pre-feasibility report for distillery...
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Pre-feasibility Report: Expansion of grain based distillery unit
M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 1
PRE-FEASIBILITY REPORT
PROPOSED EXPANSION FROM 60 TO 200 KLPD CAPACITY
OF GRAIN BASED DISTILLERY UNIT OF
M/S ANKUR BIOCHEM PVT. LTD., DHANBAD, JHARKHAND
SUMMARY
The proposed project is an expansion of existing grain based distillery unit of M/s. Ankur Biochem
Private Limited (ABPL). The capacity of existing unit is of 60 kilo litres per day (KLPD), which will be
enhanced to 200 KLPD. The existing unit is located at Tetulia More, Lakheiya Bridge Post Dubi,
Dhanbad, Jharkhand, (PIN 828205). The constructed area (including process, office, waste
management, storage, etc) of the existing unit is approximately four acres (~15,050 sq.m.). The
proposed unit will be installed within the existing industrial premises. It will require about two and
half acres of land (~9,900 sq.m.). The industry has 28 acres of land which is adequate for the
proposed expansion. The required raw material and resources such as grains and fuel (coal and rice
husk) will be made available from the local market. The machinery required for the unit is also
available indigenously. The capital cost of the project is Rs. 11,900 Lakhs of which Rs. 500 lakhs are
allocated for environment management purpose.
The effluent treatment scheme of existing unit comprised of decantation, evaporation and distillers’
dry grains with soluble (DDGS) units. Condensate Polishing Unit (CPU) has been provided to treat the
vapour condensate from DDGS. The effluent from proposed unit will also be treated by same
method but by adequately enhancing the capacity of existing units. During the effluent treatment,
DDGS of 115 Tons per day (TPD) is estimated to be generated as a solid waste. DDGS is popularly
used as a cattle or poultry feed and will be sold in the nearby markets. Steam condensate from
manufacturing process will be recycled as boiler feed water. The treated water from CPU will be
recycled in process and irrigation purpose. This way the industry has planned to achieve Zero Liquid
Discharge (ZLD) guideline prescribed under CREP norms.
Pre-feasibility Report: Expansion of grain based distillery unit
M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 2
2.1 Project Highlights
1 Name of the Proponent M/s. Ankur Biochem Private Limited (ABPL)
2 Type Large Scale Industry (private limited company )
3 Project Expansion of grain based distillery unit from 60 to 200 KLPD ( by
adding a unit of 140 KLPD)
4 Location of the project Tetulia More, Dubhi, P.S. Nirsa, Duvi, Dist: Dhanbad- 828 205
State: Jharkhand, India
Email: [email protected]
Tel. : 09434002234 / 09332075801
Fax: 0341-2303281
A Latitude & Longitude 23°47'7.18"N and 86°38'47.49"E (altitude 162m)
5 Environmental Settings of the Area
A Nearest National Highway NH-2/AH1 is ~2.7 Km away from site
B Nearest Railway Station Kalubatham is ~13 km (towards SE), Dhanbad: ~25Km
C Nearest air port Dhanbad: ~25Km, Kolkatta: ~240 Km
D National Park, Wild Life
Sanctuary, Biosphere Reserves
etc.) within 10
km radius
None within 10 km radius of the project site
E Nearest Town / City Dhanbad: ~ 25Km (towards West)
F Nearest River Khudia river ~ 0.8 km towards south
G Seismic Zone Seismic zone III as per IS: 1893 (Part-I) : 2002
6 Land Requirement 2.5 acres of land for proposed unit; 28.11 acres of land is
available with project proponent
7 Product and Raw material details
A Product Product Production
ENA
Impure Spirit/Technical alcohol
200.00 KLPD
10.00 KLPD
Distillers’ Dry Grain with
Soluble (DDGS)
115.00 TPD
B Operation Days per annum Around the year
C Main Raw Material Quantity
Grain Flour 530.00 TPD
Nutrients DAP and Urea ~0.5TPD each
Turkey Red Oil (TRO) As per requirement
D Water Requirement 1721 cum / day
