M/S. Ponni Sugars (Erode) Limtied (Distillery Plant)
M/S. Ponni Sugars (Erode) Limtied (Distillery Plant)
M/S. Ponni Sugars (Erode) Limtied (Distillery Plant)
1.0PROJECT DESCRIPTION......................................................................................................................4
1.1 INTRODUCTION............................................................................................................................................4
1.2 PLANT LOCATION .......................................................................................................................................5
1.3 PRODUCTS MANUFACTURED..........................................................................................................................5
1.4 RAW MATERIALS........................................................................................................................................5
1.5 MANUFACTURING PROCESS...........................................................................................................................5
1.6 POWER AND FUELS.....................................................................................................................................12
1.7 RAW WATER............................................................................................................................................13
1.8 LAND......................................................................................................................................................13
1.9 MANPOWER..............................................................................................................................................13
1.10 ORGANIZATION STRUCTURE......................................................................................................................13
........................................................................................................................................................................14
1.1 Introduction
Although India is the largest producer of sugarcane and sugar, the sugar
factories in India are facing problems due to the mismatch between sugar
cane price and sugar price. Sugar factories are not viable if they produce
sugar alone. It is necessary to develop the factory into an integrated complex
and use the valuable byproducts more beneficially.
Molasses is one of the important by product of the sugar industry. The profits
earned by the conversion of molasses to alcohol will be higher that that of
the value realized by sale of molasses. There is a good demand for alcohol in
the country, as production and consumption of alcohol are not quite
balanced.
The proposed new distillery will have the flexibility to produce Rectified Spirit,
Extra neutral alcohol and Anhydrous Alcohol based on the market
requirement. The plant will incorporate multi-pressure distillation over
conventional steam distillation for better energy efficiency and consistent
good quality of the product.
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Ponni Sugars (Erode) Limited – (Distillery Division)
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Ponni Sugars (Erode) Limited – (Distillery Division)
1. Fermentation Section
Yeast is grown in laboratory during plant start up. Yeast propagation section
comprises of molasses diluter and hygienically engineered yeast vessels
equipped with heating, cooling and air sparging facility. Dilute molasses
media are prepared in yeast vessel by recirculating media through molasses
diluter. Laboratory propagated cell mass is scaled up in series of yeast
vessels.
Sterile air is sparged in pasteurized and cooled dilute molasses medium for
optimum growth of yeast. Temperature is maintained at 30-32°C by
recirculation cooling water through jacket of yeast vessels. Cell mass from
Yeast vessel is transferred to Prefermentors to build up cell mass required for
fermentation transferred by cell mass transfer pump.
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Ponni Sugars (Erode) Limited – (Distillery Division)
2. Distillation Section
A) Wash to RS Mode: -
Following columns will be under operation
i. Analyser Column (Vacuum)
ii. Degasifying Column (Vacuum)
iii. Rectifier cum Exhaust Column (Pressure)
iv. Recovery Column (Atmospheric)
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Ponni Sugars (Erode) Limited – (Distillery Division)
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.
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Ponni Sugars (Erode) Limited – (Distillery Division)
3. Dehydration Section
The process drives the rectified spirit feed from rectifier column through a
bed of desiccant beads. Twin beds are provided to allow for bead
regeneration in continues operation. One bed is in dehydration mode while
the other is regenerating. Depending on feed and product specifications,
dehydration-regeneration exchange takes place approximately every few
minutes. As the regeneration process releases adsorbed water together with
contained ethanol, it is recycled back to the vaporizing column for
reprocessing.
A small portion of the product vapor is sent, under high vacuum, through bed
2, in regeneration mode, to prepare the desiccant for cycle changeover when
bed 2 goes online.
The stream (lees) from the bottom of the vaporizing column, containing a
maximum of 2000 PPM of ethanol, is pumped to battery limits.
4. Evaporation Section
The Spent Wash at the concentration of 17-18% w/w solids is fed to the
First effect of the Falling film Evaporator through specially designed
Distribution nozzles which ensures the thorough wetting of the tubes and
thereby ensures that there are no dry surfaces created on the inside tube
surface. The partially concentrated spent wash is then pumped to the second
effect from where the concentrated product is drawn out at the desired
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Ponni Sugars (Erode) Limited – (Distillery Division)
The Spent wash is fed from an inlet nozzle into the lower section by a
specially designed distributor plate. The liquid along with solid bits is then
distributed through the tubes. The solid bits are maintained in a fluidized
state. The solids impart a gentle scouring effect on the inside of the tube
walls while moving upward through the tubes. While keeping the tubes clean,
this also enhances the heat transfer coefficient without damage to the tube
material.
The system operates under pressure & vacuum. Water-ring vacuum pumps
are used to maintain a desired vacuum in all the effects. Cooling water from
cooling tower is used in the surface condenser for condensing the vapors
from the last effect.
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Ponni Sugars (Erode) Limited – (Distillery Division)
Cooling and
Neutrialization
Membrane Filtration
Permeate to Reject
Cooling
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Ponni Sugars (Erode) Limited – (Distillery Division)
The condensate / Spent lees treated by such system can be reused back in to
the bio-ethanol 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.
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Ponni Sugars (Erode) Limited – (Distillery Division)
This proposed unit is depending on bore well for its different water
requirements and the quantity will be 709 KLD regularly and 3040 KLD for
once fill up. The unit is proposed in semi critical area, so, the unit has to get
the permission from Ground water division. The unit already applied for
ground water clearance. The same will be submitted at the time of consent
for establishment.
1.8 Land
Factory will be in a land area of 6.07 Hectares.
