for interconnecting all the above

systems.
f. Data highway and network for connecting the control and

data acquisition sub-systems, operator interface sub-
systems to a duplexed data highway such that there will be
information exchange among each one of them.
g. Auxiliary units such as system cabinets, printer consoles,

marshaling cabinets and power supply distribution cabinets.
7.17 The Distributed Control system is proposed for Control and

Instrumentation system, keeping in view the safety, reliability and
availability for comprehensive presentation of plant operation
status, trends and essential operator interaction facility.
The Distributed Control System based plant control will have the
following inherent advantages:
 Integration of information from different individual controls

provides centralized data on plant operation.
 Increased reliability due to the use of Large Scale

Integrated (LSI) components.
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 Increased flexibility for modification at any stage due to

software configuration capability.
 Modular design concept provides easy expandability for

future in hardware and software.
 Higher maintainability due to improved self-diagnostic and

display features.
 Less number of operating personnel.
The major design aspects of the system will be as follows:
 Control will be of the type which normally relieves the

operator of continual regulating duties and will be backed up
by interlocks and safety systems that will take pre-planned
action in cases where unsafe trends and/or conditions
develop faster than the operator's ability to respond.
 Continuous self checking features shall be incorporated in

system design with automatic transfer to healthy/redundant
circuits to enhance the reliability of the complete system.
 All the closed loop analog signals, open loops, safety and
interlock signals and digital signals shall be processed by the
DCS.
 Redundancy will be provided in the Central Processing unit,

power supply and Communication modules (both between the
controller & the operator station and between the I/O
modules and the controller).
 Redundancy will also be provided for the communication

cables.
 Power supply used for interrogation with field devices shall

also be redundant.
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 The Input/Output modules will be provided with noise filter

and galvanic / opto isolation from external control source.
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 All analog signals from distillery area to DCS and from DCS
to distillery area shall be routed through signal barriers.
 The Inputs / output module shall also be provided with

protection against reversal of polarity of supply voltage.
 The input modules shall be suitable for processing the field

signals. The outputs will be short circuit proof and
protected by fuses.
 The memory will be non-volatile or battery backed up as

required.
 The control logic building shall be user friendly based on

windows based software.
 The graphic displays on the operator station shall be

developed using windows based software.
 On-line replacement of modules shall be possible without

affecting the process.
 Auto boot up facility for the DCS shall be within 2 minutes.
 Display response time shall be less than 2 Sec.
 Data communication network response time shall be less than

100m Sec.
 Closed loop control task execution (Control response time)

shall be done within 250 msec.
 Sequence control / Interlocks scan time should be within

100 msec.
 Display update time shall be less than 1 sec.
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 The system shall be designed so that the failure of any
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monitoring device or control components or spurious

intermediate grounding in the signal path shall not open the
signal loop nor cause the loss or malfunction of signal to
other devices using the same signal.
 All equipment/systems located in the field shall be suitable

for continuous operation without loss of function, departure
from the specific function or damage at the ambient
temperature and humidity conditions.
 The control system software shall have all the essential

capabilities to perform advanced control algorithms as a
minimum. It shall be user friendly, easily programmable and
have excellent Data acquisition, Graphic display and logging
capabilities.
7.18 The field instruments those are primarily responsible for

measuring the process parameters will be having the following
major design features:
 All the field instruments/equipment that are used shall be

of the same make for ensuring the smooth & optimal
maintenance including efficient spare parts management.
 All field instruments used for sensing, transmission and

measuring shall be of electronic smart type with local
indication & signal transmission in current mode of 4-20 mA.
 All control valves and control damper drives will be of

pneumatic type because of their fast response and ease of
maintenance.
 All the field instruments, control valve positioner and

Junction boxes shall comply explosion proof/ intrinsically
safe requirements
 Cable glands used in hazardous area shall be of double

compression, flame proof type.
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 Materials of construction of instruments shall be consistent
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with temperature, pressure and corrosion conditions.
 Appropriate derating of electronic components and parts.
 Important plant parameters, that are required to assess the

plant efficiency, must be serially communicated to the
operator station for the purpose of display / logging.
 All solid state systems/equipment shall be able to withstand

the electrical noise and surge as encountered in actual
service conditions and inherent in a distillery plant, and shall
meet the specification requirements of surge protection.
 All solid state electronic system/equipment furnished shall

meet the requirements of Burn-in and Elevated temperature
test.
 All the instrumentation cables shall be flame retardant low

smoke type.
 The instrumentation cables and wires shall function without

breakdown for surges experienced in the control system.
Voltage class and insulation level shall be compatible with the
signals they convey.
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8.0 PROJECT CIVIL & ARCHITECTURAL REQUIREMENTS
This section of the report covers the basic requirements of civil

work to be executed in the distillery Project. More detailed
specifications are to be drawn at the time of Project engineering
stage, depending upon the nature of the soil and based on the soil
investigations for the project execution.
8.1 Geo-technical investigation
The Geo-technical investigation shall cover the entire distillery

area. Required and adequate field tests in the form of test boring
including drilling through rocks (if required), direct load tests, trial
pits, tests for dynamic properties, electrical resistivity tests etc.
and necessary laboratory tests shall be conducted to determine
soil and sub-soil characteristics required for site preparation and
foundation design. Soil Investigation tests shall be conducted at
all major structure / foundation / building locations within the
battery limits of the plant. A comprehensive report on soil
investigations shall be prepare incorporating all the data collected
and firm recommendations with regard to the type of foundations
shall be given supported by calculations.
Contour mapping of the site with proper surveying should be

obtained by taking spot level of ground at every 5 meter intervals
in both directions. Bench marks with co-ordinates and reduced
level for the site should be established. Based on the preliminary
contour survey, the level difference across the distillery plant is
around 17 to 20 meters.
8.2 Equipment Foundations
8.2.1 Foundation for rotating machinery
The foundation design will take into considerations all the loads
from the machine including dynamic loads as per the
manufacturer’s loading data. The design and construction will be
done as per provisions laid down in applicable Indian Standards. The
Grade of concrete for the complete foundation including the top
deck shall be at least M25 (specified characteristic compressive
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strength of 25N/sq.mm for a 150mm test cube at 28 days). The

High strength deformed reinforced steel bars used for reinforced
concrete shall conform to Indian standards.
Detailed static and dynamic analysis shall be done for the

foundation. The static analysis shall include all the operating
condition loads as well as abnormal loads. A fatigue factor of at
least 2 shall be considered for all dynamic loads. The mass of the
foundation block shall be not less than three times the mass of the
machine.
Dynamic analysis shall be carried out to calculate the natural

frequency and mode shapes and to evaluate the dynamic response
of the foundations to the applied dynamic loads. Unbalance loads
for the normal operating conditions as given by the manufacturer
or VDI 2060, whichever is more conservative shall be used for
calculating the dynamic response. Transient dynamic analysis shall
be carried out for the short circuit condition with an appropriate
forcing function.
The detailed design and vibration analysis shall be carried out to:
 The determination of the natural frequencies of the system,

to ensure that at least 20% frequency separation exists.
 Ensure the suppression of vibration amplitudes to acceptable

limits.
 The provision for adequate foundation bearing capacity and

settlement, limited to acceptable amounts.
The reinforcements shall be designed to the working stress

methods for the worst load combinations of static and dynamic
loads.
All necessary provisions by way of cut-outs, embedment and

foundation bolt assemblies shall be incorporated into the
foundation block to meet the functional requirements.
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The foundation shall be isolated from adjoining parts of buildings

and other foundations for vibration control. Joints at floor /
grade shall be suitably sealed.
For foundations supporting minor equipment, weighing less than

One Tonne or if the mass of the rotating parts is less than one-
hundredth of the mass of the foundations, no dynamic analysis
need be done. However, if such minor equipment is to be supported
on buildings, structures etc. suitable vibration isolation shall be
provided by means of springs, neoprene pads etc. and such
vibration isolations system shall be designed suitably.
8.2.2 Static Equipment Foundations
All the static equipment foundations shall be constructed with

cast-in-situ reinforced concrete. All foundations shall be extended
to a depth, which conforms to the allowable bearing pressure of
the soil.
The design of foundations will take into account all the loads from
the equipment as per the equipment manufacturer’s loading data.
The design and construction will be done as per provisions laid down
in Indian Standards. The grade of concrete shall be at least M20.
(Specified characteristic compressive strength, of 20N/ sq.mm for
a 150mm test cube at 28 days). The High strength deformed
reinforced steel bars used for reinforced concrete shall conform
to applicable Indian standards.
The design of foundations shall be carried out by Limit State

Method. All necessary provisions by way of cut-outs,
embedment, and foundation bolts assemblies shall be incorporated
into the foundation block to meet the functional requirements. The
foundations will be isolated from building foundations and
superstructures.
8.3 Buildings
8.3.1 General
All buildings will be designed and constructed as per applicable

Indian standards and codes. Loads shall be calculated based on IS
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875, and Earthquake loads shall be as per IS 1893. The analysis

and design of structures shall be carried out by Limit state method
and by using standard computer programs as per technical
specifications and using reinforced concrete Grade of concrete
M20 (specified characteristic compressive strength of 20N/ sq.mm
for a 150mm test cube at 28 days). The High strength deformed
reinforced steel bars used for reinforced concrete shall conform
to relevant Indian standards.
The buildings shall be designed to suit the climatic conditions of

the region. Roofs of all the buildings shall be weatherproof and
leak-proof under all conditions. Proper drainage arrangement will
be made and these are connected to main storm water drains. All
buildings shall be provided with suitable approach roads connecting
to main plant roads. The buildings will be properly ventilated and
illuminated to meet their functional requirements.
8.3.2 Non Plant Buildings
Non Plant Buildings like, Laboratory building, MCC Rooms, Pump

house, excise authority building, security cabin, office building etc.,
will be of concrete shallow foundations and superstructure with
reinforced concrete / Structural steel frame work, reinforced
concrete cast in situ / Plastic coated steel sheeting roof. External
walls shall be of 230 mm thick brick masonry and internal walls will
be of 115 mm thick brick masonry depending upon the functional
requirement of the buildings.
Exterior and interior walls, ceiling shall be plastered and painted

with approved colour and brand. Doors and rolling shutters with
steel frame and adequate windows / ventilators with steel frame
with 6 mm thick glass shall be provided. Flush doors and glazed
windows shall be provided as per requirement. Exhaust fans shall
be provided as required. Around the buildings a 10 m wide smooth
finished concrete walkway and necessary steps and ramps shall be
provided.
8.4 Distillery plant civil works
The molasses tanks and bulk storage tanks shall be open to

atmosphere with suitable foundation. Covered area is required for
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fermentation section (fermenters wash settling, yeast and

molasses handling area), distillation section, daily receiving section,
etc. These buildings can be of MS steel structure buildings with
plastic coated steel sheet roofing on MS trusses and purlins. The
structural steel buildings shall have civil work up to plinth + 0.3m
above ground. Platforms at 3m intervals shall be provided. The daily
receiver building shall have brick masonry up to 2m height and RCC
grill above the masonry wall. The tank and equipment foundation
will be in concrete. The floors of the building shall be of steel
platforms and wherever required they should be of removable type.
Some of the operating floors will be of chequered plates to avoid
spillage reaching the floors below. The flooring at ground floor
shall be hardened concrete flooring 50 mm thick.
The bulk storage section shall have Uncrushed Rubble masonry in

plinth, chain link fencing of 1.2 M high above the wall all around and
gate for entry purposes. The excise authority office, security
cabin and distillery office will be of RCC construction with floor
slabs and RCC roofs.
The construction of impervious storage tanks for spent wash

should meet the pollution norms. It shall be constructed of
masonry / brick work with impervious one using composite PVC
lining duly finished and Sulphate resistant cement shall be used.
Since spent wash is highly acidic corrosion resistant epoxy painting
shall be used.
8.5 Tank Foundations
Flat bottomed steel tanks are extensively used for storage of

liquids such as water, products and molasses in the distillery. These
are placed directly on grade; by just levelling the ground if the
strata below are firm or improving the strata by compacting the
soil to desired density or replacing the top layer by well compacted
sand layer. The foundations for steel storage tanks supported
directly on firm grounds can be economically constructed by
allowing larger settlements than permitted for framed structures
or equipment foundations. Since the loading on soil resulting from
these tanks is necessarily uniform hydrostatic load the
settlements are also uniform over well prepared grade.
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Loose soil under the tank area is first removed and the soil below is
compacted using 10 T rollers after watering at optimum moisture
content. The prepared grade is overlain by well compacted sand
layer of min 150mm thicknesses. The area under the tank is
enclosed in concrete ring wall. The diameter of this ring wall is
approximately 2m more than the tank diameter. The tank is placed
entirely on soil. The purpose of the ring wall is to confine the soil
under the tank and take care of the resultant hoop tension
resulting from tank load and lateral pressure from soil. The tank is
then placed on 50 mm thick Bitumen mastic layer with 6 mm stone-
grit and coarse sand mixed with 80/100 grade bitumen.
The tank shall be supported on well designed foundations, installed

in the open and surrounded by wall or embankment not more than
two meters high and made of earth, steel, concrete or solid
masonry capable of withstanding full hydrostatic load. Ground
within the enclosure shall not be lower than the level of the ground
outside the enclosure and shall be finished to form a slope of not
less than half a percent from tank to drain or sump.
The drainage from the enclosure shall be controlled by a valve

which shall be accessible in fire conditions and capable of being
operated from outside the enclosure. Where Petroleum class A
(Ethanol) or Petroleum class B is stored in an enclosure, the
capacity of the enclosure shall be hundred percent of the capacity
of the largest tank in the enclosure after deducting the volume
upto the height of the enclosure wall of all other tanks in the same
enclosure.
8.6 Cooling Towers
The basin underneath the cooling tower for the collection of the
cold water shall be of grade M25 concrete. The raft slab shall be
checked for uplift forces considering empty condition of the basin
with ground water table at the maximum level. A minimum factor
of safety of 1.2 shall be ensured for the condition that the basin
walls are constructed up to finish ground level and there is no
water in the basin and superstructure columns are not constructed
and the ground water table is at the maximum level. The basin
shall be water tightness, to prevent mixing of the ground water
with the cooling water in the basin.
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Water proofing admixture (plasticizer cum water proofing

compound), shall be added to the concrete for basin, channels,
drain pits, hot water basins etc. Two (2) Nos. of Stairs, one at
each gable end shall be provided. The stairs shall be of steel
construction with galvanized step treads and hand railing.
8.7 Pipe Racks
Pipe rack supporting structure will be of structural steel columns

with interconnecting longitudinal & transverse beams, properly
braced with vertical & horizontal bracings. All structural steel
members will be painted suitably. Width and tier of the rack shall
be as per the system requirements. Access ladders at suitable
places will be provided.
The steel columns will be resting on RCC pedestals / footings

(grade M20). The analysis and design of structures and
foundations will be done as per provisions laid down in the codes.
8.8 Cable / Pipe Trenches
Cable trench walls and base slab will be of cast in situ reinforced
concrete (Grade of Concrete M20) (specified characteristic
compressive strength of 20 N/sq.mm for a 150mm test cube at 28
days). The High strength deformed reinforced steel bars used for
reinforced concrete shall conform to relevant Indian standards.
Trenches shall be covered with precast RC cover slabs of

standard design. Suitable slope in the longitudinal direction shall
be provided and to be connected to nearby plant drainage system.
Necessary embedment and edge protection angles shall be provided
as per functional requirements.
8.9 Roads and Pavement
All roads within the plant shall be either double lane roads with 6.0
m black topping or 2.5 wide shoulders on either side of the roads or
shall be single lane roads with 4.0 m black topping and one meter
wide shoulders on either side of the road. Roads geometry and
construction shall be in accordance with applicable Indian
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standards for road construction. All the roads shall be designed to

withstand the largest expected loads. Minimum longitudinal slope of
the road shall be 1 in 200 where there are curbs on each side.
Without curbs the roads may be laid flat. Slope from crown to edge
should be 1 in 50 generally on straight stretches. Super elevation
shall be provided on curves.
The sub grade shall be compacted to the levels, falls, widths and
cambers as per the grade requirements. Sub base will be laid on a
prepared sub grade. Base and final road surfacing shall be of
bitumen macadam. Seal coat will also be provided. Precast RC
kerbs on both sides of road shall be provided. The rainwater shall
be collected in road side gullies and let into the plant surface
drainage system.
Paving areas shall be properly graded and compacted to required

grade and slopes before providing the base layer. Reinforced
concrete paving (grade M 15) shall be done in alternate panels not
exceeding 3.0 m x 3.0 m in size. Construction joints shall be filled
with sealing compound. Around equipment foundations / columns
isolation joint shall be provided up to full depth of the pavement.
Expansion joints shall be provided at a spacing of 15m (max)
Top surface of the pavement shall be provided with adequate

slopes as required for the surface drainage.
8.10 Surface Drainage
All the paved and unpaved areas shall be adequately drained. The
surface drainage system shall be designed for surface washings
and / or rain / fire water as the case may be.
Contaminated area surface drainage shall be collected and

discharged through catch pits. The catch pits shall of RCC
construction and shall be covered with CI / MS gratings.
Uncontaminated areas surface drainage shall be done through
rectangular RCC drains to be connected to open storm water
drains.
The catch pits, interconnecting pipes and rectangular / trapezoidal

drains shall be sized for carrying the design discharge when
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running full. Adequate bottom slope shall be provided to maintain

minimum velocity. The paved areas shall be sloped towards the
catch pits drains. At the road and other crossings suitable pipe /
open RC culverts shall be provided.
8.11 Plumbing and Sanitary System
Plumbing and sanitary system shall serve all toilets, showers,

bathrooms, kitchens and laundry room. Wherever possible all
discharge pipes shall be fully vented. The design, installation,
testing and maintenance of all plumbing systems & sanitary
appliances shall comply with latest applicable Indian Standards.
Toilets shall have western style water closets. All piping shall be
concealed. Floor drains shall be designed in such a way that their
taps are always filled with water to guard against odours as well as
insect and rodent infiltration.
All wash basins shall be equipped with pop up drain stops. All sinks
shall have water taps.
All urinals and water closets shall have flush valves. The minimum
acceptable mounting height of a shower head shall be 1.8 m from
the finished shower floor.
8.12 Sewerage Drainage System
The sewerage drainage system consists of connecting the sanitary

waste disposal from different buildings to the Septic tank through
necessary pipeline. All the pipes shall be of RCC material. Minimum
size of pipe at a service connection shall be 100 mm and the
minimum size of pipe for sewers shall be 200 mm. Minimum slope in
service connections shall be 1 in 40 and in sewers 1 in 400. All
sewers shall be located along with roadways or public open spaces.
Manholes shall be provided at the head of each sewer, at all
changes in slope, direction or pipe size or at junctions of sewers.
Maximum distance between manholes shall be 50m.
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8.13 Site Clearance
All the materials and equipment employed for construction purpose

shall be taken away from the site. All the rubbish and unwanted
plant material shall be cleared and dumped away from the site. All
areas within and outside the site which have been used during the
construction shall be cleared and the ground surface shall be left
in a safe and aesthetically good condition.
8.14 Fencing / Compound Wall
The storage area, loading, unloading area etc should be provided

with suitable Compound wall / Fencing for a height of 2.5 m and
steel gate with security room. Compound wall shall be provided
wherever necessary for isolation of specific plant areas.
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9.0 SITE FEATURES AND PLANT LAYOUT
9.1 Location and Features of the Plant Site
The proposed Distillery at GSML will be located at a distance of about