Water will be drawn from three Source: 1) Ground water
(permission available for existing unit), 2) from Maithan
reservoir (permission available) and 3) from rivulet Khudia
(permission available)
Pre-feasibility Report: Expansion of grain based distillery unit
M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 3
E. Steam and Fuel Coal: Max. 13 TPH i.e. 312 TPD (for 200 KLPD capacity)
OR
Rice husk: ~13.4TPH i.e. 322 TPD (for proposed only)
Considering steam requirement of 51TPH
fuel to steam ratio of 1:4 (coal) and 1:3.8 (Rice husk)
Source of coal : Local market at Dhanbad
Rice husk: markets from Jharkhand, Bengal and Bihar
8 Effluent Treatment System Decantation followed by evaporation followed by dryer
For Secondary effluent Primary followed by Ecophoto-X
followed by carbon filtration as a tertiary treatment
9 Man power Existing 65, additional about 20 persons = 85
11 Total Project Cost Rs. 11,900.00 Lakhs
12 Capital expenses for
environment management
Rs. 500.00 lakhs
INTRODUCTION
1.2 Project Proponent: M/s. Ankur Biochem Private Limited is a business unit belonging to a
business group that consists of M/s. Ankur Chemfood Pvt. Ltd, Gandhidham, Gujarat and M/s. Ankur
Salt Marketing. Mr. Mahendra Sharma is the project proponent. Mr. Sharma is also engaged in steel
industry as a Director of M/s. Kunj Bihari Steel Pvt. Ltd. Jamuria, West Bengal. His business roots are
largely spread over the states of Jharkhand and West Bengal. The average annual turnover of the
group is around Rs. 15,000 Lacs employing around 350 persons.
M/s. Ankur Biochem Pvt. Ltd. has planned to enhance/expand the existing grain based distillery
unit’s capacity from 60 – 200 KLPD. The industry is registered under the Companies Act 1956, having
Corporate Identity Number U24100WB2008PTC128390.
The proposed unit will manufacture mainly Extra Neutral Alcohol (ENA) and Impure Spirit using
grains as raw material. If needed, the plant will manufacture Rectified Spirit (RS). Distillers’ Wet
Grains with Soluble (DWGS) or DDGS will be a byproduct of the process which has a demand in the
market as cattle or poultry feed.
2.3 Need of project and its importance to the country and region
In India, mainly three types of alcohol are popularly produced, i.e. rectified spirit (RS), extra neutral
alcohol (ENA) and anhydrous alcohol (AA). Of these, RS is used for large number of industrial,
scientific, laboratory, medical and many other applications. Thus, demand for the same is immense
and it is ever increasing. ENA is used for making liquors and other alcoholic beverages.
2.4 Demand and Supply Gap
There are more than 300 distilleries in the country with a total installed capacity of 3,500 million
litres per annum. However, it is discouraging to note that in spite of such abundant licensed and
installed capacity alcohol production in the country has been lagging behind and is varying only
around 1,900-2,000 million litres per annum. Thus, it is not withstanding the great demand for
alcohol both for chemical industry and for potable purpose, The target of alcohol demand as
projected in the perspective plan for Chemical Industry; Department of Chemical & Petrochemicals,
Government of India is 2,710 million litres per annum.
Pre-feasibility Report: Expansion of grain based distillery unit
M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 4
2.5 Import vs. Indigenous production
The process is straight line and the technology even for the pollution control/disposal is available
indigenously.
2.6 Export Possibility
The finished products i.e. Extra Neutral Alcohol has an excellent export potential.
2.7 Domestic / export markets
Market places such as Kolkata, major cities of UP, Bihar, West Bengal as well as markets of Delhi are
the potential domestic market for ENA. ENA also has excellent export potential. Kolkata is the
nearest port for international export.