1.9 Manpower
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Ponni Sugars (Erode) Limited – (Distillery Division)
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Ponni Sugars (Erode) Limited – (Distillery Division)
2.1 Climate
2.2 Ecology
There is no endangered species of flora and fauna noticed in this area. The
area does not shelter any specific wildlife.
The run-off during monsoon period contributes to the surface water. There is
no perennial stream or river in the surrounding villages. These villages get
water from open wells and bore wells which get recharged in rainy season
Water samples were collected from different locations, and the following
parameters will be monitored for pH, Colour (Visual), Odour, Turbidity
(NTU), Electrical Conductivity, Total Suspended Solids, Total Dissolved
Solids, Chlorides (as Cl), Sulphates (asSO4), Calcium (as Ca), Magnesium (as
Mg), Total Hardness(as CaCO3), Phenolphthalein Alkalinity(as CaCO3), Total
Alkalinity (as CaCO3), Iron (as Fe)
The ambient air quality was studied for various locations. It is found that the
Suspended Particulate Matter (SPM) is found to vary from 91µg/m3 to a
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Ponni Sugars (Erode) Limited – (Distillery Division)
maximum of 139 µg/m3. The concentration of NOx and SO2 are found to be
very low. The noise levels recorded at various locations indicate that it is
mostly less than 51 dB(A).
The entire area is a patta land owned by the company and it is in the form of
shrub land. The buffer zone has no forests.
QUANTITY
S.No. WASTEWATER METHOD OF TREATMENT
(KLD)
Incinerate in boiler after
1. Spent wash water 670
concentration
Wastewater from Disposed through a Septic tank
domestic usages of size 3.0 x 2.0 x 3.0 m
2 3.20
followed by a dispersion trench
of size 5.0 x 4.0 x 2.5 m.
Sl.No
Solid Wastes Quantity Method of Disposal
.
1. Settled Yeast Sludge 10.0 t/Day Burnt in boiler along with
spent wash after
concentration.
2. The Potash rich ash 44 t/Day collected and dispose
from boiler 1. To local farmers as a
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Ponni Sugars (Erode) Limited – (Distillery Division)
The noise level in the inside & outside the factory is maintained at low level.
Since the entire process like distillation and CO2 scrubber will be proposed
with world-class technology, the Odour from the process will be of very
minimum.
The environment, safety and health monitoring programme in the factory are
as follows:
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Ponni Sugars (Erode) Limited – (Distillery Division)
Capital Annual
Investment Operating Costs
Category
(Rupees in Lakhs)
Total population of the 10 villages within 10 km radius from the project site
is 20834. The male to female ratio is 100:100. The population in the age
group of 6 constitutes about 9.3% of the population as per 2001 census
data. The major source of income of the local population is from these types
of industries and agriculture only.
Due to the proposed project, indirect employment to the extent of 150 will be
generated. The Government revenue from the project will increase by way
of direct and indirect taxes, duties, etc. The infrastructure development will
get an impetus with this industrial growth. Communications, transport,
schools, hospitals, trade and commerce will indirectly get an impetus.
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Ponni Sugars (Erode) Limited – (Distillery Division)
The wastewater from the domestic usages (3.2 KLD) will be sent directly to
the septic tank of size 3.0 x 2.0 x 2.0 m followed by the dispersion trench of
size 3.0 x 2.0 x 3.0 m . The spent wash water from the process 632 KLD will
be concentrated in multiple effect evaporator followed by incineration is
specially designed boilers.
Flow = inlet – E1 – E2 – E3 – E4 - E5
The above flow pattern is specially designed for utilization of available
energy. High wetting rates are provided in falling film bodies. This will
reduce scaling and the offline CIP frequency/downtime of evaporator.
The spent wash from distillery from storage is fed to falling film Evaporator
system, where it is concentrated from 17% to 25% solids. The analyzer
column vapors and exhaust steam from Turbine are used as heating media.
All the Effects are falling film type with vapour separators.
The feed from feed tank will be introduced into the effect 1. The vapours
from analyzer column are used as heating media in Effect 1 and recovered in
the form of condensate. Partially concentrated feed is then transferred to
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Ponni Sugars (Erode) Limited – (Distillery Division)
Effect 2 and subsequently to effect 3. The vapour from Effect 1, are given to
Effect 2 as heating media. Evaporated vapours from effect 2 are used as
heating media in Effect 3 and so on. Finally the vapours separated in VS 3
are condensed in a Plate type surface condenser.
The concentrated spent wash of around 55 brix from the concentration plant
is then pumped in to the specially designed boiler for incineration along with
pulverised coal as supplement fuel. The concentrated spent wash with above
composition and calorific value is burnt to generate steam at designed
pressure and temperature. This steam is then taken into turbine for
generation of power and the exhaust steam is utilized for concentration and
other process requirements.
The flue gas from combustion process is vented out after removal of
suspended particulate matter in specially made bag filters and sulfur-dioxide
in scrubbers. The ash collected from the process rich in potash can be sold
for fertilizer application and used in brick / cement blocks manufacturing.
Sl.No
Solid Wastes Quantity Method of Disposal
.
1. Settled Yeast 10.5 t/Day Burnt in boiler along with spent
Sludge wash after concentration.
2. The Potash rich 44 t/Day collected and dispose
ash from boiler 1. To local farmers as a
fertilizer (potash rich).
2.To Near by Brick
manufacturing units
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Ponni Sugars (Erode) Limited – (Distillery Division)
As per the observations, the noise level in the buffer zone is found to be very
low.
PRESIDENT
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