250 meters from the sugar plant complex, on its eastern side. The
land on which the distillery complex will be located belongs to GSML
and is presently being used as a farm land. However part of this farm
land is presently being converted as bagasse storage area with
conveyor interconnections, for carrying the bagasse from and to the
sugar mill. This farm land complex will house the distillery along with
the bulk bagasse storage yard and the distillery complex will be
located on the northern side of this farm area. The Drawing No. 0-
15003-600-0016 gives the overall plant layout for the complete sugar
and distillery complex and Drawing No.0-15003-600-0017 gives the
Unit Plot Plan for the Distillery Complex. The layout is made for the
complete distillery including the fermentation, distillation,
evaporation, Condensate and spent lees treatment system, spent wash
incineration based Cogeneration plant and the product storage (daily
and bulk). The distillery complex occupies and area of approximately
7.8 acres.
The following specific features of the site have been discussed in this
section of the report.
- Availability of adequate space for locating the Distillery and

associated plants and adequate space for the construction
activities.
- Suitability of the site from topographical and geological
considerations.
- Availability of rail and road connections for material
movements.
- Availability of adequate quantity of water for meeting the
plant’s water requirements.
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- Availability of adequate fuel and its transport.
- Availability of Raw materials.
- Ecological Impact.
9.1.1 Space Availability
Adequate land is available within the identified area premises for

locating the Complete Distillery including all the sections like the
Fermentation, Distillation, Evaporation, Condensate treatment,
Product Storage etc. The Distillery is an independent plant and could
be located anywhere as long as adequate space is available for the
installation of all the sections. However the whole lot of logistics have
to be developed for accommodating the plant with all the associated
plants. There are definite advantages in locating the plant close to or
within the sugar mill considering the transportation and storage of
molasses, transportation and storage of fuel, arranging for water for
the plant operation, providing construction power and water etc. The
proposed distillery complex is just about 250 meters away from the
sugar mill and is very convenient for the interconnections for bagasse,
molasses, steam water and power. Even though the distillery will be
developed as a standalone unit the interconnections with the sugar
mill for power and steam always gives flexibility in the continuous
operation of the distillery complex.
The turbogenerator in the distillery would be paralleled with the

proposed 30 MW Cogeneration plant in the sugar mill. This will ensure
a backup power supply to the distillery in case of non-availability of
the distillery power plant for any reason. Also during the
commissioning of the distillery this will come in handy as
commissioning and stabilizing both the distillery and the spent wash
incineration based power plant at the same time will pose some
interruptions during the commissioning and running in.
Considering the various advantages as discussed above, it has been

decided to locate the Distillery on the eastern side of the existing
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sugar plant, in the location identified in the overall layout. The main
plant consisting of the Distillation Section, Fermentation section and
the product storage Section will be located on the western side of
the distillery complex. The 2.2 MW Cogeneration power plant and the
spent wash incineration boiler will be located on the southern side of
the distillery complex. The boiler will be laid out with its axis in the
east west direction. The building housing the 2.2 MW TG will be
located on the eastern side of the spent wash fired boiler. The raw
water storage tank, WTP, effluent treatment and polishing plant and
the spent wash lagoons will be located on the eastern and north
eastern side of the complex.
9.1.2 Topographical and Geological Aspects
The proposed distillery complex is a plain area used as the cane farm
of the sugar mill. Filling will be required to raise the ground level for
locating the plants.
The soil is good and the Soil bearing capacity is around 12 Metric
Tonnes per Sq.M at a depth of two (2) meter into the virgin soil. Piling
will be required for most of the equipment foundations and building
column foundations.
9.1.3 Rail and Road Facilities
The nearest railway station is the Town of Lakhimpur-Kheri. All plant

and machinery can be transported only by road. Approach road near
the proposed area needs to be made for bringing in the equipment.
9.1.4 Water Availability
Distillery plants are water intensive. The water required for the
distillery also varies in quality requirements for different applications.
Process water that is required for molasses dilution should be
bacteria free and a higher TDS in the water is not a problem. The
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cooling tower make up water need to be at least filtered and treated
to bring the TDS to some acceptable level. The DM water is required
for Extractive Distillation and for boiler make up. GSML’s distillery is
being designed as a “Zero Effluent Discharge” plant and some of the
aqueous effluents will be treated and used as process water or cooling
tower make up water. Nevertheless there will still be requirements
for a large quantity of water from the raw water source. It is
proposed to get this water from the bore wells to be located within
the distillery complex. There could be interconnections between the
sugar mill bore wells and the distillery complex bore wells so as to
ensure continuous availability of the raw water and also to make use of
the bore wells effectively.
9.1.5 Availability of Fuel
As the proposed Distillery will be having its own Cogeneration plant,

there is no need for any steam supply from external sources.
However, interconnection arrangement is provided between the
existing sugar mill’s cogeneration plant and the distillery for any
emergency situation. The new technology of spent wash concentration
and incineration is adopted in the plant design and hence part of the
fuel requirements for steam generation will be met from the
concentrated spent wash generated within the distillery. As the
concentrated spent wash cannot meet the full steam generation, the
plant needs a supplementary fuel in the form of bio-mass or coal. For
the GSML’s distillery it is proposed to use the in-house generated
bagasse as the supplementary fuel. The bagasse requirement will be
about 5 MT per hour for the normal operation of the plant, with the
availability of 60% w/w concentrated spent wash. The bagasse will be
stored on the southern side of the distillery complex and will be fed
to the boiler through a system of conveyors.
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9.1.6 Availability of Raw Material
The raw material for the distillery operation is, mostly the molasses
generated in GSML’s sugar mill. However the plant will be designed to
operate with bought out molasses also in case GSML is able to procure
molasses at a reasonable price. For the purpose of this Detailed
Project Report it is assumed that GSML will be able to procure about
15,000 MT of molasses per annum from nearby sugar mills.
9.1.7 Ecological Impact
A molasses based Distillery is considered as highly polluting. However

the GSML’s Distillery is designed as “Zero Liquid effluent Discharge”
plant and hence no pollutant is let out. On account of this there is no
impact on the ecology consequent to the implementation of the
distillery.
9.2 Distillery Plant Layout
9.2.1 As seen elsewhere, the layout enclosed to this report gives the
location of all the sections of the distillery. The proposed Distillery
Plant will be located on the eastern side of the sugar plant complex at
a distance of about 250 metres. The Main plant consisting of the
fermentation section, Distillation section and the product storage
section is located on the western side of the complex. The
fermentation section, distillation section and the product storage
section are arranged in a row in the North-South direction with the
fermentation section on the southern side and the product storage
section on the northern side. of the Spent was incineration boiler and
the 2.2 MW Cogeneration plant. The product storage section will
include all the daily receiver tanks and bulk storage tanks. The new
molasses storage tank will be located west of the proposed
fermentation section and the incineration boiler. The cooling towers
are located east of the distillation section and the product storage
tank farm. The water treatment plant and the condensate and spent
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lees treatment plant are all located east of the product storage tank
farm and the distillation section.
9.2.2 Another important plant in the distillery is the spent wash

concentration plant. This plant is basically a multiple effect
evaporation plant to evaporate the water in the spent wash so as to
concentrate the spent wash to a final solids content of 60% w/w. It
receives the raw spent was from the lagoons and sends the
concentrated spent wash to the boiler for incineration. This plant will
be located near the boiler, on the northern side of the boiler. Locating
the plant close to the boiler ensures that the concentrated spent
wash is piped only for a short distance. The complete concentration
plant with all the evaporator bodies, pumps, condenser, vacuum pumps
concentrated spent wash storage tank are all located in the same area.
9.2.3 Another major section of the Distillery is the spent wash incineration
boiler and the turbogenerator which provide the required process
steam and the power for the operation of the distillery. As seen
elsewhere in this report, the boiler will be firing concentrated spent
wash and bagasse for the generation of steam required for the
operation. The evaporation section mentioned earlier will concentrate
the spent wash to 60% w/w solids and supply to the boiler for
combustion. It is proposed to have a 100 Cu.m capacity concentrated
spent wash storage tank near the boiler from where the spent wash
will be pumped to the spray guns in the boiler. The boiler, which will be
of 20 TPH MCR capacity and will be located on the southern side of
the distillery complex. The TG house to accommodate the 2.2 MW back
pressure TG will also be located in the same area east of the proposed
new boiler. All the electrical and instrumentation systems related to
the power generation and distribution to the distillery will be located
within the TG building.
The boiler Drawing No.1-15003-800-0008 gives the general

arrangement of the boiler. It may be seen that for the MCR capacity
of 20 TPH, the boiler is quite big. This is mainly because of the spent
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wash firing which puts restriction on the gas temperature entering
the superheater of the boiler. The boiler will be provided with only an
economizer and air heater is not provided mainly from the point of
view of low temperature corrosion. Bag filter will be used for dust
separation from the flue gases and the same is located between the
boiler economizer sections and the ID fans. The boiler will be
provided with a new RCC chimney of 55 m height.
An ash silo will be located in the area of the new boiler chimney. All
the ash from the discharge points shall be stored in this silo for
disposal to the fields as fertilizer.
9.2.4 The most important section of the distillery which is the product
storage is located separately from the main distillation plant. The
location of the product storage is also decided based on the
requirement of easy accessibility for the excise authorities. Adequate
approach roads shall be provided. The product storage will have the
daily receiver tanks and the bulk storage tanks for industrial alcohol,
Extra Neutral Alcohol, Anhydrous Alcohol and Technical Alcohol.
There will also be a small bulk storage tank for the Fusel oil. The
product from the distillation section will be pumped to the daily
receiver tanks. Each of the daily receiver are designed to
accommodate the production made in a day. Once the daily receiver
tank is filled at the end of the day and after inspection by the excise
authorities, the product will be pumped to the bulk storage. All the
pumps required for pumping the product to the bulk storage tank and
for the final issue to the tankers will be located in the same area.
This product storage area will be fenced and the daily receiver tank
area will be kept in a lockable space.
9.2.5 Three raw spent wash lagoons of RCC construction and will be
provided east of the east of the distillation section and the product
storage section. These lagoons will also act as settling tanks for the
raw spent wash received from the distillation section. In case of
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cleaning of the evaporator bodies the spent wash could be temporarily
stored in this tank.
9.2.6 Another important point to be considered in finalizing the layout is

that the Distillery plant construction activities pose minimum
disturbance for the operation of the sugar plant. This is very
important in an operating sugar plant as the distillery construction and
the sugar mill operation may for some time go simultaneously. By
locating the Distillery plant in the identified area, which is at a
distance from the sugar mill complex, this point is adequately taken
care off.
9.2.7 Adequate construction space is available for the storage of materials

of the various contractors and for them to carry out pre-fabrication
work. Specific areas to be identified at the time of start of the site
activities.
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10.0 OPERATION AND MAINTENANCE REQUIREMENTS
10.1 General
10.1.1 This section of the report outlines the operation and maintenance
philosophy to be adopted for the new 60 KLPD distillery with spent
wash fired boiler and a 2.2 MW TG. These broad outlines given
here will provide useful guidelines for the basic and detailed
engineering of the plant, so that all the requirements of the
operation and maintenance of the Distillery plant are met and
provided for in the engineering stage itself.
10.1.2 The production of alcohol from molasses involves the interaction of

several major sections of the distillery. The fermentation section
supplies the fermented wash at the appropriate concentration of
alcohol to the distillation section for further processing into RS or
ENA or AA. The MSDH section purifies the RS to absolute alcohol
(AA) through molecular sieve dehydration system. The
independent evaporation section of the distillery concentrates the
spent wash to a level of solids concentration of 60% w/w. The
spent wash fired boiler and turbo generator supply the steam and
power requirement of the distillery for the various conditions of
operation. The 2.2 MW TG will operate in parallel with the new 30
MW TG in the sugar mill’s Cogeneration plant. The incoming
molasses and the product should be measured and stored
appropriately for further distribution. The water treatment plant
supplies the DM water required for the process and for the power
plant. Different cooling towers circulate cooling water for
maintaining appropriate temperature of the process fluids in the
various sections of the distillery.
10.2 System Design Philosophy
10.2.1 The main O&M objective is the high availability and reliability of
the plant. In order to achieve the main objective, the following
principles would be adopted.
 Optimum margins on the operating parameters of all

important equipment and auxiliaries and systems to ensure
operation of the plant at rated capacity under all modes of
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operation.
 Providing redundant and standby capacity for all critical

equipment.
 Use of Equipment and systems with proven design,

performance and have a high availability track record under
similar service conditions.
 Selection of the equipment and adoption of a plant layout to

ensure ease of maintenance.
 Strict compliance with the approved and proven quality

assurance norms and procedures during the different phases
of the project.
10.2.2 The basic and detailed engineering of the plant will aim at achieving
high standards of operational performance especially with respect
to the following key parameters.
 Optimum efficiency of the equipment.

 Low Auxiliary power consumption.
 Low make up water consumption.
 Low process steam consumption
 No effluent discharge (Zero Liquid effluent discharge)
10.2.3 The plant Instrumentation and control system should be designed

to ensure high availability and reliability of the plant to assist the
operators in the safe and efficient operation of the plant. It
should also provide for the analysis of the historical data and help
the plant maintenance engineers to take up the plant and equipment
on preventive maintenance.
10.3 Operation Requirements
10.3.1 The operation of the plant starts with the Commissioning of the
various sections of the distillery and the spent wash fired boiler.
In broad terms commissioning can be defined as setting up of the
plant to work safely and on program. It is necessary to ensure that
all equipment is completely erected before operations begin.
Although this may be considered difficult, the other extreme of
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operating a plant with insufficient instrumentation, controls and

alarms is very dangerous. Although some compromise can be made
with regard to plant completion, the commissioning procedures
should never compromise personnel and the system safety.
10.3.2 A proper checklist must be drawn up, which shall include all the
sections of the plant and shall take into account, the contractual
responsibilities, the technological relationship between the various
sections, pre-commissioning, cleaning requirements, etc. The
checklists procedure helps in the following:
a) To ensure that the necessary checks are carried out on each

item of the plant before it is put into commercial service.
b) To indicate a contractor's commissioning requirements from
the client or from other contractors.
c) To ensure that energy is supplied to equipment or a plant
when it is safe to do so.
d) To facilitate the recording of the progress on the various
commissioning activities.
e) To provide a basis for the plant history.
10.3.3 The Operation of the multi product distillery is an activity that

must be co-ordinated well with the factory management and
marketing section of the factory to decide on the product mix of
the distillery. In addition the raw material input quality and
product quality shall be recorded and ensured at all times of
operation of the distillery.
10.3.4 The operation of a multi product distillery demands closely

controlled operating conditions. The unit start-ups, shut-downs
and even emergency shut downs must strictly follow the carefully
laid down procedures given in the operational Manuals. Generally,
the plant shall be sufficiently instrumented to permit close checks
on such operating parameters of the various columns in the
distillation section and the various parameters in the fermentation
section.
10.3.5 An important feature of the modern DCS system for the distillery
plant is the automatic safety lock-out devices. While sufficient
thought goes into it at the design stage, it remains the
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responsibility of the operating staff to ensure that the safety

devices are set correctly and kept in operation.
While safety of the plant and personnel is the foremost

importance in the operation, the efficient operation of the plant
cannot be ignored. While operating, it is important to check the
essential parameters of the plant and equipment to ensure that the
plant performance is at the optimum level. Any variations in the
operating parameters or any deviations from normal performance
of the equipment or plant shall have to be analysed immediately to
diagnose the problem and to take remedial measures to bring back
the plant and equipment to its original parameters.
10.4 Distillery Operation
The detailed treatise on the operation of the distillery is

beyond the scope of this report. However, the important areas
are highlighted.
10.4.1 The factory should have a good quality control programme to

establish product specifications, develop and implement sampling &
testing methods and recording/ reporting of results. Quality
checks must be in place to maintain consistent quality of the raw
materials to reduce the chances of down stream processing
problems stemming from the use of sub standard materials.
10.4.2 Effective testing and monitoring of fermenters is important to

maintain fermentation efficiency and finished product quality. The
fermentation section plays a major role in ensuring the efficient
operation of the distillery. The specific gravity of mash, pH,
Acidity, temperature, bacterial level, yeast count, concentration of
alcohol has to be closely monitored to ensure the quality of down
stream products. Low pH in the fermenter usually suggests a
thriving population of bacteria, which, if left unchecked can disrupt
both enzyme activity and yeast growth. Proper control of process
temperature in fermentation section is very important for
maintaining performance and quality. Proper control of microbial
activities in the fermenters is essential to maximising the
efficiency of alcohol production and in maintaining the quality of
distillate.
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10.4.3 Continuous checks on the quality of molasses to assess its grade,

total sugars, FS etc., laboratory test for fermentation
characteristics and alcohol yield potential are important. The
quality of water used for dilution of molasses should be good with
out any bacterial contamination. Good scrubbing of CO2 from
fermenter outlet is necessary to arrest escape of alcoholic
vapours. Wash feed rate into distillation column and product
outflow rate should be monitored continuously. Precise control of
multiple effect evaporation system in the distillation area and
spentwash concentration area ensures steam economy and
optimisation of the auxiliary fuel consumption.
10.4.4 A properly implemented sanitation programme is essential for the

distillery operation. This should cover establishment of physical,
chemical and bacteriological cleanliness standards covering all
areas of production, house keeping, process and maintenance
equipment cleanliness etc.,
10.4.5 Effluent generation should be controlled and proper usage of spent

wash recycling, if used, condensate polishing etc., reduce the total
water requirement for the distillery complex.
10.4.6 Ensuring good quality of water assumes greater importance for the
distillery and the co-generation plant. Maintenance of water
quality shall be ensured for both feed water and boiler water
within limits for proper operation of the boiler and avoiding scale
or deposit formation in turbogenerators. A routine check-up of
the feed water quality during the start-up of the plant and also
periodic check-ups result in the elimination of any serious problem
due to the water quality. Similarly, the monitoring of water
treatment plant and the water quality at DM plant outlet, the
water quality at the inlet of the DM plant and cooling tower is of
utmost importance.
10.4.7 The modern multi product distillery like the one envisaged for
GSML cannot be effectively operated without proper
instrumentation and control system. An effectively designed
instrumentation and control system performs the following
functions:
 Provides operators with the indication or record of the
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instantaneous, averaged or integrated value or condition of

the various operating parameters such as temperatures,
pressures, flows, levels, position of valves, switches,
currents, voltages, power, etc.
 It also provides at convenient locations either local, remote

or automatic control system to control the above operating
parameters and gives alarms and even ensures automatic trip
outs, when operating parameters reach beyond the normal
range to the unsafe or undesirable range.
Instrumentation is increasingly taking over many functions of the

operator. Its response to changing and transient conditions, its
ability to anticipate, detect and discriminate faulty conditions and
act accordingly is quicker and for more accurate if well designed.
With the ability of the microprocessor based systems to include
data acquisition and processing capabilities, the systems' ability, to
log and process periodically the plant data, is also far superior
and permits more timely corrective actions. Presently some of the
responsibilities of the operation section are taken over by good
instrumentation. The most difficult thing to be encountered in the
initial stages of plant operation is the necessity to develop in the
operation staff a faith in the instrumentation. Many times the
operators' first response to a meter reading too high or too low is
to disbelieve it on the ground that it may be reading incorrectly. If
instruments are not checked and calibrated frequently an operator
will delay taking corrective actions.
The plant operator should follow the guidelines given below:
 Frequent checking and calibration of instruments

 Developing a habit of cross checking instrument indications
with each other to determine whether the instrument is
faulty or there is an abnormal operating condition; and
 Developing a habit of analysing indicated data to determine
accurately what could be wrong.
10.4.8 The distillery co-generation power plant has to operate in parallel

with the sugar mill’s co-generation plant. Co-ordination between
the two plants regarding power supply should be ensured by the
distillery plant operation.
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10.5 Maintenance Requirements
10.5.1 The main objectives of the maintenance section are to keep the
plant running reliably and efficiently as long as possible. Reliability
is impaired when a plant is thrown to forced and unforeseen
outages. This aspect assumes greater significance in the distillery,
since the profitability of the distillery entirely depends on the
product output and the quality of the product.
10.5.2 Efficient operation implies close control not only over the cost of
production but also over the cost of maintenance. There are two
components in maintenance cost, one is the direct cost of
maintenance i.e., the material and labour and the other is the cost
of production loss.
10.5.3 There are two categories of maintenance work. One is the irksome
breakdown maintenance, which is expensive. Much as it is desirable
to avoid or minimize this, its existence must be accepted. Secondly,
it is the preventive maintenance with proper planning and execution
of plant and equipment overhauls. This maintenance activity should
be clearly planned with regard to the availability of material and
labour. It is also essential to develop proper inspection procedures
with non-destructive testing methods. Such inspections, by trained
personnel reveal defects not necessarily detected by mere visual
inspection.
10.5.4 The following help in reducing the breakdown maintenance and also
help in planning for preventive maintenance.
 Careful logging of operation data/historical information from

the DCS and periodically processing it to determine abnormal
or slowly deteriorating conditions. Walk down checks of the
plant.
 Careful control and supervision of operating conditions.