2.8 Employment Generation
Proposed project will generate about 20 new employment opportunities for skilled as well as
unskilled persons. Apart from this, the project is anticipated to give plenty of indirect opportunities
to transporters, shopkeepers, and various facility providers such as refreshment centres, etc.
3.0 PROJECT DESCRIPTION
3.1 Grain Storage
Grains will be procured in bulk and manually unloaded onto pit for bucket elevator. Unloaded grains
are pre-cleaned through de-stoner and classifier equipment and further stored in Grain Silos.
3.2 Grain Milling
Grains will be milled in to flour of desired quality and mesh size using hammer mill (dry milling
process). Different grains such as broken rice, maize, sorghum, millets, etc. can be used in the same
mills. However, the flour so obtained is passed through classifiers and screens to retain certain mesh
size as desirable by the process. Weighed quantity of Flour is sent into liquefaction process, where
the starch is liquefied completely.
3. 3 Liquefaction Section
In liquefaction process, starch is hydrolyzed to dextrin. The liquefaction is carried out in single stage
liquefaction tank. Feedstock flour is transferred to pre-masher and mixed with recycle streams and
liquefying enzyme. Slurry from pre-masher is taken to liquefaction tank where temperature is
maintained by means of steam. Necessary retention time is maintained in the liquefaction tank.
Slurry pH is maintained by supplying dilute caustic solution. Contents in slurry tank are kept in
suspension by agitation. The liquefied slurry is then cooled in slurry cooler using cooling water
supply and transferred to pre-fermentation and fermentation section.
3. 4 Saccharification & Fermentation
Yeast Activation
Yeast seed material is prepared in pre-fermenter by inoculating sterilized mash with yeast. Optimum
temperature is maintained by circulating cooling water. The contents of the pre-fermenter are then
transferred to fermenter. The purpose of fermentation is to convert the fermentable substrate into
alcohol.
Pre-feasibility Report: Expansion of grain based distillery unit
M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 5
3.5 Distillation
Pre-heated fermented wash will be fed to degasser column. Alcohol is stripped off from fermented
wash by ascending vapours in analyser column. Rectifier vapours provide energy to analyser column
through a thermosyphon reboiler. Vapours of degasser column are condensed and taken to recovery
feed tank. The condensed analyser vapors are taken to pre-rectifier column. Analyser condensate is
concentrated in pre-rectifier column, which operates under pressure. Condensing steam provides
energy to pre-rectifier column through a vertical thermosyphon reboiler. A technical alcohol cut of
about 1-2% of total spirit is taken from the pre-rectifier column. Concentrated alcohol draw from
pre-rectifier column is fed to ED column for purification. Dilution water in the ratio of 1:9 is added in
this column for concentrating higher alcohol at the top. Technical alcohol cut is taken out from the
top of this column while ENA draw is taken out from appropriate upper trays and fed to simmering
column after cooling. Fusel oil build up is avoided by taking fusel oil draws from appropriate trays.
These fusel oils along with the condensate of degasifying & extractive distillation columns are fed to
recovery column for concentration. A technical alcohol cut is taken out from the top of this column.
3.6 Decantation & Thin Slops Recycle Section
Decantation section comprises of a centrifuge decanter for separation of suspended solids from
spent wash coming out of grain distillation plant. Wet cake has 30-32% solids (w/w) as removed
from bottom of decanter which can be sold directly in wet form as cattle feed (DWGS).
Thin slops coming out of decanter are collected in a tank and partly recycled into the process and
further for evaporation for concentration up to 35-40% w/w solids. The concentrated thin slops
called as Syrup is mixed with wet cake and sold in wet form as cattle feed (DWGS) or the entire
mixture can be dried in a DDGS Dryer and then sold in dry form as cattle feed (DDGS).