Careful control of the raw material and products to ensure
quality output.
 Regulate routine maintenance work such as keeping

equipment clean, cleaning heat exchangers, filters,
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effectively executed lubrication program, effective

operating supervision over bearings, commutator or slip ring
brushes, mechanical seals, vacuum systems etc.
 Correct operating procedures.
 Frequent testing of plant equipment to determine internal

condition of equipment such as heat exchanger and pump
performance tests, generator and turbine shaft vibration
tests, turbine lube oil testing, etc.
 Close coordination with the manufacturers to effect

improvements in plant layouts and design, use of better
material, introduction of such facilities as cathodic
protection, use of better protective paints, etc.
10.5.5 It is extremely important that proper records are maintained not

merely for the maintenance work done but also of the material
used and actual man hours spent, etc. Some sort of a card system
shall have to be introduced to keep records that are most useful in
future planning of outages and providing for effective control.
10.5.6 Another important requirement of a good maintenance program is to

ensure that spares are ordered in time and good stocks of the
frequently required spares are maintained.
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11. MANPOWER AND TRAINING
11.1 General
11.1.1 Growth of industrial activity in the country in general and in particular

the growth in the sugar, distillery and power generation industry, has
brought about shortage of skilled and trained manpower. Hence, it is
essential that the manpower requirement for the new distillery plant
is well planned and a proper program of recruitment and training is
thought of at the beginning stage of the project itself. The Plant,
operating and maintenance personnel must be trained and available
before the plant commissioning commences and therefore, it is
essential that appointments are made well before the programmed
plant commissioning date. The staffing and the organizational
structure should be decided considering the specific requirements of
the plant operation and the company practices.
11.1.2 The recruitment of the personnel required must be based on the

rational assessment of the following factors:
a) The nature of the plant and machinery i.e modern distillery with
multi product system, evaporation system, spent wash fired
boiler, in house power generation and distribution etc.,
b) Socio economic conditions.
c) Availability of personnel with the right back ground and
experience.
d) Company's policy regarding recruiting permanent labour and
contract labour.
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11.1.3 Once the staffing is finalized and agreed, a suitable training scheme
shall be programmed and implemented. The objective of the training
program must be to equip each and every individual to carry out his
particular function with skill and confidence. The training program
shall be based on the classification of the main functions as Operation
and Maintenance, and within this main classification, designed to cater
to engineers, supervisors, skilled workers, etc.
11.2 The organisation proposed for GSML’s 60 KLPD Distillery assumes

that the distillery will have a Manager in charge of complete distillery
operations, who will be assisted by the Senior Engineers in charge of
process operation, Maintenance, Utilities, Procurement and
administration. The Distillery Plant Manager will be reporting to the
Factory Manager.
The staffing recommended here takes care of the operation,

maintenance, procurement, administration and record keeping for the
entire plant. There could be some overlapping of functions between
the staff of various sections; however the responsibility of each
group will be well defined. The drawing No.4-15003-800-0012 gives
the organization chart proposed for this project.
11.3 The Senior Engineer process operation will be responsible for the
various sections of the process plant operation for the three shifts,
including the spent wash concentration system. The Distillery plant
laboratory will be under the control of the Senior Engineer – process
Operation. The Senior Engineer Utilities operation will be responsible
for the operation of boiler & auxiliaries, water treatment plant, fuel
systems, Turbo generator, cooling tower, compressed air system etc.
Since the plant is having good amount of instrumentation, it is
necessary to have one Instrumentation Supervisor, common for both
process area and utility area, for each shift for the operation.
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11.4 The Senior Engineer – process Operation will have the following
persons assisting him for each shift operation.
 Supervisor - Instrumentation (1)

 Plant Operators - Fermentation Area (2)
 Plant Operators – Distillation and Evaporation area (1)
 Laboratory & ETP – Chemist - (1 )
11.5 The Senior Engineer – Utilities Operation will have the following
persons assisting for each shift operation.
 Boiler Operator - (1)

 TG and Electrical Supervisor – (1)
 Auxiliary system Operator – (2)
11.6 The Senior Engineer – Sales & Procurement will take care of the
procurement of Molasses, Chemicals, Product despatch, procurement
of fuel, procurement of spares etc. In addition he will be responsible
for co-ordinating with Excise authorities, plant stores and also
transportation of goods. He will be assisted with the following persons
in the general shift. Contract labour will be utilized for loading,
unloading operations of the materials coming into the plant and going
out the plant.
 Store Keeper
 Loading Operator
11.7 The Distillery plant will have a separate Senior Engineer to take care
of the maintenance of the plant. However, the facilities of workshop,
electrical repair shop, instruments, tools, etc. could be common
between sugar plant maintenance and distillery plant maintenance
group. The Senior Engineer / maintenance will be assisted by the
following persons for all the three shifts.
 Mechanical Technician (2)

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 Electrical Technician (2)

 Instrumentation Technician (2)
11.8 The Quality Control and effluent monitoring cell is an important

section, which serves both the operating and maintenance sections by
providing useful feed back to the operating staff and valuable
information to the maintenance staff on the performance and the
healthiness of the various equipment. The major responsibilities of
this cell are :
a) To collect the daily operating data from the DCS system in the
control room.
b) To analyze the daily plant performance data to detect

departures from normal expected performance and to keep
track of trends indicating gradual deterioration.
c) To establish from the design and plant acceptance test data, as

well as after-overhaul test data norms against which day-to-day
performance can be monitored.
d) To carry out frequent tests on the plant and individual

equipment to determine their internal conditions to help
maintenance scheduling.
e) To investigate special problems as and when they arise.
f) To monitor the quality of product and advice the process

section for adjusting parameters.
g) To monitor the effluents and advice the process section and

utilities section for achieving zero effluent discharge.
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The analysis and the data provided by the quality control and effluent
monitoring cell, enables plant operation and maintenance personnel to
take suitable corrective actions promptly and with proper priorities.
11.9 The documentation of the engineering office is in the charge of the

Senior Engineer - Quality control and effluent monitoring cell
reporting to the Distillery Plant Manager. He is responsible for
maintaining the master copies of all the technical documentation of
the process area and utilities area. The Senior Engineer in charge of
quality control and effluent monitoring cell will be assisted by One
Designer for the functioning of the section.
11.10 The distillery will have a full fledged plant laboratory for the process
and utility area. The plant laboratory will analyse the raw material,
products, water quality in addition to growth of culture etc. There
will be one Chemist for each shift, discharging the function in the
laboratory, reporting to the Senior Engineer – process Operation.
11.11 Few labour contractors could be registered with a Company for

meeting the surge load requirements of the operating and
maintenance group to handle major break down / maintenance work. In
addition to the above, sufficient number of contract labourers may be
required for assistance in ash disposal, fuel feeding, cleanliness
operation, loading and unloading etc.
11.12 The GSML’s main plant complex Administration Officer will take care
of the Administrative activities, Services, Accounts, Finance,
Personnel, Legal, Security, Statutory authority cooperation etc. For
the distillery, the proposed Organization does not consider a separate
functioning of administration section, since it will be taken care of by
the main factory. The service activities like Secretaries, Office
Assistants, Security, Driver etc could be on contract basis to be
administered by Administration Officer of the main factory.
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11.13 It is necessary that GSML identifies the Plant Manager for the
distillery at the start of the project itself so that he will be
associated with the project during the initial stages of finalisation of
the packages and the project execution by the Contractor. It is also
necessary that the Plant Manager is assisted by Two Mechanical and
One Electrical cum Instrumentation Engineer during the course of the
project execution so that these Engineers could assume Senior
Positions, later in the Distillery Operation. The other operating staff
should be recruited three months before the scheduled commissioning
of the distillery so that all the operating staff will be in position and
will be ready to assume charges right from the commissioning of the
project.
11.14 Training
11.14.1 The major objectives of the operational training shall be to

acquaint the operators of the following:
 The nature, purpose and limitations of all plant and equipment.

 The detailed operating instructions of each section and
equipment of the plant.
 Normal start up and shutdown program for the unit.
 The emergency procedures.
11.14.2 The basis for the training shall be the Plant’s operating and
Maintenance Manuals, which are compiled from the manufacturers'
instructions, the contract documents and the drawings. In addition,
the information gathered from the visits to the other operating
plants and to the manufacturers works shall also be included in the
training. Supervision and co-ordination of the training program
requires full time attention of a senior executive of the plant, and the
consultant's assistance may also be taken. The training program shall
include lectures, expositions by experienced plant operators and
maintenance personnel, informal discussions and visits to operating
plants and manufacturer's works. The training programme shall
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also include training provided by various vendors to the GSML’s

operating personnel, during erection and commissioning of the plant
and machinery of the distillery plant.
11.14.3 The maintenance training program should be based on the

requirements of the individual maintenance functions, like mechanical,
electrical, instrumentation etc. The engineers and the technicians
should be sent to the manufacturers’ works to witness the production
and be associated with the erection of the plant and machinery.
11.15 The plant should be equipped with proper measuring/testing

instruments for the periodic cross checking of parameters displayed
in the control room monitors and plant area local gauges. Logging of
data and periodic review of the plant operation, review of failures,
break downs, etc. should be done to improve the availability of the
plant. The proposed DCS based control system takes care of almost
all the above requirements.
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12.0 PROJECT IMPLEMENTATION AND SCHEDULE
12.1 General
12.1.1 The most essential aspect regarding the implementation of this “Zero
Liquid Effluent discharge” Distillery complex consisting of 60 KLPD
multi product distillery with 2.2 MW Co-generation power plant is to
ensure the project completion within the schedule, spanning for
Sixteen (16) months from the date of ordering of the main distillery
and the spent wash fired Boiler (1st December 2015) which are long
lead items for the project. While financial closure, permits and
statutory authority clearances are being processed, final tender
documents could be floated for Distillery and the spent wash fired
boiler after completing the basic design. The distillery project
could be commissioned by 1st April 2017.
12.1.2 With the final Detailed Project Report available by end June 2015,
GSML could initiate actions for the tying up of the finances for the
project. It is expected that the financial closure, permits &
statutory authority clearance could be obtained within a period of
four (4) Months from the date of completion of the Project report.
The basic design and the tender documents preparation for the long
lead items could start in August 2015 so that the ordering of the main
equipment could be done in December 2015. The layout of the plant
and machinery has been so chosen that the installation of the
equipment for the Distillery plant could be carried out in an
independent area near the sugar plant.
12.1.3 A good planning, scheduling and monitoring program are imperative to

complete the Distillery project along with 2.2 MW co-generation
power plant on time and without cost overruns.
12.2 Project Team
12.2.1 The successful and timely implementation of the project and the
avoidance of overspending and frustration depend on the performance
of the project team. This project team shall be formed within the
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company and will be assisted by the consultancy organisation. This

project team shall be directed by a Project Manager, who has
experience in the implementation of similar projects. The engineers
from this group should be involved from the early stages of the
execution of the project, right from the engineering and procurement
stages of the project. This would give them ample opportunity to
familiarize themselves with the equipment and the systems being
procured.
12.2.2 Subsequently, at the time of installation at site, these personnel

should be involved with the critical phases of installation and
commissioning. These engineers should also be trained at the
distillery plant & machinery manufacturer’s works and or at similar
plants operating elsewhere. After the plant has been commissioned,
these engineers would occupy key positions in the organizational
structure for the operation and maintenance of the plant. This
approach ensures a smooth transition from engineering and
procurement to erection and commissioning and finally to operation
and maintenance.
12.2.3 The responsibilities of this project team shall be;
a) Plan and program all the work and resources required for the
project completion.
b) Project engineering and co-ordination involving the Design of
the plant, plant support systems and the inter-package
engineering.
c) Co-ordination with various vendors and furnishing data at
terminal points.
d) Inspection of the major items and expediting.
e) Organize the construction and commissioning of the plant by
progressively integrating individual systems.
f) Monitor and control the project progress with regular
interactions and co-ordination.
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12.3 Contract Strategy
12.3.1 The first step to be taken in the execution of the project is the
constitution of an appropriate project organization, as discussed
above, which would be responsible for the execution of the project.
The development and the size of the project organization must be
based on the tasks that need to be performed in the project. For a
Distillery complex project the following are the identified important
phases. These phases are not mutually exclusive and some degree of
overlapping is envisaged.
 Appraisal of the Project Report by Financial Institution.

 Financial Closure
 Statutory authority clearances.
 Planning, marketing of the products and outlets.
 Procurement of Packages including Inspection and Expediting.
 Inter-package Engineering.
 Project management
 Construction Phase.
 Commissioning and performance testing.
12.3.2 The plant should form an effective Project management group within
their organization for the project execution involving the above
mentioned phases of the project. The consultancy organization shall
take care of the procurement, inter-package engineering, project
engineering and will technically assist the project team in the other
activities.
12.3.3 The nature of the project calls for the division of the project into
recognizably discrete plant areas with specific terminal points that
can stand alone for engineering and contract purposes. An appropriate
contract strategy involves, the decision on the number and the type
of contracts to be let, vendor evaluation, formulation of contract
agreement defining respective obligations, the basis for discharging
them and remedies for default.
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The major points to be considered in packaging are:
 The packages proposed are compatible, which ensures adequate

competition in bidding and consequent procurement at optimum
cost either within the country or from overseas vendors.
 The packages include such combination of equipment and

services that can be advantageously engineered for the
preparation of specifications for bidding and subsequent design
including manufacture/construction.
 The packages formed are mutually exclusive as well as

collectively exhaustive.
 The number of packages and their sizes are optimum for

effective implementation.
 The terminal points of each of the packages are clearly defined

and proper tie-ups of these points between the packages are
ensured.
12.3.4 The following gives the tentative list of contract packages for this
project. Each package is an EPC package, wherein, the responsibility
of engineering, procurement and construction is left to the vendor
with guarantees for each package clearly defined. The package
route also gives an advantage in choosing the vendor considering the
availability of after sale service, spare parts, factory preferences
and technical support from the vendor.
 Distillery process area with fermentation, distillation,

evaporation, electrical within the process plant area and
Product storage sections.
 Condensate & Spent Lees treatment and polishing.
 Spent wash fired boiler and auxiliaries
 2,2 MW co-generation TG with its auxiliaries
 Balance of plant mechanical system consisting of plant piping
system, product and daily storage tank for the distillery,
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distillery building structures, Air conditioning & ventilation

system, piping from boilers/TG to distillery process area, utility
piping up to distillery battery limit, fabrication of tanks for the
utilities, fire fighting system etc.
 Balance of plant electrical system consisting of transformers,
Electrical distribution, MCC, PCC, cables, lighting & installation
package
 DCS for the process and utilities and Balance Of Plant (BOP)
Instrumentation Package
 Civil works package
12.3.5 Preparation of the Tender Specifications, obtaining offers from

qualified bidders, technical and commercial evaluation of offers,
finalization of the vendor, formulation of the contract agreement,
contract reviews, vendor drawing review and approval etc. are the
major activities for each of the packages. The scope of the package
vendors will be the design and engineering, procurement,
manufacturing, inspection, testing, transportation to the site,
installation and commissioning & performance guarantee of the
respective packages.
12.3.6 The specifications for major equipment like the spent wash fired
boiler, turbogenerator, cooling towers, Distillery process area
equipment etc., technical information of which is essential to the
development of the plant design and in particular to the civil design,
shall be drawn up at an early stage of the project. Program of design
information submission from the mechanical and electrical contractors
that satisfies the overall project schedule shall be drawn up. The
most important among such information are the location of the
individual plants, floor loading, support requirements etc. which are
required for the civil design.
12.3.7 Since the project execution calls for closer coordination among
the contractors, consultants and the power plant, proper contract co-
ordination and monitoring procedures shall be formulated. Detailed
bar charts or networks shall be made to plan and monitor the project
progress. Contract drawings and documents requiring approval from
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statutory authorities shall be clearly identified and scheduled so that

the procedural formalities do not affect the project progress.
12.3.8 Procurement
12.3.8.1 Procurement is an important function in the implementation of the

Project. The procurement of the systems equipment and services will
be through a series of suitably packaged contracts as outlined earlier.
The Project team with the consultants floats the enquiries with the
appropriate commercial conditions, delivery requirements, guarantees
etc. to renowned suppliers. The technical specifications for the
procurement of the equipment and systems will be provided by the
consultants.
12.3.8.2 Evaluation of the offers is done by the consultants, with

coordination form other related members of the project team, based
on the evaluation criteria stipulated in the tender documents. After
evaluation and taking a decision on placement of the order, the
contract agreement with commercial terms and conditions, delivery
schedule and guarantees etc. are drafted and purchase order placed
on the selected bidder. Once the purchase order is placed, the
project team follows up regularly to ensure smooth and timely
execution of the contract and for obtaining technical information for
the inter-package engineering. The procurement activity includes the
review of the vendor drawings by the consultant/project team,
expediting, stage and final pre-delivery inspection, supervision of
installation and commissioning.
12.3.8.3 When the contract for the packages are awarded, detailed program
in the form of network are tied up with the contractor to clearly
indicate the Owner’s obligations and the supplier’s responsibilities.
The factory inputs are in terms of land availability, construction
power and water availability, civil fronts, etc. while that of the
contractors are in terms of drawing submission, manufacture, supply,
transportation, erection and commissioning. The progress for each
work package against the schedules drawn up is evaluated regularly.
Such evaluation indicates the causes for the delay, if any, in meeting
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the schedules and identifies actions to be taken for rectifying the

delays.
12.3.8.4 To expedite supplies from the contractors, regular visits to the

supplier’s works will have to undertaken by the project
engineers/consultants. The manufacturing program and the quality
plans finalized at the time of contract award are utilized by the
engineers for the monitoring of the manufacturing and quality status.
Regular reports shall be prepared indicating the schedule variations, if
any, their likely impact on the delivery schedule and the
recommendations to meet with the schedules.
12.3.9 The Construction Phase
12.3.9.1 This is the critical phase of the project where work progresses in
almost all the fronts. The erection and commissioning phase of all
the contracts proceed simultaneously and it is important to ensure
that the various contractors have adequate facilities and are
established on the site in time to meet their programmed
commitments. Adequate power and water shall be made available for
the construction.
12.3.9.2 The construction manager from the Distillery plant side takes the
overall responsibility of the site, assisted by the resident engineer
from the consultant's side. The construction team's key task is to
continuously monitor the site progress against the agreed program and
to initiate whatever corrective action is necessary to maintain
satisfactory site progress. During the execution stage of the project
at site, quite a few of the various contracts progressing
simultaneously are interrelated and hence, the delay in the activities
of one contractor will invariably affect the progress of the other
contractors and ultimately the project progress.
This aspect emphasizes the importance of progress review, project

monitoring and timely remedial measures, for the smooth and `within
the budget' execution of the project.
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12.3.9.3 Certain basic responsibilities of the construction management are:
a) The contractors shall be encouraged to give the earliest