3.7 DWGS DRYER WITH COOLING AND CONVEYING SYSTEM
Wet distiller’s grains shall be fed into the dryer housing at controlled rate through a suitable feeding
system. The Rotary tube bundle is enclosed in an insulated dryer housing and its outer flights are
fixed. Dry saturated steam is to be supplied to the tube bundle through rotary joint at one end and
the condensate is discharged through rotary joint mounted on another end. During the course of
rotation, these flights pick up the material and shower them on to the tube bundles. The heat
transfer is primarily by conduction. The water vapours are exhausted through an exhaust blower &
passed through a cyclone separator for separating fines. Dry product is partially recycled back to
feed conditioner through product screw and recycle conveyor.
Pre-feasibility Report: Expansion of grain based distillery unit
M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 6
Fig 1: Flow Diagram of manufacturing process
Grain Cleaning, Milling And Flour Handling Section
Slurry Preparation & Liquefaction Section
FERMENTATION SECTION
Multipressure Distillation Section
Decantation
Section
Spirit Storage Section
(ENA/TA)
EVAPORATION PLANT
Water Storage
Power Generation
House
Boiler
Turbine
Process
Condensate Treatment &
Recycle
DWGS Dryer
Steam & Water Supply
Wet cake
Conc. Syrup
DDGS
Pre-feasibility Report: Expansion of grain based distillery unit
M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 7
3.6 Raw materials
Table 1: Availability raw materials & finish good product and transport mode
Raw materials
Estimated quantity /day
Source/ market
final product
Estimated quantity KL/day
Source/ market
Transport mode
Grain 530MT Damaged grain and surplus grain from markets of Jharkhand, West Bengal, Bihar, Uttar Pradesh
ENA + Impure Spirit (Technical alcohol) DDGS
200 KLPD 10KLPD 115TPD
Major markets of India from West Bengal, Bihar, Uttar Pradesh
Surface transport using track and Tankers
Nutrients N, P
As per requirement
Local market at Dhanbad, Ranchi, Kolkatta
- - -- Surface transport using Trucks/ Tempo
Turkey Red Oil (TRO)
As per requirement
Local market at Dhanbad, Ranchi
- - --
Surface transport using Trucks/ Tempo
3.7 Resource optimization / recycle and reuse envisaged in the project, if any, briefly describe
Optimum utilization of the available resources is strived by the management. These resources
include land, coal, steam, grain and power.
3.8 Availability of water and its source
a) Source: Water required for the proposed capacity will be 1,721 cum for day-to-day operations. It
will be drawn from (a) bore well, (b) rivulet Khudiya and (c) from reservoir at Maithan. The
permissions for water drawl from respective authorities are available with project proponent.
Power: Power requirement for the proposed capacity (i.e. 200KLPD) will be of 4000kWh. Captive
power will be used. Presently, turbine of 2 MW is installed, in addition to which a new turbine of 4
MW will be installed. These two turbines together will fulfill the power requirement of the proposed
distillery capacity.
Fuel: Coal or rice husk will be use as a fuel for the steam generation activity. If coal (Indian) is
utilized, its requirement will be maximum 13 TPH i.e. 312 Tons per day. If rice husk is utilized its
requirement will be Max. 13.4 TPH i.e. 322 TPD for the operation of distillery at proposed capacity
(i.e. 200 KLPD). This is based on steam requirement of 51 TPH and fuel (coal and rice husk) to steam
ratio of 1:4 for coal and 1:3.8 for rice husk.
Pre-feasibility Report: Expansion of grain based distillery unit
M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 8
3.9 Quantity of waste to be generated & its disposal scheme
A) Liquid waste
Daily water intake will be of 1,721 m3/day. Reduction in water requirement will be due to recycling
of (i) condensate water at 40TPH i.e. 960 m3/day as well as spent lees of 600m3 (considering 3 L of
lees per liter of ENA). Thin slope can be treated by decantation followed by multi effect evaporation
followed by dryers. The DWGS can covert in to the DDGS and sold in the market as cattle or poultry
feed.