possible warning of actual or potential difficulties.
b) Ensure that the senior management in the contractors'
organisation are made aware of the serious problems at an early
date.
c) Provide a focus for early discussion of any potential problem
and possible remedial measures, while clearly maintaining the
contractor's responsibility for recovering delays.
d) Help to foster a climate among all concerned that no extension
of site deliveries and erection schedule are allowable.
12.3.9.4 A fortnightly progress review meeting will be held with each

contractor, where formal reports are tabled, giving an agreed
progress statement. From these agreed progress statements, an
accurate prediction of the state of the project is available which
helps the construction team to adjust, if necessary, the activities of
the particular contractor and also the activities of any affected
contractor.
12.3.9.5 Major problems such as non-availability of drawings, clarifications,

documents from various disciplines of engineering group, non-receipt
of required materials from the various contractors, reasons for the
default, remedial measures initiated, impact of such delays on the
project progress will be taken up and resolved in the progress review
meetings.
12.3.9.6 Interface problems among engineering, contracts and site groups of

the Owner/Consultant and between the factory and the contractors
affecting the project progress will also be reviewed and appropriate
decisions taken to expedite the release of drawings, materials and
such other requirements.
12.3.10 Plant Commissioning
12.3.10.1 The commissioning phase in a project is the one where the design,
manufacturing, erection and quality assurance expertise are put to
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test. The commissioning team for each plant will consist of

representatives from the contractor, consultant and the power plant.
As discussed earlier, it is essential to associate the staff identified
to operate the plant in the commissioning stage itself.
12.3.10.2When construction work is complete, the checklists, designed to

ensure that the plant has been properly installed and appropriate
safety measures have been taken are gone through and all the
documentation pertaining to the statutory inspections and approvals
are presented, the commissioning team shall take over. The
commissioning team will follow scrupulously the commissioning and
operating instructions laid down by the plant & equipment
manufacturer/supplier, to prove that the plant/equipment is in every
respect, fit for service. The plant shall be subjected to a
performance test, after the stipulated trial operation and the
reliability run. After the successful completion of the performance
test the plant will be taken over by the power plant.
12.4 The Responsibilities of the Factory
12.4.1 Since the Distillery project is coming up adjacent to the sugar plant,
it is important that the area identified for the Distillery plant is
cleared for the early start of the civil work. The soil investigation and
site grading shall be taken up in the very beginning so that the civil
work can proceed without any hindrance. The site development shall
include the levelling of site, clearing the site for construction of the
Distillery process section buildings, identifying or constructing
adequate storage space, providing lighting, water connection,
construction power in the work area, etc.
12.4.2 It is essential that before the Zero Date of the project all the
clearances from Government & statutory authorities are obtained. It
is also essential that uninterrupted fund flow is ensured for the
successful execution of the project on schedule.
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12.5 Project Schedule
12.5.1 The Fig-12.1 gives the overall project schedule in the form of a bar
chart. This schedule envisages the project commissioning and
synchronization in Sixteen (16) months from the date of ordering of
the Spent wash fired boiler and the distillery process plant.
12.5.2 For the major packages, the schedule includes the following applicable
activities. The time period requirement for these activities has been
included in the periods shown against each package.
a) Basic Study
b) Tendering
c) Receipt of offers, evaluation, discussions and Purchase order
placement.
d) Manufacturing and delivery
e) Erection and other work at site
f) Commissioning, trial run and testing
12.5.3 In the Distillery plant and the Spent wash fired boiler are the long
lead items and the planning of the schedule for the project
implementation should provide adequate time period for the
installation of these equipment.
12.5.4 Once the project gets started, it is essential that a more detailed bar
or network chart is prepared incorporating all the contract activities,
so that the planning and the monitoring is effectively carried out.
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10
AVANT-GARDE
Engineers and Consultants (P) Ltd
GOBIND SUGAR MILLS LIMITED FIG : 12.1
PROJECT SCHEDULE FOR MOLASSES BASED 60 KLPD DISTILLERY WITH

SPENT WASH INCINERATION
ID Task Name Duration Start 2016 2017
Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun
1 MOLASSES BASED 60 KLPD DISTILLERY WITH SPENT WAST INCINERATION 488 days Dec 1 '15 Dec 1 '15 Apr 1 '17
2 Distillery Package 436 days Dec 1 '15 Dec 1 '15 Feb 8 '17
3 Bid Release & Offer Evaluation 45 days Dec 1 '15
4 Ordering of Distillery Package 0 days Jan 21 '16 Jan 21 '16
5 Manufacturing , Supply , Erection & Pre Commissioning 370 days Feb 5 '16
6 Boiler and Auxiliaries 436 days Dec 1 '15 Dec 1 '15 Feb 8 '17
7 Bid Release & Offer Evaluation 45 days Dec 1 '15
8 Ordering of Boiler and Auxiliaries 0 days Jan 21 '16 Jan 21 '16
9 Manufacturing , Supply , Erection & Pre Commissioning 370 days Feb 5 '16
10 TG and Auxiliaries 385 days Jan 22 '16 Jan 22 '16 Feb 9 '17
11 Bid Release & Offer Evaluation 45 days Jan 22 '16
12 Ordering of TG and Auxiliaries 0 days Mar 13 '16 Mar 13 '16
13 Manufacturing , Supply , Erection & Pre Commissioning 310 days Mar 28 '16
14 Rolling of Turbogenerator 0 days Feb 9 '17 Feb 9 '17
15 BOP Mechanical 310 days Apr 13 '16
16 BOP Electrical 270 days Jun 2 '16
17 BOP Instrumentation 240 days Jul 10 '16
18 Civil Works & Chimney 330 days Feb 19 '16
19 Plant Testing & Commissioning 24 days Mar 7 '17
20 Synchronisation 0 days Apr 1 '17 Apr 1 '17
Task Milestone Project Summary

Project : GOBIND SUGARS
Progress Summary
13.0 PROJECT COST ESTIMATE
13.1 Methodology of Cost Estimate
This section of the Detailed Project Report gives the project cost
estimate for the proposed 60 KLPD multi product distillery with spent
wash concentration and incineration boiler system and a 2.2 MW
Cogeneration power plant at GSML’s proposed distillery plant. This
section also gives the financial analysis based on the cost estimate and
expected revenues from the distillery operations. The distillery and
the utilities will be located as discussed in the earlier sections of this
report. The project will be executed through the package route
and not through the EPC route. The cost estimates are based on the
recently finalized orders for similar plant and equipment and from the
data bank of Avant-Garde.
The costs indicated in this section include all taxes and duties and
erection and commissioning.
Tables 13.1 and 13.2 give the estimate of the project cost. The Table
13.1 cover all the works costs for the project. Table 13.2 gives the
total project cost inclusive of the pre-operative cost, interest during
construction and the working capital margin.
The works costs are divided into civil, mechanical and electrical. All
the commissioning spares required for the commissioning of the
project are included in the cost. However as the two year
operational spares are not capital items, they have not been
included in the cost estimate. The cost of the two year operational
spares will be approximately 2% of the equipment costs.
13.2 Cost of Civil Works
The cost of civil works include the cost of survey and soil
investigation, cost of all the plant buildings, equipment foundations,
pipe rack and conveyor foundations, cooling tower, RCC chimney for
the spent wash fired boiler and its foundation and drains and
trenches. The civil cost also includes the approach road to the
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- ETAILED PROJECT REPORT
D 13.1 AVANT-GARDE
distillery plant equipment. Considering the topography of the proposed
site, cost of site grading and levelling is included in the civil works
cost.
Piling has been envisaged for critical and major foundations and the
rest of the foundations are designed with footings. Separate Raw
water reservoir for the storage of the plant’s requirement of the raw
water is envisaged for the distillery. The water for the distillery will
be drawn from the deep bore wells, the source from which water is
drawn for the existing sugar mill operations and stored in the raw
water storage tank.
The civil works cost does not include the cost of land for locating the
complete distillery plant as adequate land is available near the sugar
factory premises and is already identified for the location of the
multi product distillery complex. The civil cost does not consider any
non-plant buildings like a new administration office, temporary site
offices and staff quarters, temporary stores, vehicle parking sheds,
etc. No separate workshop or stores is considered in the project cost
as the existing facilities of the sugar mill will be used for the
distillery plant also. However, a separate laboratory has been
considered for the distillery.
The civil work quantities and the cost of civil works given are only
estimates and will have to be suitably modified and firmed up after
the equipment supply is finalized and adequate data regarding the
loading and dimensions of equipment are available from the
manufacturers and suppliers during the engineering stage, and also on
the actual soil conditions encountered at different stages of
construction.
The Cost of civil works is estimated to be Rs.1463.40 Lakhs.
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D 13.2 AVANT-GARDE
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13.3 Cost of Mechanical and Electrical works
The cost of the mechanical equipment include the process sections of

distillery, spent wash concentration plant, cooling towers and cooling
water system, spent wash fired steam generator & back pressure
turbogenerator, electrical panels, plant lighting, earthing, laboratory
equipment etc. The distillery process plant, spent wash concentration
plant, spent wash fired boiler and turbogenerator are the major ones
in the project and have substantial influence on the cost of the
project. The costs for the above are based on the recently finalized
orders for similar equipment.
The distillery plant cost includes the cost for fermentation section,
distillation section, spent wash concentration section and storage of
the product and raw material. The distillery can produce RS, ENA and
AA in any percentage mix depending on the market demand. The
impure spirit or Technical Alcohol and fusel oil will be the by
products. The CO2 generated in the fermentation section could be
utilised by installing a bottling plant consisting of cleaning and drying
system for the Carbon-di-Oxide gas emanating from the fomenters.
This carbon-di-oxide has a variety of uses in the food & beverage
industry, welding and pharmaceutical industries etc. However, this
report does not include the addition of the Carbon-Di-Oxide plant
to the distillery. As such it is envisaged that the Carbon-Di-
Oxide produced in the distillery will be let out to the atmosphere
downstream of the CO2 scrubber in the fermentation section.
Included in the cost of the spent wash fired boiler are the auxiliary
systems like the fans, boiler feed water pumps, deaerator, dosing
system, desuperheating system, pressure reducing and desuperheating
stations (PRDS) for meeting with the process steam requirement,
piping, instrumentation for the complete boiler package etc.
The cost of the turbogenerator includes the cost of all its auxiliary
systems like lube oil system including the emergency lube oil system,
governing system, turbine and generator control system, generator
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D 13.3 AVANT-GARDE
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protections etc., The power generation is at 415V from the

turbogenerator for power distribution within the distillery.
The cost of the auxiliary fuel, which is bagasse in this case of GSML
and the ash handling systems are separately included in the cost
estimate. The fuel handling system will be with belt conveyors and slat
chain conveyors and the fly ash handling will be based on the dense
phase pneumatic handling system. The main fuel storage yard for the
bagasse generated in the sugar mill be just adjacent to the distillery
complex and hence the fuel handling system for feeding the bagasse
to the spent wash fired boiler will be a simple system.
For the supply of the cooling water to other auxiliaries of the plant
like the oil coolers, generator air coolers etc., a Cooling tower is
included in the project. This cooling tower will be of RCC construction
and will be of the counter flow type. The cost of the cooling tower,
the cooling water pumps and the piping from the cooling water pumps,
to the various equipment and the return piping from the equipment to
the cooling tower are included in the cost estimate. This will be in
addition to the process cooling towers which are already included in
the process plant.
In the distillery and for the spent wash fired boiler, the supply of
treated good quality water to the boiler and distillery is an important
factor for the reliable operation of the plant. This calls for a suitable
water treatment plant which will supply the treated water to the
boiler and distillery to the required quality. The necessary membrane
system based water treatment plant is included in the cost estimate.
Also included in the cost of the mechanical systems are the cost of
the Air-conditioning and ventilation system, fire fighting system,
compressed air system for providing the service and instrumentation
air for the distillery, the piping system with in the battery limits of
the distillery, all the tanks for the storage of the treated water,
tanks for storage of final products (ENA, IA, Fusel oil and impure
spirit),a hand operated overhead travelling crane for the maintenance
of the turbogenerator etc.
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D 13.4 AVANT-GARDE
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At present GSML is having six molasses storage tanks with an

aggregate storage capacity of 25860 MT. Another new tank with the
capacity of 7500 MT will be added, in the distillery complex, for the
molasses storage and the cost of this storage tank is included in the
estimate.
The costs of all the electrical equipment are estimated, in the same
way the cost of other mechanical systems is estimated. For the cost
estimate for the electrical items in house data of Avant-Garde and
the data based on similar projects have been used.
The power generation in the proposed back pressure 2.2 MW TG will

be at 415 V level in the distillery. However, the turbogenerator in the
distillery will be paralleled with the 30 MW Cogeneration plant in the
sugar mill to have flexibility in the operation of the plant. The
generated power will be stepped up to 11 kV for paralleling with the
co-generation plant TG. The project cost estimates include
transformer, cabling, protection system, etc. The internal power
distribution for the distillery, spent wash evaporation etc., and plant
is considered in the project cost estimate. All the cost towards the
distribution transformers, Power control centres (PCC), Motor Control
Centres (MCC), Variable Frequency Drives (VFD) for meeting the
internal power requirements are included in the cost estimate.
Judicious use of the VFDs have been made to reduce the internal
power consumption of the plant.
The cost of cabling from the co-generation plant to the distillery and
protection devices required are also included in the distillery plant
cost estimation.
The plant operation and control is envisaged through a well designed

Distributed Control System (DCS). All the field instrumentation is
included in the scope of the individual package suppliers. The package
suppliers will terminate the signal cables at the I/O rack of the DCS.
The scope of the DCS system supplier will be to take the signals at
the I/O racks, process the signals and give the output signals at the
I/O racks for the individual package suppliers to take the same for
operation of the control elements in the field. The cost of the
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D 13.5 AVANT-GARDE
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complete DCS system along with the cost of the balance of plant
instrumentation is included as part of the cost estimate for the
project.
The cost of mechanical and electrical works are estimated to be

Rs.6818.00 Lakhs and Rs.610.00 Lakhs respectively. The cost of the
controls and Instrumentation works is estimated to be Rs.350.00
Lakhs. The miscellaneous fixed assets is estimated to be Rs.45 Lakhs.
The total works cost for the complete 60 KLPD distillery plant with
the spent wash incineration systems works out to be Rs.9286.40
Lakhs.
13.4 Contingency
The project implementation is expected to be completed in about 16

months. There could be some escalations in the cost because of the
escalation in the price of the commodities. As the detailed
engineering is not yet completed, the budgetary specifications used
for getting the budgetary quotes are likely to undergo some changes
when the purchase specifications are issued after the detailed
engineering of the project. To accommodate all such variations, a
contingency provision of 3% is made on the non-firm costs (all the
costs estimated are non-firm at this point of time). The calculated
contingency for this project is Rs.293.00 Lakhs.
13.5 Project Financing
GSML will be approaching some of the financial institutions and Sugar

Development Fund (SDF) for the funding of this ethanol distillery and
spent wash incineration Cogeneration projects. As GSML is part of
the Adventz Group, many of the Financing Institutions may be
interested in funding this project. The actual terms of the funding
will have to be decided at that time of finalization of the funding
agency. The funding norms of SDF are furnished in the policy laid
down by SDF. For the purpose of this Detailed Project Report, GSML
has assumed the following with regard to the funding.
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D 13.6 AVANT-GARDE
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 For the molasses based ethanol distillery projects producing

anhydrous SDF will fund a maximum of 40% of the equipment and civil
costs.
 The SDF loan will be available with an interest rate of 6.5 % and with
a moratorium period equal to the term loan repayment period. The
SDF loan will be repaid after the term loan is repaid and in ten (10)
half yearly instalments.
 The Debt Equity Ratio is assumed to be 1. The SDF loan will be

considered as Quasi equity. The promoters' equity shall be a minimum
of 10% of the project cost.
 It is assumed that the interest rate on the term loan will be 12.5%.
The maximum loan repayment period inclusive of the moratorium will

be eight (8) years. It is also presumed that the moratorium period
will be two (2) years and the moratorium period starts from the first
loan disbursement. The repayment will be in twenty four (24)
Quarterly instalments.
It is also assumed that the disbursement of term loan and SDF loan
will be made available only in the third quarter after the project
"zero" date. As the processing of both the term loan and SDF loan
takes time and based on the past experience this assumption is made.
To meet with the project fund flow requirement, apart from pumping
in the equity, the company will have to make some arrangements for a
bridge loan. It is assumed that the cost of bridge loan will be same as
that of the term loan and the interest is included in IDC and
capitalized.
13.6 Other costs
13.6.1 Preliminary expenses.
Preliminary expenses include the cost of the initial studies,

Environment Impact assessment studies, statutory authority
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D 13.7 AVANT-GARDE
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clearances, project management, travel, third party inspection

charges, training, plant start up and all such expenses prior to the
start of the project itself.
The preliminary expenses also include the site clearances, arranging

construction power and water requirements for the various
contractors, arranging space (both open and covered) for the storage
of the equipment and materials at the site and space for the pre-
fabrication for the various contractors, arranging site communication
facilities, accommodation for the visiting personnel related to this
project. The estimated cost under this head is Rs.320.00 Lakhs.
13.6.2 Cost of Technical Know how and consultancy
The cost estimate provides the estimated Consultancy fees for the
detailed engineering services and for the construction and
commissioning supervision services for the distillery project. The
estimate is Rs. 150.00 Lakhs.
13.6.3 Interest During Construction

The interest during the construction (IDC) period is capitalized to
calculate the total project cost. The rate of interest considered in
the computation of the IDC is 12.5% for term loans from the
financing institution and 6.5% for the SDF loan. In the computation
of the IDC, the project fund flow what is required for a project of
this nature proposed for GSML is considered. The Table 13.3 gives
the, quarterly project fund flow and the IDC calculation, drawl of
loan etc. The project construction period is taken as 16 months.
While calculating the IDC, considering the fact that the processing of
the term loan and SDF loan takes some time, it is assumed that the
drawl of the term loans from the Financing Institution and SDF loan
sugar Development Fund will commence only from the third quarter of
the project construction period. The project's fund flow
requirements for the initial period will be met with the Equity and a
short term bridge loan. An interest rate of 12.5% is assumed for the
bridge loan.
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D 13.8 AVANT-GARDE
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The IDC calculated for the proposed GSML project is Rs.390.91

Lakhs.
13.6.4 Working capital margin.
The working capital is required, to take care of the expenses, for the
running of the Distillery plant, like purchase of fuel for the boiler,
purchase of molasses for the distillery operations, and Repairs and
Maintenance expenses. In addition the working capital is required to
tied over the situation due to the non receipt of the receivables and
holding the stock of finished product in the bulk storage tanks for a
period of 30 days. The estimated working capital for this project is
Rs.976.44 Lakhs. Seventy Five percent of this working capital will be
raised as short term loans and the balance will be the margin money
for the working capital. The estimated working capital margin for this
project is Rs.244.11 Lakhs and this is capitalized. Table 14.7 gives the
workings for the working capital requirements.
13.6.5 Cost of Arranging for the Finance:
It is assumed that the expenses towards the arranging and processing

of the term loan will be One (1) percent of the term loan value. In this
computation SDF loan is not considered. This also includes the legal
fees and the stamp duty etc
13.7 Total Installed Project Cost
The total works cost for the proposed Distillery project is Rs.
9286.40 Lakhs. The total installed project cost inclusive of the
pre-operative expenses, contingency and working capital margin is
estimated to be Rs. 10738.11 Lakhs.
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D 13.9 AVANT-GARDE
Table 13.1
PROJECT WORKS COST ESTIMATE
S.NO. DESCRIPTION UNIT QUANTITY RATE (Rs) Rs. In Lakhs

A. CIVIL WORKS
1 Land 0
2 Land Development, grading & Leveling 100.00
3 TG Building 225.00
4 Plant Buildings for the Fermentation 200.00

Control Room,sElectrical rooms, WTP
Alcohol Issue area
5 Foundation for the complete 550.00

distillery & power plant & Tanks
6 Raw Water Tank 70.00
7 Conveyor Foundations 90.00
8 Road and Drain Work - Land & Site 80.00
9 Pipe Rack Support & Cable Rack 68.40
10 Concrete Chimney 80.00
TOTAL FOR CIVIL WORKS 1463.40
B.MECHANCIAL WORKS
1 Complete distillery plant (fermentation No. 1 3000.00

distillation, evaporation) including
Interconnecting piping, structural
supports etc.
2 20 TPH spent wash incineration steam No. 1 1450.00

generator including fabric filter, fans
pumps, valves and specialities, piping
PRDS and other Auxiliaries
3 1 x 2.2 MW back pressure turbogenerator No. 1 350

unit, inlcuding all auxiliaries, piping, governor
turbovisory, controls and Instrumentation
and electricals as per scope.