Fig 2 Flow diagram of Thin liquor and effluent stillage treatment
Effluent grain stillage
Decantation
Section
EVAPORATION PLANT
Process
Condensate Treatment &
Recycle
DWGS Dryer
Wet cake
Conc. Syrup
DDGS
115 TPD
Thin Liquor re-circulated to
Distillery
Pre-feasibility Report: Expansion of grain based distillery unit
M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 9
Other wastewater such as process condensate, boiler blow down, etc. will be treated in effluent
treatment plant (condensate polishing unit – CPU). The quantity of this effluent would be about 589
cum. Treated water will be recycled to process, cooling tower makeup and gardening.
Air emission and its control measures
From the proposed project, flue gas emissions would be in the form of PM, SOx and NOx due to use
of coal or rice husk as a fuel for boiler. Adequate capacity of ESP along with 45 metres height of
chimney will be provided to control the PM level below 100 mg/m3.
Solid waste
The proposed industrial activity will generate solid waste in the form of ETP sludge, Yeast sludge and
boiler ash. Generated DDGS can be sold to the market as a cattle feed as well as poultry feed. The
sludge from ETO has the biodegradability in nature hence it used to prepared manure. The ash can
sold to the brick manufacturers.
Figure 3: Flow sheet for Secondary treatment
Pre-feasibility Report: Expansion of grain based distillery unit
M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 10
Table 2: Solid waste generation and disposal
# Waste Quantity/day Treatment Disposal Remark
1 DDGS 115 MT --- To sell as cattle feed or
poultry feed Organic
2 Yeast sludge 1.2 MT Compost Mixed with DDGS Organic
3 ETP sludge 0.600 MT Compost Mixed with DDGS Organic
4. Ash (Bottom +
fly ash)
125 MT (for
coal) Or 80.5MT
(for rice husk)
- Nearby brick
manufacturing unit Inorganic
Fig 4: Schematic representation of the feasibility drawing which give information of EIA purpose
Expansion of grain based distillery from 60 to 200 KLPD capacity
Application (Form I) and Pre- Feasibility study as project proposal
Categorization as per EIA notification Sep. 2006 and its amendment till the date –
Category A; project activity 5 (g)
Submitted to Ministry of Environment and Forest (MoEF), Govt. of India for obtaining
‘Environmental Clearance’
Pre-feasibility Report: Expansion of grain based distillery unit
M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 11
4. SITE ANALYSIS
4.1 Connectivity
Table 4: Connectivity of the project
4.2 Land form, land use and ownership
The land required for the proposed distillery expansion (along with ancillary units) is two and half acre
(i.e. ~ 9,990 sq.m.). The industry already has 28 acres of land. The proposed distillery unit along with
ancillary units for treatment and disposal of wastewater as well as solid waste will be established
within existing industrial premises. Hence, there will not be any change in the existing land use. The
land is already procured by the project proponent.
4.3. Information of District
4.3.1 Information about Dhanbad
Dhanbad is famous for its coal mining and has some of the largest mines in India. Tata steel, BCCL,
ECL and IISCO (Indian Iron And Steel Company) are some of the companies having coal mines in the
district. The Indian School of Mines is located in Dhanbad. Among the rail divisions of Indian Railway,
Dhanbad Rail Division is the second largest in terms of revenue generation after Mumbai division.