4 Bagasse handing system with all its LS 150.00

accessories
5 Ash handling system for the boiler LS 120.00

consisting of submerged scrapper
conveyars, for wet ash and dense
phase handing system for fly ash
6 Induced draft cooling tower (RCC work LS 60.00

included in civil scope)
7 Centrifugal Pumps with base frames LS 60.00

and electric motor drives for the
cogeneration power plant
8 Steam, Water piping and valves & LS 325.00

supports from the power plant. Tanks for
Molasses, DM & Process water.
9 ReverseOsmosis based water LS 220.00

Treatment Plant
10 Day receiver and Bulk Storage Tanks for LS 400.00

the products
11 Power House EOTCrane LS 30.00
12 Air Conditioning system & Ventilation system LS 80.00

for the TG building, MCC room & control
rooms in process plant & cogen. Plant
13 Air Compressors for both Process and LS 65.00

cogeneration plant
14 Fire Protection Systems for the process LS 180.00

and cogeneration plant
15 Laboratory LS 28.00
16 Weigh Bridge LS 25.00
17 Condensate & Spent lees treatment and LS 275.00

Polishing
TOTAL FOR MECHANICAL WORKS 6818.00

C. INSTRUMENTATION WORKS
1 Distributed Control ssytem & Misx LS 225.00

Instrumentation other than those covered
by other packages and UPS
2 Balance of Plant Instrumentatiion LS 125.00
TOTAL FOR INSTRUMENTATION WORKS 350.00
D. ELECTRICAL WORKS
1 Generator and all generator accessories Included in

including relay metering and control panels, Turbine
AVR, Synchronising panel, NGR & LAVT and
Switchbaord - - -
2 Plant Electircal Package including LS - - 500.00

Transformers, cables, LT Panels, VFD
Panels, contract package etc.
2.8 DG Set Package Nos. 2 - 110.00
TOTAL FOR ELECTRICAL WORKS 610.00
E. MISCELLANEOUS FIXED ASSETS
1 Furnitures for Office, WTP building 15.00

office including computers, EPABX etc.
2 Furnitures for process control rooms 10.00

and office
3 Plant Vehicles 15.00
4 Office Air Conditioning & Ventilation 5.00

Equipment, Lighting, s etc.
TOTAL FOR MISC. FIXED ASSETS 45.00
TOTAL WORKS COST 9286.40
Notes:
1 This works cost is inclusive of all taxes and duties.

TABLE 13.2 Sh. 1 Of 2

Rs. In
Lakhs
1.0 SUMMARY OF PROJECT COST ESTIMATE (Rs. In Lakhs)

1.1 Land 0.00
1.2 Buildings And Civil Works 605.00
1.3 Plant And Machinery and Misc. Fixed Assets including foundations 8681.40
1.4 Preliminary expenses. * 320.00
1.5 Technical Knowhow Fees 150.00
1.6 Contingencies (~3%) 293.00
1.7 Front end Fee to the FI (@ 1 % of the Loan Amount) 53.69
1.8 Working Capital Margin 244.11
1.9 Total Cost Including contingency & WCM

But Excluding IDC 10347.20
2.0 CALCULATION OF INTEREST DURING CONSTRUCTION
2.1 Construction Period (Months) 16
2.2 Rate Of Interest for Term Loan 12.50
2.3 Rate of Interest for SDF Loan 6.50
2.4 Rate of Interest for Bridge Loan ** 13.00
2.5 Debt Equity Ratio (SDF Loan is also considered as Equity) 1.00
2.6 Total IDC Rs. in Lakhs 390.91
3.0 Total Project Cost Including IDC & WCM Rs. in Lakhs 10738.11
4.0 Equity Rs. in Lakhs 1654.49
5.0 SDF Loan Rs. in Lakhs 3714.56
6.0 Term Loan Rs. in Lakhs 5369.05
* Preliminary expenses include the cost of feasibility study, project Management, travels,
third party inspection, training, plant start up etc.
** Bridge loan will be a short term loan to make up for the shortfall in fund flow due to late receipt of
Term loans and the SDF Loan disbursements.

Table - 13.2 (Contd.) Sh. 2 Of 2
8.0 SPLIT UP OF THE PROJECT COST : (Rs.in Lakhs):
8.1 Land 0.00
8.2 Buildings & Civil Works 605.00
8.3 Plant & Machinery Including Misc. Fixed Assets 8681.40
8.4 Pre-Operative Expenses (Including IDC & Front end Fee) 914.60
8.5 Contingencies 293.00
8.6 Working Capital Margin 244.11
8.7 TOTAL INSTALLED PROJECT COST : Rs. in Lakhs 10738.11
9.0 Project Cost Without WCM Rs. in Lakhs 10494.00
Date 4/27/2015 Revn. 0
**

Table 13.3
Phasing of Capital Expenditure and IDC Calculations
I Phasing Of Capital Expenditure (Tentative) : (RS.IN Lakhs):
Quarter Capital Equity SDF Loan Term Loan Bridge Loan Interest on Interest on Int. on the Term Loan Total
Expenditure Portion Portion outstandiing SDF Loan till Term Loan till + IDC Capital
Outstanding
at the end of the the completion Spent
the Quarter Bridge Loan (Equity +
completion of of
for the Loan)
construction construction
(IDC) (IDC) Quarter
1 1000.00 661.80 0.00 0.00 338.20 0.00 0.00 5.50 0.00 661.80
2 1500.00 496.35 0.00 0.00 1341.85 0.00 0.00 21.81 27.30 523.65
3 2000.00 496.35 928.64 1244.54 672.33 42.76 110.19 10.93 1408.41 2833.40
4 2500.00 0.00 928.64 1244.54 999.15 27.67 71.30 16.24 1359.74 2288.38
5 2500.00 0.00 928.64 1244.54 1325.98 12.58 32.41 21.55 1311.07 2239.71
6 847.20 0.00 928.64 1244.54 0.00 5.03 12.96 0.00 1262.53 2191.17
Total 10347.20 1654.49 3714.56 4978.15 88.03 226.87 76.01 5369.05 10738.11
II Total Project Cost Including IDC & WCM Rs. in Lakhs 10738.11
III Equity Rs. in Lakhs 1654.49
IV SDF Loan Rs. in Lakhs 3714.56
V Term Loan Rs. in Lakhs 5369.05
VI Total IDC Rs. in Lakhs 390.91
VII Actual Debt Equity Ratio 1.00

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14.0 FINANCIAL ANALYSIS
14.1 General
This section of the report gives the financial viability analysis of the
proposed 60 KLPD molasses based distillery project with spent wash
incineration plant at Gobind Sugar Mills Limited (GSML) located in
Aira Estate in Lakhimpur Kheri District of Uttar Pradesh. The
financial analysis based on the cost estimates given in the earlier
section on the ‘Project Cost Estimate’ and on the technical data on the
input and output and the operating costs discussed in the various
sections of the report. The financial analysis gives the details of the
operation and profitability, cash flow for a period of fifteen (15)
years from the date of commissioning of the project facilities. The
analysis also gives the Internal Rate of Return (IRR) for the project,
Debt Service Coverage Ratio (DSCR) and payback period.
The Financial viability of the project is worked out based on certain

assumptions. The Table-14.1 give the Basis for the Financial Analysis
for the proposed distillery project.
14.2 Mode of Financing
The total project cost with the interest during construction and
working capital margin is estimated to be Rs.10738.11 Lakhs as given
in Table-13.2 of the section on ‘Project Cost Estimate’. GSML has said
that they will go for funding from Sugar Development Fund and a
reputed financing Institution and has suggested that the financial
analysis of the project is made with a debt equity ratio of 1:1. The
funding from the SDF shall be treated as quasi equity. For the
modernization and expansion of crushing capacity with simultaneous
implementation of Cogeneration, SDF fund will be available to the
extent of 40% of the cost of the plant and machinery and the civil
works. The total project cost of Rs.10738.11 Lakhs will be funded
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with, an equity of Rs.1654.49 Lakhs SDF loan of Rs.3714.56 Lakhs and
a term loan of Rs.5369.05 Lakhs.
Based on the information provided by GSML, it is assumed that the

term loan from the Financial Institution will be available at an interest
rate of 12.5% and the repayment will be quarterly over a period of six
(6) years with a moratorium of 2 years. The SDF loan will be
available with an interest rate of 6.5% and with a moratorium period
equal to the term loan repayment period. Thereafter the SDF loan will
be repaid in 5 years in half yearly instalments. As seen in the earlier
section of this report, it is assumed that the SDF loan and the term
loan will be available only in the third quarter of the project
construction period, due to the processing time. Till such time, the
project fund flow requirements will be met by the equity and short
term bridge loans.
14.3 Plant Operation
The proposed plant will be a multi product distillery capable

manufacturing Rectified Spirit (RS), Extra Neutral Alcohol (ENA) and
Anhydrous Alcohol (AA). The capacity of the plant in terms of total
spirit production is 60 KLPD. Under 100% RS manufacturing mode the
plant will produce 57000 Litres per day of RS. Under the ENA and AA
mode of operation, the plant respectively can produce 56320 litres
per day and 56000 Litres per day of ENA and AA. Under all modes of
operation, the plant will also produce as by products, 3000 Litres per
day of Technical alcohol and 60 Litres per day of Fusel Oil.
Eventhough the plant is capable of operation in any mode, a product
mix of 70% ENA and 30% AA is assumed for the study of the viability
of the project.
The raw material for the production of alcohol is molasses. As the

distillery plant will be located near the complex of the sugar mill, the
entire molasses produced from the sugar operations will be made
available to the distillery. The sugar mill crushing Thirteen Lakhs and
Fifty Thousand (13.5 Lakhs) MT of cane per annum will produce about
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60750 MT of molasses per annum. With the daily requirement of
about 270 MT of molasses for the full production in the distillery and
with 90 % capacity utilization, the total molasses produced in the
sugar mill enable the distillery to operate for a period of 250 days.
However with the spent wash incineration system installed, the
distillery should be operated for a longer period in a year. GSML has
indicated that they could procure about 15,000 MT of molasses per
annum from nearby sugar mills, apart from their own production of
molasses. Considering this maximum of 15,000 MT of molasses
available in addition to the 60750 MT of molasses produced by GSML
in their sugar mill, the 60 KLPD distillery could be operated for a
period of 310 days. The fermentable sugar in the in-house molasses is
36.8% and the level of fermentable sugar in the bought out molasses
is also expected to be same.
With 310 days of operation of the distillery, the total annual molasses
requirement will be 75,337.53 MT, with 90% capacity utilization of
the distillery. Out of this 60,750 MT of molasses will be bought from
the sugar mill and the balance of 14,587.53 MT will be procured from
nearby sugar mills.
Molasses price varies round the year. It is taken that the average
basic price of molasses in the plant area will be Rs.4000 per MT. It is
assumed that even the in-house molasses from the sugar mill will be
bought at this price of Rs.4000 per MT, to study the viability of the
distillery unit as a standalone entity. There will an excise duty
payment of RS.750 per MT, both for the in-house and bought out
molasses. Apart from the above there will be a cess of Rs.22.5 per
MT of molasses and a molasses development fee of RS.110 per MT of
molasses. So the cost of both the in-house molasses and the bought
out molasses work out to Rs.4882.50 per MT. For the bought out
molasses an average transportation cost of Rs.300 per MT is also
considered and hence the landed cost of in-house molasses and the
bought out molasses will be respectively Rs.4882.50 and Rs.5182.50
per MT. This cost is not escalated in the viability analysis.
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The distillery will generate the necessary steam and power in house.
There will be no external steam or power supply for the distillery
operations. As the plant is designed for zero effluent discharge, the
spent wash generated in the distillery will be used as a fuel in the
boiler to generate steam. The spent wash will be concentrated to
approximately 60% solids (w/w) and fired in a boiler along with
bagasse, procured from the sugar mill, to generate the required
quantity of steam. The viability of the project is studied with this
bought out bagasse as the supporting fuel for the boiler. The
estimated bagasse consumption in the plant will be 5 MT per hour
and the bagasse cost is assumed to Rs.1000 per MT. The high
pressure steam generated in the boiler will be used in a back
pressure turbine to generate the required quantum of power for the
operation of the distillery. As there will be a surplus power of an
average of 300 kW, and also for the purpose of providing operational
flexibility, the turbogenerator in the distillery will be operated in
parallel with the 30 MW Cogeneration TG in the sugar mill. In case the
30 MW Cogeneration plant is not exporting to the grid, the 300 kW of
power could be used in the sugar mill for off- season maintenance or
for meeting the requirements of the colony, thereby reducing the
drawl from the grid or generation in the sugar plant’s DG sets.
14.4 Alcohol Production and Sales
With proposed product mix of 70% ENA and 30% AA, the plant will
produce 109.99 Lakhs litres of ENA and 46.87 Lakh Litres of AA
respectively per annum. In addition the plant will also produce 8.37
Lakh Litres of Technical alcohol and 0.17 Lakhs litres of Fusel oil
respectively. The prevailing sale price of RS, ENA and AA are
respectively Rs. 39 Rs.43 and Rs.40.5 per litre. The price of TA and
FO is expected to be Rs.20 per Litre. The exportable power is
assumed to be sold at Rs.5.50 per kWhr. In the viability analysis, no
escalation is considered on the above indicated sale prices.
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14.5 Other Input Costs:
The distillery plant uses a lot of chemicals and utilities for its
operation. The chemicals are used for various applications from being
a nutrient to yeast, for pH correction, cleaning, preventing scaling etc.
The major chemicals are urea, Di-ammonium phosphate, sulphuric acid,
anti foaming oil, nitric acid, phosphoric acid, caustic soda etc. The
consumption and the cost of the chemicals are given in Table 14.1.
Apart from the various chemicals, the plant also uses a lot of raw
water, Demineralised water and soft water for the process as well as
for the boiler make up. The estimated consumption of the raw water
is 1000 Cu.m/day. The DM plant is part of the distillery and the cost
of the DM plant and its operation costs are already included in the
project cost and other operating costs. Even though the raw water is
going to be pumped from the bore wells, to cover the cost of pumping
and any possible charges to the government a cost of Rs.2 per Cu.m is
considered for the raw water.
Other Utilities Cost:
A provision of Rs.10 Lakhs per Annum is made towards the Cost of

Balance of the Utilities, Other Chemicals & Yeast Culturing. This also
includes the cost of chemicals and other consumables used in the plant
occasionally or in small quantities.
14.6 Operation and Maintenance Cost
The repairs and maintenance cost for this project is assumed as

2.0% of the total works cost which comes to Rs.155.56 Lakhs per
annum. In reality this cost will not be incurred in full for the first
year of operation as the plant will be under warranty. Still this
cost is considered for all the operating years. The salaries and
wages of the operation and maintenance personnel of the plant and
the administrative expenses are respectively considered as Rs.220
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Lakhs and Rs.10 Lakhs per annum. No escalation is considered on all
the costs for the viability analysis.
14.7 Insurance
The cost of insurance, for the distillery and the spent wash
incineration cogeneration plant equipment has been taken to be 0.2%
of the cost of the plant and machinery and the civil works. This cost
works out to Rs.18.57 Lakhs per annum.
14.8 Escalation Provision for Various Costs and Expenses
The financial analysis does not consider any escalation on both the
input costs and the output prices.
14.9 Depreciation
A straight line depreciation rate of 3.34% for the buildings and civil
works and 6.33% for the plant and machinery is considered in the
financial analysis. Table-14.3 gives the details. For Income-tax
calculation purposes, 10% depreciation for buildings and civil works
and 15% depreciation for the sugar plant's plant and machinery, on
the Written Down Value (WDV) is considered. Table 14.9 gives the
details.
14.10 Estimates of Cost of production
The Table-14.4 gives the estimates of cost of production for the

ethanol distillery and the spent wash incineration Cogeneration plant
for fifteen (15) years operation from plant commissioning.
14.11 Sales and Profitability Statement
Table-14.5 gives the estimates of sales for the ethanol distillery

plant operations. The saleable products are the ENA, AA, Technical
Alcohol, the Fuseil oil and the surplus electrical energy generated in
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the 2.2 MW Cogeneration plant. Table-14.6 gives the working results
(Gross Profit) for the plant operations. Table-14.8 gives the
calculation of the Net Profit for the plant operation. Table 14.7 gives
the computation of the working capital requirements, as given in the
earlier section on the "Project Cost Estimate". The interest for the
working capital loan is taken as 14%. An amount of about 25% of the
total working capital requirement is considered as margin money and
the balance is considered as loan from banks.
Provision is made for Income Tax in the analysis of the profitability.