4.3.2 Geographical features
The location of proposed grain based distillery project of Ankur Biochem Private Limited, is at village
Dubhi, Nirsa, District Dhanbad Jharkhand. National highway 2 (NH2) which was earlier known as
Grand Trunk road is about 1.5 km away towards the north of the site. The site is situated on a flat
terrain. There are no hills or hillocks in the surrounding of the site. There are approx 75 villages in
the 10 km radius of the site. The surrounding land use is mainly agricultural and residential. The
main crops of the district are rice, ragi, maize, wheat, red gram, etc. The geographical coordinates of
the site are 23047’N and 86038’E; the proposed site region is at elevation of 155m above the mean
sea level. The nearest surface water body is a rivulet Khudia, situated at a distance of 0.8 km from
the site towards south
Location of the project Within existing distillery premises at Tetulia More, Lakheiya Bridge Po-Dubhi, Dist: Dhanbad, Jharkhand, India
Nearest City/Town Dhanabad 25 Km
Asansol (West Bengal) ~50 Km
Road NH-2 - 1.5 km away towards north
Railway Station Dhanabad 25 Km & Asansol (West Bengal state) -40 Km
Air Port Kolkata, 250km from project site
State Boundary West Bengal approx 20 km towards south and 35km towards east
Pre-feasibility Report: Expansion of grain based distillery unit
M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 12
4.4 Existing land use pattern of Nirsa block
Land use of the Nirsa block was distributed as, out of total area, 694.79 ha is under forest, 4601.31
ha is under culturable waste, 12066.67 ha is under unculturable wasteland (Area not available for
cultivation) The irrigation is done on, 18.21 ha with Government canal, 2523.2 ha with well (without
Electricity), 126.81 ha by well (with Electricity), 207.44 ha with tube-well (without Electricity),
3343.94 ha with Tank, 734.27 ha with River, 7.15 ha with Lake, 4606.09 ha with Others
Total Irrigated Area: 11567.11
Total Unirrigated Area: 11467.04 ha
Since, the project will be requiring 4 ha of unculturable land, which is 12066.67 ha, in the said block
(Nirsa). Therefore, the land use change under the head uncultivable land will be 0.0033% of the total
land.
4.5 Existing Infrastructure
Land 19 acres of land available with sugar factory of which 10 acres will be used
for capacity expansion of distillery and ancillary units as well as greenbelt
Water Source: from 1) rivulet Khudia and 2) existing bore/tube well
Power Captive power supply from 3.0 MW TG set
Road approach road of 1.5 KM connecting to National Highway 2 (NH 2)
Medical, banking
facilities
Easily available at Nirsa and Dhanbad
Education Available at village Dubhi, Nirsa as well as at Dhanbad
Telephone, cell phone, post office, etc are available
4.6 Soil classification
The region mainly comprises soils developed on granite gneiss (32.6%) and granite schists
(14.2%). There is practically no problem of soil salinity or flooding. Soil acidity problem (pH <5.5) is
observed in some areas of the district. The land surfaces being uneven are subject to sheet and gully
erosion, causing loss of soil and plant nutrients.
The soils of the region have very poor water holding capacity. These soils contain less 'Humus'
organic matter. The soil and pH of the soil are suitable for cultivation of cereals such as rice,
sorghum, etc.
4.7 Climate
The climate of the region ranges from dry semi-humid to humid semi arid type. During summer, the
climate is hot and humid. Rains during June to September are occasionally heavy. Summer season is
Pre-feasibility Report: Expansion of grain based distillery unit
M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 13
observed during mid of March to May, there is a steady increase in the temperature, with maximum
temperatures of the year occurring in April and May. It is very pleasant during the cold weather from
November to February. Thereafter the climate becomes warm. It remains hot until the monsoon
breaks towards the middle of June. With the setting in of rains the temperature falls and humidity
rises, July to October are the rainy months. The monsoon winds from Bay of Bengal bring rains to the
region. July and August are the wettest months. The average annual rainfall in the Dhanbad district
is approximately 1400mm.The sky is generally clear during non-rainy season
4.8 Social Infrastructure available
Infrastructure such as roads, schools, electricity supply, health centers/hospitals, transportation,
banking, market, communication and postal facilities are available to the local people easily.
Table 8: Summery of demography
The study area encompasses total 75 villages of Nirsa and Gobindpur block. The population details for
Nirsa block are as follows
Community Children Population Below 7 Years
Literates Workers All 921
Total SC ST Others Total Main Margi-nal
Non-Worker
SC 927
Total 240766 3689
2
48580 155294 37945 113117 69912 44034 25878 170854 ST 998
Male 125341 1914
4
24311 81886 19323 76070 57698 40070 17628 67643 Other
s
896
Female 115425 1774
8
24269 73408 18622 37047 12214 3964 8250 103211 Childs
.
964
Table 9: Basic infrastructure
Name of Block Primary School Middle School Total
Dhanbad 104 51 155
Govindpur 115 29 144
Nirsa 163 52 215
Within 10km Area
There is no tropical forest
There is no biosphere reserve
There is no national park
There is no wildlife sanctuary
There is no coral formation
No defense installations;
No historically important site, monument,
structure, etc (Declared by Archeological Survey of
India)
No recreational site or pilgrimage centre etc.
Pre-feasibility Report: Expansion of grain based distillery unit
M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 14
5.0 PLANNING
5.1 planning concept
Type of industry: Manufacturing industry (Expansion of existing grain based distillery unit
from 60 to 200 KLPD)
Facilities for the drinking water: Water filtration units have been provided in the existing
unit. The main sources of water in Nirsa Block are 27 Tap Water schemes, 215 Well Water, 155 Tank
Water, 47 Tube well water, 158 Hand pump, 3 Canals
Facilities for transport: Grand Trunk road i.e. National Highway 2 (NH 2) Highway 1.5 KM
away from Industry. Telephone as well as mobile phone services are available in the region. This
block is linked with 13 Bus Services, 3 Railway Services, 1 Navigable water way including River, Canal
etc.
Post & Telegraph: There are 18 Post Office, Telephone connectivity is also available in the
region.
Power Supply: Captive power will be used in the proposed project. I
Town and country planning / Development authority classification
The project site came under the jurisdiction of Belkupa Gram Panchyat. The Gram panchayat has
issued ‘No Objection Certificate’ letter on dated 02/06/2014 for this proposed capacity expansion of
grained based distillery from 60 to 200 KLPD.
5.2 Population projection: The proposed expansion activity is generating approx 85 opportunities.
Sons of the soils will be preferred while selecting the employee. Thus, migration of sizable
population near the project will automatically avoid. Skilled and semi-skilled workers could be easily
available in the district, since engineering college as well as ITI are available in the district and
surrounding areas. Thus, influx of population could be negligible.
5.3 Land use Planning: The proposed distillery will be within the existing industrial premises.
Table 10: Land allocation for proposed unit
Unit Land (in Acres)
Existing distillery unit including storage of raw material,
finished products, solid and liquid waste handling and
disposal, etc.
04.00
Proposed unit 02.50
Greenbelt (33% of built-up area) 02.20
open space 19.41
Total Land available 28.11
Pre-feasibility Report: Expansion of grain based distillery unit
M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 15
5.4 Assessment of infrastructure Demand (Physical & Social)
The infrastructures such as land, roads, power, water, transportation, etc are easily available for the
proposed unit. Raw material and fuel will also be available locally.
As explained earlier, very minor influx of population is anticipated due to the project. Available
social infrastructure such as schools, colleges, market, medical facilities, etc. is adequate to support
the probable minor population increase.
5.5 Amenities/ Facilities
The following amenities/facilities are available industry
Canteen
Medical facility
Separate dedicated parking facility for goods vehicle and personal vehicles at site
Provision of street light within premises as well as on approach road
Rest room
Security check post and round the clock security persons on duty
Fire extinguishing facilities
Drinking water
Diesel generator as a backup facility
Fresh water and wastewater treatment plants
6.0 PROPOSED INFRASTRUCTURE
Social Infrastructure: The road developed for the existing distillery unit will remain available for the
local population.
6.1 Connectivity
Table 11: Connectivity of the project
Nearest City/Town Dhanabad 25 Km
Asansol (Weast Bangel state) -50 Km
Road NH-2 - 1.5 km away towards north
Railway Station Dhanabad 25 Km & Asansol (West Bengal state) 50 Km
Air Port Kolkata, 250km from project site
6.2 Drinking water Management: The industry has installed fresh water treatment plant to treat
the water for drinking purpose and supplies it to employees.
Sewage Management: Available system of septic tank and soak pits for sewage
management will be used even after expansion of the unit.
6.3 Power Requirement and source
Pre-feasibility Report: Expansion of grain based distillery unit
M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 16
Daily requirement of power is about 4000 KWh. Power will be made available through own captive
power generation system.