A tax rate of 30% with 5% surcharge and 3% Cess is considered for
the taxable portion of the profit. Minimum Alternate Tax rate of
18.5% with 5% surcharge and 3% Cess is taken to compute the MAT
obligations. Table-14.10 gives the work out for Income-tax liability for
the Distillery operations.
14.12 Cash Flow
The detail of the estimated cash flow generated by the project

operations over a period of fifteen (15) years is given in Table-14.11.
14.13 IRR, DSCR and Payback
Table-14.12 gives the working of the Project Internal Rate of Return

(IRR) and The Debt Service Coverage Ratio (DSCR). The project post
tax IRR works out to 16.22% and the DSCR values are given for the
operating years in the table. The minimum value of DSCR is 1.24 and
the maximum value is 4.1 with the average of 1.84. While computing
the IRR the terminal value of the equipment in the fifteenth year is
taken into the calculations. Considering technological obsolescence and
the fact that the plant would have served a substantial part of its
useful life, it is assumed that the dismantling and selling will fetch
about 50% of its original value. It is assumed that the income tax is
payable on the disposal value of the equipment and the currently
applicable rate of tax is used in the computations.
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The Table 14.12 also gives the Net Present Value (NPV) considering a
Weighted Average Cost of Capital (WACC) of 11.3%. The calculated
NPV for this project is Rs.3039.74 Lakhs. The equity, SDF loan and
the Institution Term loan works out to 15%, 35% and 50% of the
total capital employed. The cost of equity is calculated to be 18% with
a risk free return on capital of 8%, a risk premium of 9% and a Beta
value of 1.11 for the industry. With the cost of Equity, SDF loan and
the institution term loan at 18%, 6.5% and 12.5% respectively, the
WACC is calculated to be 11.3%.
The return on Equity is calculated to be 35.51% based on the

fifteen years of operation. The calculated simple payback period
is 5.2 years.
14.14 Conclusion
GSML is an operating sugar plant with the present crushing

capacity of 7200 TCD. Considering the excellent cane potential in
the command area, the company is increasing the crushing capacity
to 10,000 TCD. With the view of value addition to the sugar
produced, GSML is planning to implement a 500 TPD sugar
refinery. These sugar plant modifications and upgradation will be
completed in the present off-season and the plant will start
crushing at the new enhanced crushing capacity from the 2015-
2016 season. The 30 MW Cogeneration plant implemented and
ready for commissioning will also start operating form the ensuing
season.
With the addition of the proposed ethanol distillery, one of the

other valuable by product of the sugar mill, which is the molasses,
will be put to better use. With the proposed distillery capable of
producing both ENA and Anhydrous alcohol, the opportunities are
enormous. With ethanol being touted as the future fuel of this
planet, utilizing the molasses to produce ethanol will make good
business sense. Even if there is a sluggish off-take of Anhydrous
Alcohol for gasoline blending, the ENA will have an ever expanding
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market with the ENA consumption in India posting an average
annual growth of 4 to 5%. With the advent of the spent wash
concentration and incineration technology, the disposal of spent
wash, one of the worst nightmares of the distillery industry has
been made easy. In fact the dreaded effluent is now used as a
fuel for powering the distillery.
The financial analysis discussed in this section of the report

indicate that the proposed distillery unit is immensely viable.
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TABLE 14.1 BASIS FOR THE FINANCIAL ANALYSIS - DISTILLERY OPERATIONS
DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
2017-20182017-2018 2018-2019 2019-2020 2020-2021 2021-2022 2022-2023 2023-2024 2024-2025 2025-2026 2026-2027 2027-2028 2028-2029 2029-2030 2030-2031 2031-2032
Installed Project Cost (Rs. Lakhs) 10738.11 - - - - - - - - - -

- - - - - - -
Promoter's Equity (Rs.in Lakhs) 1654.49 - - - - - - - - - -
- - - - - - -
SDF Loan (Rs. In Lakhs) 3714.56
Term Loan From FI (Rs. Lakhs) 5369.05 - - - - - - - - - -
Cost of Plant & Machinery (Rs.in Lakhs) 7778.00
Cost of Total Civil Works (Rs.in Lakhs) 1463.40
Cost of Misc. Fixed Assets (Rs.in Lakhs) 45.00
Distillery Capacity interms of Total Spirits (LPD) 60000.00 60000.00 60000.00 60000.00 60000.00 60000.00 60000.00 60000.00 60000.00 60000.00 60000.00 60000.00 60000.00 60000.00 60000.00
Number of Days of Distillery operation per Annum 310.00 310.00 310.00 310.00 310.00 310.00 310.00 310.00 310.00 310.00 310.00 310.00 310.00 310.00 310.00
Operation under RS mode (100% RS from Wash)
RS (LPD) 57000.00 57000.00 57000.00 57000.00 57000.00 57000.00 57000.00 57000.00 57000.00 57000.00 57000.00 57000.00 57000.00 57000.00 57000.00
Technical Alcohol (LPD) 3000.00 3000.00 3000.00 3000.00 3000.00 3000.00 3000.00 3000.00 3000.00 3000.00 3000.00 3000.00 3000.00 3000.00 3000.00
Fusel Oil (LPD) 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00
Operation under ENA mode (100% ENA from Wash)
ENA (LPD) 56320.00 56320.00 56320.00 56320.00 56320.00 56320.00 56320.00 56320.00 56320.00 56320.00 56320.00 56320.00 56320.00 56320.00 56320.00
Technical Alcohol (LPD) 3000.00 3000.00 3000.00 3000.00 3000.00 3000.00 3000.00 3000.00 3000.00 3000.00 3000.00 3000.00 3000.00 3000.00 3000.00
Fusel Oil (LPD) 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00
Operation under AA mode (100% AA from Wash)
AA (LPD) 56000.00 56000.00 56000.00 56000.00 56000.00 56000.00 56000.00 56000.00 56000.00 56000.00 56000.00 56000.00 56000.00 56000.00 56000.00
Technical Alcohol (TA) (LPD) 3000.00 3000.00 3000.00 3000.00 3000.00 3000.00 3000.00 3000.00 3000.00 3000.00 3000.00 3000.00 3000.00 3000.00 3000.00
Fusel Oil (FO) (LPD) 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00
Rectified Spirit (RS) as % of Annual Production (%) 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Extra neutral Spirit (ENA) as % of Annual Production (%) 70.00 70.00 70.00 70.00 70.00 70.00 70.00 70.00 70.00 70.00 70.00 70.00 70.00 70.00 70.00
Anhydrous Alcohol (AA) as % of Annual Production (%) 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00

TABLE 14.1 BASIS FOR THE FINANCIAL ANALYSIS - DISTILLERY OPERATIONS (Contd.)
DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
2017-20182017-2018 2018-2019 2019-2020 2020-2021 2021-2022 2022-2023 2023-2024 2024-2025 2025-2026 2026-2027 2027-2028 2028-2029 2029-2030 2030-2031 2031-2032
Distillery Plant Capacity Utilization (%) 80.00 85.00 90.00 90.00 90.00 90.00 90.00 90.00 90.00 90.00 90.00 90.00 90.00 90.00 90.00
Annual Production of RS (Lakh Litrres) 141.36 150.20 159.03 159.03 159.03 159.03 159.03 159.03 159.03 159.03 159.03 159.03 159.03 159.03 159.03
(assuming 100% of the production is RS)
Annual Production of ENA (Lakh Litres) 139.67 148.40 157.13 157.13 157.13 157.13 157.13 157.13 157.13 157.13 157.13 157.13 157.13 157.13 157.13
(assuming 100% of the production is ENA)
Annual Production of AA (Lakh Litres) 138.88 147.56 156.24 156.24 156.24 156.24 156.24 156.24 156.24 156.24 156.24 156.24 156.24 156.24 156.24
(assuming 100% of the production is AA)
Annual Production of TA (Lakh Litres) 7.44 7.91 8.37 8.37 8.37 8.37 8.37 8.37 8.37 8.37 8.37 8.37 8.37 8.37 8.37
Annual Production of FO (Lakh Litres) 0.15 0.16 0.17 0.17 0.17 0.17 0.17 0.17 0.17 0.17 0.17 0.17 0.17 0.17 0.17
Surplus power available in the Distillery Plant that

could be exported by Synchronizing with the Sugar mill 300.00 300.00 300.00 300.00 300.00 300.00 300.00 300.00 300.00 300.00 300.00 300.00 300.00 300.00 300.00
Cogeneratioin plant (kW)
Exportable Energy per Annum (MkWhr) 1.79 1.90 2.01 2.01 2.01 2.01 2.01 2.01 2.01 2.01 2.01 2.01 2.01 2.01 2.01
Fermentable Sugar in Molasses (%) 36.80 36.80 36.80 36.80 36.80 36.80 36.80 36.80 36.80 36.80 36.80 36.80 36.80 36.80 36.80
Total Spirit Production per MT of Molasses (Litres) 222.20 222.20 222.20 222.20 222.20 222.20 222.20 222.20 222.20 222.20 222.20 222.20 222.20 222.20 222.20
Annual Molasses Requirement (MT) 66966.70 71152.12 75337.53 75337.53 75337.53 75337.53 75337.53 75337.53 75337.53 75337.53 75337.53 75337.53 75337.53 75337.53 75337.53
Molasses Generated in the Sugar Mill (MTPA) 60750.00 60750.00 60750.00 60750.00 60750.00 60750.00 60750.00 60750.00 60750.00 60750.00 60750.00 60750.00 60750.00 60750.00 60750.00
Basic Cost of In-house Molasses (Rs./MT) 4000.00 4000.00 4000.00 4000.00 4000.00 4000.00 4000.00 4000.00 4000.00 4000.00 4000.00 4000.00 4000.00 4000.00 4000.00
Exise Duty on In-house Molasses (Rs./MT) 750.00 750.00 750.00 750.00 750.00 750.00 750.00 750.00 750.00 750.00 750.00 750.00 750.00 750.00 750.00
Cess on In-House Molasses (Rs./MT) 22.50 22.50 22.50 22.50 22.50 22.50 22.50 22.50 22.50 22.50 22.50 22.50 22.50 22.50 22.50
Molasses Drevelopment Fund (Rs./MT) 110.00 110.00 110.00 110.00 110.00 110.00 110.00 110.00 110.00 110.00 110.00 110.00 110.00 110.00 110.00
Landed Cost of In-House molasses (Rs./MT) 4882.50 4882.50 4882.50 4882.50 4882.50 4882.50 4882.50 4882.50 4882.50 4882.50 4882.50 4882.50 4882.50 4882.50 4882.50
Bought Out Molasses (MTPA) 6216.70 10402.12 14587.53 14587.53 14587.53 14587.53 14587.53 14587.53 14587.53 14587.53 14587.53 14587.53 14587.53 14587.53 14587.53
Basic Cost of Bought Out Molasses (Rs./MT) 4000.00 4000.00 4000.00 4000.00 4000.00 4000.00 4000.00 4000.00 4000.00 4000.00 4000.00 4000.00 4000.00 4000.00 4000.00
Excise Duty on Bought out Molasses (Rs./MT) 750.00 750.00 750.00 750.00 750.00 750.00 750.00 750.00 750.00 750.00 750.00 750.00 750.00 750.00 750.00

DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
2017-20182017-2018 2018-2019 2019-2020 2020-2021 2021-2022 2022-2023 2023-2024 2024-2025 2025-2026 2026-2027 2027-2028 2028-2029 2029-2030 2030-2031 2031-2032
Cess on bought out Molasses (Rs./MT) 22.5 22.5 22.5 22.5 22.5 22.5 22.5 22.5 22.5 22.5 22.5 22.5 22.5 22.5 22.5
Molasses Drevelopment Fund (Rs./MT) 110.00 110.00 110.00 110.00 110.00 110.00 110.00 110.00 110.00 110.00 110.00 110.00 110.00 110.00 110.00
Transportation Cost of Bought out Molasses (Rs./MT) 300.00 300.00 300.00 300.00 300.00 300.00 300.00 300.00 300.00 300.00 300.00 300.00 300.00 300.00 300.00
Landed Cost of Bought Out Molasses (Rs./MT) 5182.50 5182.50 5182.50 5182.50 5182.50 5182.50 5182.50 5182.50 5182.50 5182.50 5182.50 5182.50 5182.50 5182.50 5182.50
Chemicals Requirement and Cost of Chemicals
Urea and DAP (kg/day) 170.00 170.00 170.00 170.00 170.00 170.00 170.00 170.00 170.00 170.00 170.00 170.00 170.00 170.00 170.00
Cost of Urea / DAP (Rs. Kg) 10.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00
Cost of Urea / DAP (Rs. In Lakhs Per Annum) 4.22 4.48 4.74 4.74 4.74 4.74 4.74 4.74 4.74 4.74 4.74 4.74 4.74 4.74 4.74
Antifoam Oil (kg/Day) 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00
Cost of Anti Foam Oil (Rs./kg) 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00
Cost of Anti Foam Oil (Rs.in Lakhs per Annum) 4.46 4.74 5.02 5.02 5.02 5.02 5.02 5.02 5.02 5.02 5.02 5.02 5.02 5.02 5.02
Sulphuric Acid (kg/day) 400.00 400.00 400.00 400.00 400.00 400.00 400.00 400.00 400.00 400.00 400.00 400.00 400.00 400.00 400.00
Cost of Sulphuric Acid (Rs./kg) 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00
Cost of Sulphuric Acid (Rs.in Lakhs per Annum) 19.84 21.08 22.32 22.32 22.32 22.32 22.32 22.32 22.32 22.32 22.32 22.32 22.32 22.32 22.32
Caustic Soda (kg/Day) 800.00 800.00 800.00 800.00 800.00 800.00 800.00 800.00 800.00 800.00 800.00 800.00 800.00 800.00 800.00
Cost of Caustic Soda (Rs./kg) 40.00 40.00 40.00 40.00 40.00 40.00 40.00 40.00 40.00 40.00 40.00 40.00 40.00 40.00 40.00
Cost of Caustic Soda (Rs.in Lakhs per Annum) 79.36 84.32 89.28 89.28 89.28 89.28 89.28 89.28 89.28 89.28 89.28 89.28 89.28 89.28 89.28
Nitric Acid (kg/Day) 170.00 170.00 170.00 170.00 170.00 170.00 170.00 170.00 170.00 170.00 170.00 170.00 170.00 170.00 170.00
Cost of nitric Acid (Rs./kg) 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00
Cost of nitric Acid (Rs.in Lakhs per Annum) 8.43 8.96 9.49 9.49 9.49 9.49 9.49 9.49 9.49 9.49 9.49 9.49 9.49 9.49 9.49
Sodium Metasulphate (kg/Day) 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50
Cost of Sodiuum Metasulphate (Rs./kg) 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00
Cost of Sodiuum Metasulphate (Rs.in Lakhs per Annum) 0.07 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08

DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
2017-20182017-2018 2018-2019 2019-2020 2020-2021 2021-2022 2022-2023 2023-2024 2024-2025 2025-2026 2026-2027 2027-2028 2028-2029 2029-2030 2030-2031 2031-2032
Anti Scalant (kg/Day) 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50
Cost of Anti Scalant (Rs./kg) 450.00 450.00 450.00 450.00 450.00 450.00 450.00 450.00 450.00 450.00 450.00 450.00 450.00 450.00 450.00
Cost of Anti Scalant (Rs.in Lakhs per Annum) 1.67 1.78 1.88 1.88 1.88 1.88 1.88 1.88 1.88 1.88 1.88 1.88 1.88 1.88 1.88
Bio-Despersant (kg/Day) 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50
Cost of Bio-Despersant (Rs./kg) 210.00 210.00 210.00 210.00 210.00 210.00 210.00 210.00 210.00 210.00 210.00 210.00 210.00 210.00 210.00
Cost of Bio-Despersant (Rs.in Lakhs per Annum) 0.78 0.83 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88
Hydro Choric Acid (33%) (kg/Day) 75.00 75.00 75.00 75.00 75.00 75.00 75.00 75.00 75.00 75.00 75.00 75.00 75.00 75.00 75.00
Cost of Hydro Chloric Acid (33%) (Rs./kg) (Rs./kg) 5.00 5.00 5.00 5.00 5.00 5.00 5.00 5.00 5.00 5.00 5.00 5.00 5.00 5.00 5.00
Cost of Hydro chloric acid (Rs.in Lakhs per Annum) 0.93 0.99 1.05 1.05 1.05 1.05 1.05 1.05 1.05 1.05 1.05 1.05 1.05 1.05 1.05
Morpholine (85%) (kg/Day) 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50
Cost of Morpholine (Rs./kg) (Rs./kg) 350.00 350.00 350.00 350.00 350.00 350.00 350.00 350.00 350.00 350.00 350.00 350.00 350.00 350.00 350.00
Cost of Hydro chloric acid (Rs.in Lakhs per Annum) 1.30 1.38 1.46 1.46 1.46 1.46 1.46 1.46 1.46 1.46 1.46 1.46 1.46 1.46 1.46
Plymer for Sludge Thickening (kg/Day) 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10
Cost of Polymer (Rs./kg) 170.00 170.00 170.00 170.00 170.00 170.00 170.00 170.00 170.00 170.00 170.00 170.00 170.00 170.00 170.00
Cost of Polymer (Rs.in Lakhs per Annum) 1.30 1.38 1.46 1.46 1.46 1.46 1.46 1.46 1.46 1.46 1.46 1.46 1.46 1.46 1.46
Scale & Corrosion Inhibitor (kg/Day) 6.00 6.00 6.00 6.00 6.00 6.00 6.00 6.00 6.00 6.00 6.00 6.00 6.00 6.00 6.00
Cost of inhibitor (Rs./kg) 200.00 200.00 200.00 200.00 200.00 200.00 200.00 200.00 200.00 200.00 200.00 200.00 200.00 200.00 200.00
Cost of inhibitor (Rs.in Lakhs per Annum) 2.98 3.16 3.35 3.35 3.35 3.35 3.35 3.35 3.35 3.35 3.35 3.35 3.35 3.35 3.35
Carbo Hydrazine (kg/Day) 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04
Cost of Hydrazine (Rs./kg) 500.00 500.00 500.00 500.00 500.00 500.00 500.00 500.00 500.00 500.00 500.00 500.00 500.00 500.00 500.00
Cost of Hydrazine (Rs.in Lakhs per Annum)) 0.05 0.05 0.06 0.06 0.06 0.06 0.06 0.06 0.06 0.06 0.06 0.06 0.06 0.06 0.06
Carbo Tri-sodium Phosphate (kg/Day) 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60
Cost of Tri-sodium Phosphate (Rs./kg) 40.00 40.00 40.00 40.00 40.00 40.00 40.00 40.00 40.00 40.00 40.00 40.00 40.00 40.00 40.00
Cost of Tri-sodium Phosphate (Rs.in Lakhs per Annum)) 0.06 0.06 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07
Sodium Hypochlorite (6%) (kg/Day) 452.00 452.00 452.00 452.00 452.00 452.00 452.00 452.00 452.00 452.00 452.00 452.00 452.00 452.00 452.00
Cost ofSodium Hypochlorite (6%) (Rs./kg) 6.00 6.00 6.00 6.00 6.00 6.00 6.00 6.00 6.00 6.00 6.00 6.00 6.00 6.00 6.00
Cost of Sodium Hypochlorite (6%) (Rs.in Lakhs per Annum)) 6.73 7.15 7.57 7.57 7.57 7.57 7.57 7.57 7.57 7.57 7.57 7.57 7.57 7.57 7.57
Bagasse Consumption in the Spent wash fired boiler (TPH) 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0
Annual Bagasse Consumption (MTPA) 20832.00 22134.00 23436.00 23436.00 23436.00 23436.00 23436.00 23436.00 23436.00 23436.00 23436.00 23436.00 23436.00 23436.00 23436.00
Landed Cost of bagasse (Rs./MT) 1000.00 1000.00 1000.00 1000.00 1000.00 1000.00 1000.00 1000.00 1000.00 1000.00 1000.00 1000.00 1000.00 1000.00 1000.00
Raw water requirement (Cu.m/day) 1000.00 1000.00 1000.00 1000.00 1000.00 1000.00 1000.00 1000.00 1000.00 1000.00 1000.00 1000.00 1000.00 1000.00 1000.00
Cost of Raw water (Royalty + Pumping Cost) (Rs/Cu.m) 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00
Sale Price of RS (Rs./Litre) 39.00 39.00 39.00 39.00 39.00 39.00 39.00 39.00 39.00 39.00 39.00 39.00 39.00 39.00 39.00
Sale Price of ENA (Rs.Litre) 43.00 43.00 43.00 43.00 43.00 43.00 43.00 43.00 43.00 43.00 43.00 43.00 43.00 43.00 43.00
Sale Price of AA (Rs../Litre) 40.50 40.50 40.50 40.50 40.50 40.50 40.50 40.50 40.50 40.50 40.50 40.50 40.50 40.50 40.50

DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
2017-20182017-2018 2018-2019 2019-2020 2020-2021 2021-2022 2022-2023 2023-2024 2024-2025 2025-2026 2026-2027 2027-2028 2028-2029 2029-2030 2030-2031 2031-2032
Sale Price of TA & FO (Rs./Litre) 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00
Price for the exported Electrical Energy (Rs./kWhr) 5.50 5.50 5.50 5.50 5.50 5.50 5.50 5.50 5.50 5.50 5.50 5.50 5.50 5.50 5.50
Repairs & Maintenance (Rs. Lakhs) 155.56 155.56 155.56 155.56 155.56 155.56 155.56 155.56 155.56 155.56 155.56 155.56 155.56 155.56 155.56
@ 2.00% Of Plant & Machinery Cost
Cost of Balance of the Utilities, Other Chemicals & Yeast Culturing 10.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00
(Rs. Lakhs)
Salaries & Wages Including Labour Contracts (Rs. Lakhs) 220.00 220.00 220.00 220.00 220.00 220.00 220.00 220.00 220.00 220.00 220.00 220.00 220.00 220.00 220.00
Administrative Expenses (Rs. Lakhs) 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00
Interest Rate for Term Loan (%) 12.5
Term Loan Moratorium Period (Years) 2
Term Loan Period including Moratorium (Years) 8
No. Of Quarterly Repayment Instalments 24
Interest on SDF Loan 6.50
SDF Loan Moratorium Till the Trm Loan is Repayed
SDF Loan Repayment (Years) 5.00
SDF Loan Reapyment Half yearly Instalments 10.00
Interest on working capital Loan (%) 14.00 14.00 14.00 14.00 14.00 14.00 14.00 14.00 14.00 14.00 14.00 14.00 14.00 14.00 14.00
Insurance On the Factory Assets (Rs.Lakhs) 18.57 18.57 18.57 18.57 18.57 18.57 18.57 18.57 18.57 18.57 18.57 18.57 18.57 18.57 18.57
(Taken as 0.20% of Equipment & Civil Cost)

DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
2017-20182017-2018 2018-2019 2019-2020 2020-2021 2021-2022 2022-2023 2023-2024 2024-2025 2025-2026 2026-2027 2027-2028 2028-2029 2029-2030 2030-2031 2031-2032
Rate of Depreciation As per Company Law
Buildings & civil Works 3.34% 3.34% 3.34% 3.34% 3.34% 3.34% 3.34% 3.34% 3.34% 3.34% 3.34% 3.34% 3.34% 3.34% 3.34%
Plant & Machinery & Misc Assets 6.33% 6.33% 6.33% 6.33% 6.33% 6.33% 6.33% 6.33% 6.33% 6.33% 6.33% 6.33% 6.33% 6.33% 6.33%
Rate Of Depreciation for IT Computation
Buildings & civil Works 10.00% 10.00% 10.00% 10.00% 10.00% 10.00% 10.00% 10.00% 10.00% 10.00% 10.00% 10.00% 10.00% 10.00% 10.00%
Plant & Machinery & Misc Assets 15.00% 15.00% 15.00% 15.00% 15.00% 15.00% 15.00% 15.00% 15.00% 15.00% 15.00% 15.00% 15.00% 15.00% 15.00%

TABLE 14.2 - TERM LOAN REPAYMENT AND INTEREST SCHEDULE
Loan amount : 5369.1 Interest Rate : 12.50

Loan Term Including Moratorium (Yrs) 8
Payment Moratorium(yrs) 2.0 No. of Quarterly Payments: 24 (RS. IN LAKHS)
Outstandin
g at the Outstanding
Loan Plant Beginning at the End of Interest Paid Repayment
Year Op.Year of Qtr. Repayment Qtr. Interest For the Qtr. for the Year for the Year
1
1 The Interest During Construction is Capitalized.
1
1 1 5369.1 0.00 5369.1 167.78
2 1 5369.1 0.00 5369.1 167.78
2 1 5369.1 0.00 5369.1 167.78
2 1 5369.1 0.00 5369.1 167.78 671.13 0.00
2 2 5369.1 0.00 5369.1 167.78
3 2 5369.1 223.71 5145.3 167.78
3 2 5145.3 223.71 4921.6 160.79
3 2 4921.6 223.71 4697.9 153.80 650.16 671.13
3 3 4697.9 223.71 4474.2 146.81
4 3 4474.2 223.71 4250.5 139.82
4 3 4250.5 223.71 4026.8 132.83
4 3 4026.8 223.71 3803.1 125.84 545.29 894.84
4 4 3803.1 223.71 3579.4 118.85
5 4 3579.4 223.71 3355.7 111.86
5 4 3355.7 223.71 3131.9 104.86
5 4 3131.9 223.71 2908.2 97.87 433.44 894.84
5 5 2908.2 223.71 2684.5 90.88
6 5 2684.5 223.71 2460.8 83.89
6 5 2460.8 223.71 2237.1 76.90
6 5 2237.1 223.71 2013.4 69.91 321.58 894.84
6 6 2013.4 223.71 1789.7 62.92
7 6 1789.7 223.71 1566.0 55.93
7 6 1566.0 223.71 1342.3 48.94
7 6 1342.3 223.71 1118.6 41.95 209.73 894.84
7 7 1118.6 223.71 894.8 34.95
8 7 894.8 223.71 671.1 27.96
8 7 671.1 223.71 447.4 20.97
8 7 447.4 223.71 223.7 13.98 97.87 894.84
8 8 223.7 223.71 0.0 6.99
8 0.0 0.00 0.0 0.00
8 0.0 0.00 0.0 0.00
8 0.0 0.00 0.0 0.00 6.99 223.71

16
TABLE 14.2 - SDF LOAN REPAYMENT AND INTEREST SCHEDULE
Loan amount : 3714.6 Interest Rate : 6.50

Loan Term Including Moratorium (Yrs) 13
Payment Moratorium(yrs) 8.0 No. of Halfyearly Payments: 10 (RS. IN LAKHS)
Outstandin
g at the Outstanding
Loan Plant Beginning at the End of Interest For the Half Interest Paid Repayment
Year Op.Year of Half Yr. Repay-ment Half Yr. Yr. for the Year for the Year
1 The Interest During Construction is Capitalized.

1 1 3714.6 0.00 3714.6 120.72
2 1 3714.6 0.00 3714.6 120.72 241.45 0.00
2 2 3714.6 0.00 3714.6 120.72
3 2 3714.6 0.00 3714.6 120.72 241.45 0.00
3 3 3714.6 0.00 3714.6 120.72
4 3 3714.6 0.00 3714.6 120.72 241.45 0.00
4 4 3714.6 0.00 3714.6 120.72
5 4 3714.6 0.00 3714.6 120.72 241.45 0.00
5 5 3714.6 0.00 3714.6 120.72
6 5 3714.6 0.00 3714.6 120.72 241.45 0.00
6 6 3714.6 0.00 3714.6 120.72
7 6 3714.6 0.00 3714.6 120.72 241.45 0.00
7 7 3714.6 0.00 3714.6 120.72
8 7 3714.6 0.00 3714.6 120.72 241.45 0.00
8 8 3714.6 0.00 3714.6 120.72
9 8 3714.6 371.46 3343.1 120.72 241.45 371.46
9 9 3343.1 371.46 2971.6 108.65
10 9 2971.6 371.46 2600.2 96.58 205.23 742.91
10 10 2600.2 371.46 2228.7 84.51
11 10 2228.7 371.46 1857.3 72.43 156.94 742.91
11 11 1857.3 371.46 1485.8 60.36
12 11 1485.8 371.46 1114.4 48.29 108.65 742.91
12 12 1114.4 371.46 742.9 36.22
13 12 742.9 371.46 371.5 24.14 60.36 742.91
13 13 371.5 371.46 0.0 12.07
14 13 0.0 0.00 0.0 0.00 12.07 371.46

17
TABLE 14.3 - ASSET VALUATION AND DEPRECIATION FOR THE DISTILLERY PLANT
The Prel. & Pre-Op expenses to be capitalised proportionately (Rs.Lakhs) : 914.60

The Contingencies to be Capitalised proportionately (Rs.Lakhs) : 293.00
Asset Value For Depreciation (Rs. In Lakhs)
S.No Particulars Basic Share Of Share of Total Rate Of Amount Of

Cost Prelm. Contin- Cost Deprecia- Depre-
Expenses -gencies -tion (%) -ciation
1 Land 0.00 0.00 0.00 0.00 NA NA
2 Buildings &
Civil Works 605.00 59.59 19.09 683.67 3.34% 22.83
3 Plant & Machinery 8636.4 850.58 272.49 9759.5 6.33% 617.77
4 Misc. assets 45.00 4.43 1.42 50.85 6.33% 3.22
9286.4 914.60 293.00 10494.0 643.83

TABLE 14.4 - ESTIMATES OF COST OF PRODUCTION FOR DISTILLERY OPERATIONS

Rs.in Lakhs
Particulars Operating Years
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
2017-2018 2018-2019 2019-20202019-2020 2020-2021 2021-2022 2022-2023 2023-2024 2024-2025 2025-2026 2026-2027 2027-2028 2028-2029 2029-2030 2030-2031 2031-2032
Raw materials,chemicals,components & consumable stores
1. Molasses From Sugar mill 2966.12 2966.12 2966.12 2966.12 2966.12 2966.12 2966.12 2966.12 2966.12 2966.12 2966.12 2966.12 2966.12 2966.12 2966.12
2. Molasses Bought Out from Near by Mills 322.18 539.09 756.00 756.00 756.00 756.00 756.00 756.00 756.00 756.00 756.00 756.00 756.00 756.00 756.00
3. Bought out Bagasse from Sugar mill 208.32 221.34 234.36 234.36 234.36 234.36 234.36 234.36 234.36 234.36 234.36 234.36 234.36 234.36 234.36
A. Total Raw Material Cost 3496.62 3726.55 3956.48 3956.48 3956.48 3956.48 3956.48 3956.48 3956.48 3956.48 3956.48 3956.48 3956.48 3956.48 3956.48
Utilities & Chemicals
Urea & DAP 4.22 4.48 4.74 4.74 4.74 4.74 4.74 4.74 4.74 4.74 4.74 4.74 4.74 4.74 4.74
Anti foam Oil 4.46 4.74 5.02 5.02 5.02 5.02 5.02 5.02 5.02 5.02 5.02 5.02 5.02 5.02 5.02
Sulphuric Acid 19.84 21.08 22.32 22.32 22.32 22.32 22.32 22.32 22.32 22.32 22.32 22.32 22.32 22.32 22.32
Caustic Soda 79.36 84.32 89.28 89.28 89.28 89.28 89.28 89.28 89.28 89.28 89.28 89.28 89.28 89.28 89.28
Nitric Acid 8.43 8.96 9.49 9.49 9.49 9.49 9.49 9.49 9.49 9.49 9.49 9.49 9.49 9.49 9.49
Sodium Metasulphate 0.07 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08
Anti Scalant 1.67 1.78 1.88 1.88 1.88 1.88 1.88 1.88 1.88 1.88 1.88 1.88 1.88 1.88 1.88
Bio-Dispersant 0.78 0.83 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88
Hydrochloric Acid 0.93 0.99 1.05 1.05 1.05 1.05 1.05 1.05 1.05 1.05 1.05 1.05 1.05 1.05 1.05
Morpholine 1.30 1.38 1.46 1.46 1.46 1.46 1.46 1.46 1.46 1.46 1.46 1.46 1.46 1.46 1.46
Polymer 1.30 1.38 1.46 1.46 1.46 1.46 1.46 1.46 1.46 1.46 1.46 1.46 1.46 1.46 1.46
Corrosion Inhibitor 2.98 3.16 3.35 3.35 3.35 3.35 3.35 3.35 3.35 3.35 3.35 3.35 3.35 3.35 3.35
Hydrazine 0.05 0.05 0.06 0.06 0.06 0.06 0.06 0.06 0.06 0.06 0.06 0.06 0.06 0.06 0.06
Tri Sodium Phosphate 0.06 0.06 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07
Sodium Hypochlorite 6.73 7.15 7.57 7.57 7.57 7.57 7.57 7.57 7.57 7.57 7.57 7.57 7.57 7.57 7.57
Raw water 4.96 5.27 5.58 5.58 5.58 5.58 5.58 5.58 5.58 5.58 5.58 5.58 5.58 5.58 5.58
Misc Utilities and Chemicals 10.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00

TABLE 14.4 - ESTIMATES OF COST OF PRODUCTION FOR DISTILLERY OPERATIONS (Contd.)

Rs.in Lakhs
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
2017-2018 2018-2019 2019-20202019-2020 2020-2021 2021-2022 2022-2023 2023-2024 2024-2025 2025-2026 2026-2027 2027-2028 2028-2029 2029-2030 2030-2031 2031-2032
B. Total Utilities & Chemicals 147.15 155.72 164.29 164.29 164.29 164.29 164.29 164.29 164.29 164.29 164.29 164.29 164.29 164.29 164.29
Labour & Plant Overheads
Wages
Factory Supervision Salaries
C. Total Labour 220.00 220.00 220.00 220.00 220.00 220.00 220.00 220.00 220.00 220.00 220.00 220.00 220.00 220.00 220.00
Repairs & Maintenance 155.56 155.56 155.56 155.56 155.56 155.56 155.56 155.56 155.56 155.56 155.56 155.56 155.56 155.56 155.56
Insurance on Factory Assets 18.57 18.57 18.57 18.57 18.57 18.57 18.57 18.57 18.57 18.57 18.57 18.57 18.57 18.57 18.57
D. Total Factory Overheads 174.13 174.13 174.13 174.13 174.13 174.13 174.13 174.13 174.13 174.13 174.13 174.13 174.13 174.13 174.13
E. Estimate of cost of Production 4037.90 4276.40 4514.90 4514.90 4514.90 4514.90 4514.90 4514.90 4514.90 4514.90 4514.90 4514.90 4514.90 4514.90 4514.90

TABLE 14.5 - ESTIMATES OF PRODUCTION AND SALES FOR DISTILLERY OPERATIONS

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
2017-2018 2018-2019 2019-20202019-2020 2020-2021 2021-2022 2022-2023 2023-2024 2024-2025 2025-2026 2026-2027 2027-2028 2028-2029 2029-2030 2030-2031 2031-2032
1. Annual Production of RS (Lakh Litres) 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
@ specified Product Mix
2. Annual Production of ENA (Lakh Litres) 97.77 103.88 109.99 109.99 109.99 109.99 109.99 109.99 109.99 109.99 109.99 109.99 109.99 109.99 109.99
3. Annual Production of AA (Lakh Litres) 41.66 44.27 46.87 46.87 46.87 46.87 46.87 46.87 46.87 46.87 46.87 46.87 46.87 46.87 46.87
4. Annual Production of TA & FO (Lakh Litres) 7.59 8.06 8.54 8.54 8.54 8.54 8.54 8.54 8.54 8.54 8.54 8.54 8.54 8.54 8.54
5. Annual Electrical Energy Exportable (MkWhr) 1.79 1.90 2.01 2.01 2.01 2.01 2.01 2.01 2.01 2.01 2.01 2.01 2.01 2.01 2.01
6. Sale Price of RS (Rs./Litre) 39.00 39.00 39.00 39.00 39.00 39.00 39.00 39.00 39.00 39.00 39.00 39.00 39.00 39.00 39.00
7. Sale Price of ENA (Rs./Litre) 43.00 43.00 43.00 43.00 43.00 43.00 43.00 43.00 43.00 43.00 43.00 43.00 43.00 43.00 43.00
8. Sale Price of AA (Rs./Litre) 40.50 40.50 40.50 40.50 40.50 40.50 40.50 40.50 40.50 40.50 40.50 40.50 40.50 40.50 40.50
9. Sale Price of TA & FO (Rs./Litre) 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00
10. Sale Price of Electrical Energy (Rs./kWhr) 5.50 5.50 5.50 5.50 5.50 5.50 5.50 5.50 5.50 5.50 5.50 5.50 5.50 5.50 5.50
10. Annual Revenue from RS (Rs. In Lakhs) 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
11. Annual Revenue from ENA (Rs. In Lakhs) 4204.18 4466.94 4729.70 4729.70 4729.70 4729.70 4729.70 4729.70 4729.70 4729.70 4729.70 4729.70 4729.70 4729.70 4729.70
12. Annual Revenue from AA (Rs. In Lakhs) 1757.39 1792.85 1898.32 1898.32 1898.32 1898.32 1898.32 1898.32 1898.32 1898.32 1898.32 1898.32 1898.32 1898.32 1898.32
13. Annual Revenue from TS & FO (Rs. In Lakhs) 151.78 161.26 170.75 170.75 170.75 170.75 170.75 170.75 170.75 170.75 170.75 170.75 170.75 170.75 170.75
14. Annual Revenue from of power (Rs.in Lakhs) 98.21 104.35 110.48 110.48 110.48 110.48 110.48 110.48 110.48 110.48 110.48 110.48 110.48 110.48 110.48
13. Total Annual Sales (Rs. In Lakhs) 6141.55 6525.40 6909.25 6909.25 6909.25 6909.25 6909.25 6909.25 6909.25 6909.25 6909.25 6909.25 6909.25 6909.25 6909.25

TABLE 14.6 - ESTIMATES OF WORKING RESULTS FOR DISTILLERY OPERATIONS (PBDIT)

Rs.in Lakhs
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
2017-2018 2018-2019 2019-20202019-2020 2020-2021 2021-2022 2022-2023 2023-2024 2024-2025 2025-2026 2026-2027 2027-2028 2028-2029 2029-2030 2030-2031 2031-2032
A. COST OF PRODUCTION 4037.90 4276.40 4514.90 4514.90 4514.90 4514.90 4514.90 4514.90 4514.90 4514.90 4514.90 4514.90 4514.90 4514.90 4514.90
Administrative Expenses 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00
B. TOTAL ADMINISTRATIVE EXPENSES 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00
C. MISC EXPENSES 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
D. TOTAL COST OF PRODUCTION 4057.90 4296.40 4534.90 4534.90 4534.90 4534.90 4534.90 4534.90 4534.90 4534.90 4534.90 4534.90 4534.90 4534.90 4534.90
(A + B + C + D)
E. EXPECTED SALES 6141.55 6525.40 6909.25 6909.25 6909.25 6909.25 6909.25 6909.25 6909.25 6909.25 6909.25 6909.25 6909.25 6909.25 6909.25
F. GROSS PROFIT BEFORE INTEREST 2083.65 2229.00 2374.35 2374.35 2374.35 2374.35 2374.35 2374.35 2374.35 2374.35 2374.35 2374.35 2374.35 2374.35 2374.35
(E-D) (PBDIT)

TABLE 14.7 WORKING CAPITAL REQUIREMENTS FOR DISTILLERY OPERATIONS
Rs.in Lakhs
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
2017-2018 2018-2019 2019-20202019-2020 2020-2021 2021-2022 2022-2023 2023-2024 2024-2025 2025-2026 2026-2027 2027-2028 2028-2029 2029-2030 2030-2031 2031-2032
1. Annual Sales 6141.55 6525.40 6909.25 6909.25 6909.2 6909.25 6909.25 6909.25 6909.25 6909.25 6909.25 6909.25 6909.25 6909.25 6909.25
2. Receivables for 15 Days 297.17 315.75 334.32 334.32 334.32 334.32 334.32 334.32 334.32 334.32 334.32 334.32 334.32 334.32 334.32
3. Stock for 30 days 497.11 528.18 559.25 559.25 559.25 559.25 559.25 559.25 559.25 559.25 559.25 559.25 559.25 559.25 559.25
(Only for Alcohol Based on the Sales less 15%)
4. Molasses Stock for 15 days 159.11 169.61 180.10 180.10 180.10 180.10 180.10 180.10 180.10 180.10 180.10 180.10 180.10 180.10 180.10
(Based on the average cost)
5. R&M For 30 days 12.96 12.96 12.96 12.96 12.96 12.96 12.96 12.96 12.96 12.96 12.96 12.96 12.96 12.96 12.96
6. Bagasse Stock for 15 days 10.08 10.71 11.34 11.34 11.34 11.34 11.34 11.34 11.34 11.34 11.34 11.34 11.34 11.34 11.34
7. Total Working Capital Requirement 976.44 1037.21 1097.98 1097.98 1097.98 1097.98 1097.98 1097.98 1097.98 1097.98 1097.98 1097.98 1097.98 1097.98 1097.98
8. Working Capital Loan (75% of WC) 732.33 777.91 823.48 823.48 823.48 823.48 823.48 823.48 823.48 823.48 823.48 823.48 823.48 823.48 823.48
9. Interest On Working Capital Loan 102.53 108.91 115.29 115.29 115.29 115.29 115.29 115.29 115.29 115.29 115.29 115.29 115.29 115.29 115.29
10. Increase in Working Capital loan 732.33 45.58 45.58 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
11. Margin Money for Working Capital 244.11 259.30 274.49 274.49 274.49 274.49 274.49 274.49 274.49 274.49 274.49 274.49 274.49 274.49 274.49
12. Increase in the Margin Money 244.11 15.19 15.19 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