7.0 Industrial waste management
The proposed unit will produce thin liquor slope and grain stillage which usually treated by
decantation followed by concentration followed by drier. During this treatment, DWGS is converted
in to the DDGS. This DDGS can be sold as a cattle feed and poultry feed.
7.1.2 Effluent treatment plant for spent lees and condensate from evaporators:
The effluent from the evaporation unit and spent lees will have collective volume of ~589 cum per
day and will be treated in condensate polishing unit (ETP).
Table 9: ETP Units for spent lees and condensate combined effluent
Unit Purpose
Primary Settling Tank To remove suspended and colloidal solids (settle able)
Bag filter unit To remove the suspended particles form wastewater
Ecophoto-X unit For photo oxidation of organic matter of condensate and other
wastewater
Carbon filtration To filter the treated water
7.2 Solid waste management: The proposed industrial activity gives solid waste in the form of
yeast sludge, boiler ash which is biodegradable. The solid waste will uses as a filler materials in the
composting process. The quantity and disposal technique is brief in following table
Effluent grain stillage
Decantation Section
EVAPORATION UNIT
Process Condensate Treatment & Recycle
DWGS Dryer
Wet cake
Conc. Syrup
DDGS
Thin Liquor re-circulated to Distillery
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M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 17
Table 10: Solid waste generation, treatment & disposal
# Waste Quantity/day Treatment Disposal Remark
1 DDGS 115 MT --- To sell as cattle feed or
poultry feed Organic
2 Yeast sludge 1.2 MT Compost Mixed with DDGS Organic
3 ETP sludge 0.600 MT Compost Mixed with DDGS Organic
4. Ash (Bottom +
fly ash)
125 MT (for
coal) Or 80.5MT
(for rice husk)
- Nearby brick
manufacturing unit Inorganic
8.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN
The required land is already available with project proponent hence; there is no question of
rehabilitation and resettlement (R & R) Plan.
9.0 PROJECT SCHEDULED & COST ESTIMATES
1. Date of start of construction (tentative) March 2016
2. Date of completion (estimated) Dec. 2016
3. Project cost Rs. 11,900.00 lakhs
4. EMP cost Rs. 550.00 Lakhs
10.0 ANALYSIS OF PROPOSAL
I) Benefits
The process is eco-friendly. The effluent problems are non-existent in the case of a grain-based
distillery.
A grain-based distillery has no dependence on the supply of molasses as raw material, having
high elasticity and sensitivity of demand and supply.
The manufacturing technology is indigenously available.
The project is flexible and can handle a variety of raw materials like cereal grain, vegetables rich
in starch like potatoes, cassava, etc.
A high protein source in the form of distiller’s wet or dry grain with soluble (DWGS/DDGS) can be
produced in the distillery. This can be sold as a cattle feed. Additional revenue can be generated
by selling DWGS/DDGS.
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M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 18
The promoter can take up the grains on contract farming from the nearby farmers. However in
order to minimize dependency of the project on the farmers, grains from outside markets can be
procured.
Grain alcohol is superior in quality to molasses alcohol. Nowhere in the world, the molasses
alcohol being termed as Indian whisky, brandy etc. if they are produced from molasses alcohol,
they are termed as Indian Spirits.
Grain based CO2 is food grade. Therefore, in future, there is a scope to put-up a food grade /
beverages grade CO2 plant. It is also possible to go for liquor project (Country liquor or IMFL) in
future, which will further improve the economic viability of the project.
II) conclusion
a) This project will help to improve the economic conditions of local people
b) The candidate site is suitable as per general MoEFCC expectations
c) Water, power, raw material and market is found available with ease
d) Full precautions will be taken for pollution control, resource conservation and
environmental protection
e) This is cost effective and sustainable development
Pre-feasibility Report: Expansion of grain based distillery unit
M/s. Ankur Biochem Pvt. Ltd., Dhanbad, Jharkhand Page 19