TABLE 14.8 - ESTIMATES OF WORKING RESULTS FOR DISTILLERY OPERATIONS (NET PROFIT)
Rs.in Lakhs
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
2017-2018 2018-2019 2019-20202019-2020 2020-2021 2021-2022 2022-2023 2023-2024 2024-2025 2025-2026 2026-2027 2027-2028 2028-2029 2029-2030 2030-2031 2031-2032
A. Gross Profit 2083.65 2229.00 2374.35 2374.35 2374.35 2374.35 2374.35 2374.35 2374.35 2374.35 2374.35 2374.35 2374.35 2374.35 2374.35
Financial Expenses
Interest on Term Loans 912.58 891.61 786.74 674.89 563.03 451.18 339.32 248.44 205.23 156.94 108.65 60.36 12.07 0.00 0.00
Interest on borrowings for working Capital 102.53 108.91 115.29 115.29 115.29 115.29 115.29 115.29 115.29 115.29 115.29 115.29 115.29 115.29 115.29
B. TOTAL FINANCIAL EXPENSES 1015.10 1000.51 902.03 790.17 678.32 566.46 454.61 363.72 320.52 272.23 223.94 175.65 127.36 115.29 115.29
C. DEPRECIATION 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83
D. OPERATING PROFIT (A - B - C) 424.7 584.7 828.5 940.3 1052.2 1164.1 1275.9 1366.8 1410.0 1458.3 1506.6 1554.9 1603.2 1615.2 1615.2
E. OTHER INCOME, IF ANY (GIVE DETAILS) 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
F. PROFIT / LOSS BEFORE TAXATION (D+E) 424.7 584.7 828.5 940.3 1052.2 1164.1 1275.9 1366.8 1410.0 1458.3 1506.6 1554.9 1603.2 1615.2 1615.2
G. PROVISION FOR TAXATION 84.98 116.98 165.76 188.14 286.49 378.85 451.53 511.95 551.80 589.66 624.35 656.34 686.04 701.47 711.13
H. PROFIT AFTER TAX (F-G) 339.74 467.68 662.73 752.20 765.71 785.21 824.38 854.84 858.20 868.63 882.23 898.52 917.12 913.76 904.10
Less: Dividend on 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%
- Equity capital (with rate) 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
I. RETAINED PROFIT 339.7 467.68 662.73 752.20 765.71 785.21 824.38 854.84 858.20 868.63 882.23 898.52 917.12 913.76 904.10
Add: Depreciation 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83
J. NET CASH ACCRUALS 983.57 1111.51 1306.55 1396.03 1409.53 1429.04 1468.21 1498.67 1502.03 1512.46 1526.06 1542.35 1560.94 1557.59 1547.92

TABLE 14.9 - DEPRECIATION SCHEDULE FOR INCOME TAX PURPOSES FOR DISTILLERY OPERATIONS
Rs.in Lakhs
Particulars Year
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
2017-2018 2018-2019 2019-2020 2020-20212020-2021 2021-2022 2022-2023 2023-2024 2024-2025 2025-2026 2026-2027 2027-2028 2028-2029 2029-2030 2030-2031 2031-2032
Buildings :
Rate of Deprecn(%) 10.00%

WDV 683.67 615.31 553.78 498.40 448.56 403.70 363.33 327.00 294.30 264.87 238.38 214.54 193.09 173.78 156.40
Depreciation 68.37 61.53 55.38 49.84 44.86 40.37 36.33 32.70 29.43 26.49 23.84 21.45 19.31 17.38 15.64
Plant & Machinery

Rate of Deprecn(%) 15.00%
WDV 9810.3 8338.77 7087.96 6024.76 5121.05 4352.89 3699.96 3144.96 2673.22 2272.24 1931.40 1641.69 1395.44 1186.12 1008.20
Depreciation 1471.5 1250.8 1063.2 903.7 768.2 652.9 555.0 471.7 401.0 340.8 289.7 246.3 209.3 177.9 151.2
Total Depreciation for 1539.92 1312.35 1118.57 953.55 813.01 693.30 591.33 504.44 430.41 367.32 313.55 267.71 228.62 195.30 166.87
Income Tax Purposes

TABLE 14.10 - COMPUTATION OF INCOME TAX LIABILITY FOR DISTILLERY OPERATIONS

Rs.in Lakhs
Particulars Year
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
2017-2018 2018-2019 2019-2020 2020-20212020-2021 2021-2022 2022-2023 2023-2024 2024-2025 2025-2026 2026-2027 2027-2028 2028-2029 2029-2030 2030-2031 2031-2032
Net Profit Before Taxation 424.7 584.66 828.49 940.34 1052.20 1164.05 1275.91 1366.79 1410.00 1458.29 1506.58 1554.87 1603.16 1615.23 1615.23
Add: Book Depreciation 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83
Profits before Depreciation 1068.55 1228.49 1472.32 1584.17 1696.03 1807.88 1919.74 2010.62 2053.83 2102.12 2150.41 2198.70 2246.99 2259.06 2259.06
And Tax
Less: Depreciation as per 1539.9 1312.35 1118.57 953.55 813.01 693.30 591.33 504.44 430.41 367.32 313.55 267.71 228.62 195.30 166.87
Income Tax Act
Tax Profit -471.4 -83.9 353.75 630.62 883.01 1114.58 1328.41 1506.18 1623.42 1734.79 1836.86 1930.99 2018.36 2063.76 2092.19
Carry Forward 0.00 -471.4 -555.2 -201.48 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Net Taxable Profit 0.0 0.0 0.0 429.1 883.0 1114.6 1328.4 1506.2 1623.4 1734.8 1836.9 1931.0 2018.4 2063.8 2092.2
Income Tax 0.00 0.00 0.00 139.23 286.49 378.85 451.53 511.95 551.80 589.66 624.35 656.34 686.04 701.47 711.13
Minimum Alternate Tax (MAT) 84.98 116.98 165.76 188.14 220.55 243.99 267.44 286.49 295.54 305.66 315.79 325.91 336.03 338.56 338.56
Tax Payable 84.98 116.98 165.76 188.14 286.49 378.85 451.53 511.95 551.80 589.66 624.35 656.34 686.04 701.47 711.13

TABLE 14.11 - PROJECTED CASH FLOW STATEMENT

Rs.in Lakhs
Particulars Construction Year
Period
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
2017-2018 2018-20192018-2019 2019-2020 2020-2021 2021-2022 2022-2023 2023-2024 2024-2025 2025-2026 2026-2027 2027-2028 2028-2029 2029-2030 2030-2031 2031-2032
Sources Of Funds :
Share Issue 1654.49 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Profit before taxation with 0.00 1439.82 1585.17 1730.52 1730.52 1730.52 1730.52 1730.52 1730.52 1730.52 1730.52 1730.52 1730.52 1730.52 1730.52 1730.52
Interest added back
Depreciation provision for 0.00 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83
the year
Increase in term loans from FI 9083.6 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Modvat Benefits 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Increase in bank borrowings 0.00 732.33 45.58 45.58 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
For Working Capital
TOTAL 10738.1 2815.98 2274.58 2419.92 2374.35 2374.35 2374.35 2374.35 2374.35 2374.35 2374.35 2374.35 2374.35 2374.35 2374.35 2374.35

TABLE 14.11 - PROJECTED CASH FLOW STATEMENT (Contd.)

Rs.in Lakhs
Particulars Construction Year
Period
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
2017-2018 2018-20192018-2019 2019-2020 2020-2021 2021-2022 2022-2023 2023-2024 2024-2025 2025-2026 2026-2027 2027-2028 2028-2029 2029-2030 2030-2031 2031-2032
Disposition of Funds :
1. Capital expenditure for 10494.0 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
the project
2. Increase in Working Capital 0.00 976.44 60.77 60.77 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
3. Decrease in term loans 0.00 0.00 671.13 894.84 894.84 894.84 894.84 894.84 595.17 742.91 742.91 742.91 742.91 371.46 0.00 0.00
4. Interest on term loans 0.00 912.58 891.61 786.74 674.89 563.03 451.18 339.32 248.44 205.23 156.94 108.65 60.36 12.07 0.00 0.00
5. Interest on bank borrow- 0.00 102.53 108.91 115.29 115.29 115.29 115.29 115.29 115.29 115.29 115.29 115.29 115.29 115.29 115.29 115.29
ings for working capital
6. Taxation 0.00 84.98 116.98 165.76 188.14 286.49 378.85 451.53 511.95 551.80 589.66 624.35 656.34 686.04 701.47 711.13
TOTAL 10494.0 2076.52 1849.39 2023.40 1873.16 1859.65 1840.15 1800.98 1470.84 1615.23 1604.80 1591.20 1574.90 1184.86 816.76 826.42
Opening Balance 0.00 244.11 983.57 1408.76 1805.28 2306.47 2821.16 3355.35 3928.72 4832.23 5591.34 6360.89 7144.04 7943.48 9132.97 10690.55
Net Surplus 244.11 739.46 425.19 396.52 501.19 514.69 534.20 573.37 903.50 759.12 769.55 783.15 799.44 1189.49 1557.59 1547.92
Closing Balance 244.11 983.57 1408.76 1805.28 2306.47 2821.16 3355.35 3928.72 4832.23 5591.34 6360.89 7144.04 7943.48 9132.97 10690.55 12238.48

TABLE 14.12 - IRR , DSCR & PAYBACK PERIOD

Rs.in Lakhs
Particulars Year
Construction
Period
-1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
2017-2018 2018-2019 2019-20202019-2020 2020-2021 2021-2022 2022-2023 2023-2024 2024-2025 2025-2026 2026-2027 2027-2028 2028-2029 2029-2030 2030-2031 2031-2032
Capital Expenditure -10494.0 - - - - - - - - - - - - - -
Working Capital Outflow 0.00 -244.11 -15.19 -15.19 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
-- DO --- 274.49
Terminal Value Of Equipment ** - - - - - - - - - - - - - - - 2850.44
Operating Inflow
Profit After Tax 339.74 467.68 662.73 752.20 765.71 785.21 824.38 854.84 858.20 868.63 882.23 898.52 917.12 913.76 904.10
Depreciation 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83 643.83
Interest on Term Loan 912.58 891.61 786.74 674.89 563.03 451.18 339.32 248.44 205.23 156.94 108.65 60.36 12.07 0.00 0.00
Total operating inflow 1896.15 2003.12 2093.30 2070.92 1972.56 1880.21 1807.53 1747.11 1707.26 1669.40 1634.71 1602.71 1573.02 1557.59 1547.92
Net Flow -10494.0 1652.0 1987.9 2078.1 2070.9 1972.6 1880.2 1807.5 1747.1 1707.3 1669.4 1634.7 1602.7 1573.0 1557.6 4672.9
IRR (after Tax) 16.22% Discount Rate (WACC)% 11.30%

********
NPV (Rs. in Lakhs) 3039.74
*********
Return On Equity (ROE):
Equity -1654.5 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Profits after Tax 339.7 467.68 662.73 752.20 765.71 785.21 824.38 854.84 858.20 868.63 882.23 898.52 917.12 913.76 904.10
Net Flow -1654.5 339.7 467.7 662.7 752.2 765.7 785.2 824.4 854.8 858.2 868.6 882.2 898.5 917.1 913.8 904.1
ROE 35.51%
***** *********
Note: ** - The Terminal Value of the Equipment is taken as 50 % of the Installed Plant and Machinery cost less the Income Tax Payable.

TABLE 14.12 - IRR , DSCR & PAYBACK PERIOD (Contd.)

Rs.in Lakhs
Particulars Year
Construction
Period
-1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
2017-2018 2018-2019 2019-20202019-2020 2020-2021 2021-2022 2022-2023 2023-2024 2024-2025 2025-2026 2026-2027 2027-2028 2028-2029 2029-2030 2030-2031 2031-2032
Interest Payment On Term Loan - 912.58 891.61 786.74 674.89 563.03 451.18 339.32 248.44 205.23 156.94 108.65 60.36 12.07 0.00 0.00
Term Loan Repayment - 0.00 671.13 894.84 894.84 894.84 894.84 894.84 595.17 742.91 742.91 742.91 742.91 371.46 0.00 0.00
DSCR 2.08 1.28 1.24 1.32 1.35 1.40 1.46 2.07 1.80 1.86 1.92 2.00 4.10 NA NA
Average DSCR 1.84

**********
Operating Inflow 1896.15 2003.12 2093.30 2070.92 1972.56 1880.21 1807.53 1747.11 1707.26 1669.40 1634.71 1602.71 1573.02 1557.59 1547.92
Project Cost - Working -10494.0

capital Margin
Cumulative Net Cash FLow -10494.00 -8597.8 -6594.7 -4501.44 -2430.5 -457.96 1422.26 3229.79 4976.89 6684.15 8353.55 9988.26 11590.98 13163.99 14721.58 16269.50
1.00 1.00 1.00 1.00 1.00 0.24 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Payback Period 5.2 Years
******** ********

TABLE 14.13 - Projected Balance Sheet

Rs.in Lakhs
Particulars Year
Construction
Period
-1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
2017-2018 2018-2019 2019-20202019-2020 2020-2021 2021-2022 2022-2023 2023-2024 2024-2025 2025-2026 2026-2027 2027-2028 2028-2029 2029-2030 2030-2031 2031-2032
LIABILITIES
Share Capital 1654.49 1654.49 1654.49 1654.49 1654.49 1654.49 1654.49 1654.49 1654.49 1654.49 1654.49 1654.49 1654.49 1654.49 1654.49 1654.49
Reserves And Surpluses 0.00 339.74 807.43 1470.2 2222.35 2988.06 3773.27 4597.65 5452.49 6310.69 7179.33 8061.56 8960.08 9877.20 10790.96 11695.05
Term Loans (FI+SDF) 9083.6 9083.6 8412.5 7517.6 6622.8 5728.0 4833.1 3938.3 3343.1 2600.2 1857.3 1114.4 371.5 0.0 0.0 0.0
Modvat Benefits 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Bank Borrowings 0.00 732.33 777.91 823.48 823.48 823.48 823.48 823.48 823.48 823.48 823.48 823.48 823.48 823.48 823.48 823.48
Total 10738.11 11810.18 11652.31 11465.77 11323.13 11193.99 11084.36 11013.90 11273.57 11388.86 11514.58 11653.90 11809.51 12355.17 13268.93 14173.03
ASSETS
Fixed Assets 10494.00 9850.17 9206.34 8562.51 7918.68 7274.86 6631.03 5987.20 5343.37 4699.54 4055.72 3411.89 2768.06 2124.23 1480.40 836.57
(Less:Depreciation)
Current Assets 0.00 976.44 1037.21 1097.98 1097.98 1097.98 1097.98 1097.98 1097.98 1097.98 1097.98 1097.98 1097.98 1097.98 1097.98 1097.98
Cash In Hand 244.11 983.57 1408.76 1805.3 2306.47 2821.16 3355.35 3928.72 4832.23 5591.34 6360.89 7144.04 7943.48 9132.97 10690.55 12238.48
Total 10738.11 11810.18 11652.31 11465.77 11323.13 11193.99 11084.36 11013.90 11273.57 11388.86 11514.58 11653.90 11809.51 12355.17 13268.93 14173.03

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15.0 DRAWING LIST
Sl. Description Drawing No.

No
1. Process flow diagram for fermentation 1-15003-800-0001, Rev.0
section
2. Process flow diagram for distillation 1-15003-800-0002, Rev.0
section
3. Process flow diagram for Molecular 3-15003-800-0003, Rev.0
Sieve De-hydration Section
4. Process flow diagram for Spent wash 1-15003-800-0004, Rev.0
evaporation system
5. Process flow diagram for Effluent 3-15003-800-0005, Rev.0

Treatment Plant
6. Block diagram for effluent generation 4-15003-800-0006, Rev.0

and treatment
7. Process flow diagram for product 1-15003-800-0007, Rev.0
storage section
8. General arrangement of boiler 1-15003-800-0008, Rev.0

(Elevation)
9. Process flow diagram for Plant Steam 3-15003-800-0009, Rev.0
System
10. Process flow diagram for Cooling Water 3-15003-800-0010, Rev.0
System
11. Process flow diagram for Raw Water and 3-15003-800-0011, Rev.0
DM Water System
12. Organization chart 4-15003-800-0012, Rev.0
13. Overall View of the control system 3-15003-800-0013, Rev.0
14. Overall plant layout 0-15003-600-0016, Rev.0
---------------------------------------------------------------------------------------------------------------------------------------
15. Unit Plot Plan for Distillery and spent 0-15003-600-0017, Rev.0
wash based incineration plant
16. Protection, Metering & Control 1-15003-900-0453, Rev.0
schematic diagram
17. Cogeneration scheme Fig-1, Rev.0
18. Power Balance Fig-2, Rev.0

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DETAILED PROJECT REPORT

GOBIND SUGAR MILLS LIMITED

M/s.GOBIND SUGAR MILLS LIMITED

AVANT-GARDE ENGINEERS AND CONSULTANTS (P) LTD.

TEL:91-44-24827843 / 24828532 FAX: 91-44-24828531

2.0 PLANT AND EQUIPMENT DESIGN CRITERIA

3.0 PROCESS DESCRIPTION, UTILITY REQUIREMENTS AND

4.0 ENVIRONMENTAL IMPACT AND EFFLUENT DISPOSAL

5.0 SPENT WASH CONCENTRATION AND INCINERATION

6.0 DESCRIPTION OF PLANT ELECTRICAL SYSTEMS AND

7.0 INSTRUMENTATION AND CONTROL SYSTEM

8.0 PROJECT CIVIL & ARCHITECTURAL REQUIREMENTS

9.0 SITE FEATURES AND PLANT LAYOUT

10.0 OPERATION AND MAINTENANCE REQUIREMENTS

12.0 PROJECT IMPLEMENTATION AND SCHEDULE

13.0 PROJECT COST ESTIMATE

14.0 FINANCIAL ANALYSIS

15.0 DRAWING LIST

3.0 Alcohol manufactured from sugar mills, by virtue of its renewable

aggressive usage of absolute alcohol, also commercially called as

5.0 This RS is further purified by removing most of the impurities,

11.0 The distillation process is the separation of ethyl alcohol from

13.0 The steam requirement for the production of RS from fermented

 Distillery Process requirement : 775 KW

With 2150 kW of generation under the MCR operation of the

15.0 The water requirements of the distillery plant is proposed to be

16.0 The implementation of the new distillery project is expected to be

19.0 GSML proposes to use in-house generated molasses predominantly

21.0 No escalation is considered both in the input materials cost and in

22.0 The depreciation computed is on straight line basis at 6.33%% for

23.0 Income tax at the rate of 30%, with a surcharge of 5% or 10%

25.0 The return on Equity is calculated at 35.51%. The average debt

1.2 India’s total installed ethyl alcohol production capacity is 4 billion

2.0 PLANT AND EQUIPMENT DESIGN CRITERIA

The proposed 60 KLPD distillery facility at Coromandel Sugars

The complete plant instrumentation and control system for the

2.2 Plant & Machinery design criteria

changes could occur as the detailed engineering of the plant

2.3 Ambient Conditions

Plant Elevation above Mean Sea Level (MSL) : 160 meters

 Maximum Temperature : 45 Deg.C

* Total Annual Rainfall, average : 600 mm

* Wind Direction : East - West

* Design Wind Velocity : As per IS:875

* Design : As per IS:1893

Soil Bearing Capacity:

* At 2.0 m Depth : 12 MT/Sq.M

2.4 Plant input specification

Molasses is the mother liquor left after crystallizing out a major

Various components present in molasses are:- Water: 20% to 30%

Molasses should be free from any foreign material including any

Fermentable Sugars : 36.8 % (w/w)

Brix (%) : 89.4%

Total Organics (other : Max. 6-8% w/w

Total inorganics : Max.13.79% w/w

Volatile Acids : Max. 500 ppm

Butyric acid : NIL

Total viable count : Max.1000 cfu/gm

Free assimilable : Min. 1300 ppm