PRE-FEASIBILITY REPORT

FOR

INSTALLATION OF 2G ETHANOL PLANT AT BATHINDA, PUNJAB BY M/S

HINDUSTAN PETROLEUM CORPORATION LIMITED

PREPARED BY

M/s. ULTRA-TECH
ENVIRONMENTAL LABORATORY AND CONSULTANCY
(Gazzeted By MoEF)
Unit No. 206, 224, 225 Jai Commercial Complex, Eastern Express Highway,
Opp Cadbury Factory, Khopat, Thane (West) – 400 061
Tel: 022 2534 2776, Fax: 022 25429650, Email: sales@ultratech.In
Website: www.ultratech.in
 TABLE OF CONTENTS
1. EXECUTIVE SUMMARY ...................................................................................................... 1

2. INTRODUCTION..................................................................................................................... 2

2.1 Project Proponent ............................................................................................................. 2

2.2 Nature of Project .............................................................................................................. 2
3. SITE INFORMATION............................................................................................................. 3

3.1 Environmental Setting ...................................................................................................... 3

4. PROJECT DESCRIPTION ..................................................................................................... 8

4.1 Process Description .......................................................................................................... 8

4.2 Manufacturing Process ..................................................................................................... 9
4.3 Land Use and Land Ownership ...................................................................................... 12
4.4 Water Requirement ........................................................................................................ 12
4.5 Power Requirement ........................................................................................................ 12
4.6 Manpower Requirement ................................................................................................. 13
4.7 Waste Management ........................................................................................................ 13
5. ENVIRONMENT CONTROL MEASURES ....................................................................... 14

6. PROJECT SCHEDULE AND COST ESTIMATES ........................................................... 15

6.1 Project Schedule ............................................................................................................. 15

6.2 Project Cost Estimates.................................................................................................... 15

LIST OF TABLES
Table 3.1: Environmental Setting ................................................................................................... 3

Table 4.1: Proposed Product List .................................................................................................. 11

Table 4.2: Proposed Raw Materials .............................................................................................. 11

Table 4.3: Proposed Water Requirement ...................................................................................... 12

Table 4.4: Proposed Manpower Requirement .............................................................................. 13

Table 4.5: Non-Hazardous Solid Waste........................................................................................ 13

Table 4.5: Hazardous Waste ......................................................................................................... 13

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Pre-Feasibility Report For Installation Of 2G Ethanol Plant at Bathinda
Table 4.6: Stack Details ................................................................................................................ 14

LIST OF FIGURES
Figure 3.1: Project Location ........................................................................................................... 5

Figure 3.2: Aerial Image of the Project Site ................................................................................... 6

Figure 3.3: Google Image of the Project Site ................................................................................. 7

Figure 4.1: Process Flowchart......................................................................................................... 8

Figure 4.2: Basic Process ................................................................................................................ 9

Figure 4.3: Project Site Layout ..................................................................................................... 10

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Pre-Feasibility Report For Installation Of 2G Ethanol Plant at Bathinda
 1. EXECUTIVE SUMMARY

HPCL is a Government of India Enterprise with a Navratna Status, and a Forbes 2000 and
Global Fortune 500 company. It had originally been incorporated as a company under the
Indian Companies Act 1913. It is listed on the Bombay Stock exchange (BSE) and National
Stock Exchange (NSE), India. HPCL owns & operates 2 major refineries producing a wide
variety of petroleum fuels & specialties, one in Mumbai (West Coast) of 6.5 Million Metric
Tonnes Per Annum (MMTPA) capacity and the other in Visakhapatnam, (East Coast) with a
capacity of 8.3 MMTPA. HPCL also owns and operates the largest Lube Refinery in the country
producing Lube Base Oils of international standards, with a capacity of 428 TMT. This Lube
Refinery accounts for over 40% of the India's total Lube Base Oil production. Presently HPCL
produces over 300+ grades of Lubes, Specialities and Greases.

The company appointed M/s. Ultra Tech Environmental Consultancy & Laboratory
(MoEFCC recognized and NABL approved), Thane to carry out study of the impacts of the
project on local environment and for obtaining Environmental Clearance. Ultra-Tech is an
established Consultancy in the field of Environmental Services. Company is giving services in
this field for past 29 years. The Notification No. S. O. 1533 promulgated on 14th September 2006
has covered this type of industries under its schedule 5(g) A. Hence, HPCL intends to approach
MoEF&CC for environment clearance for proposed Distillery. The prefeasibility report is
prepared for forming a frame work for EIA study, scoping and finalizing terms of reference as
may be required. Form I, as is prescribed by the said notification is duly filled up and submitted.
The Prefeasibility Report is an accompaniment to the same and prepared as per MoEF guideline
dated 27/02/2012.

HPCL proposes to Installation of 2G Ethanol plant at Bathinda, Punjab. HPCL has acquired 15.1
ha (37.28 Acres) from Government of Punjab on a long term lease in the Village Nasibpura,
District Bathinda.

The Khasra No are 1136(39-3), 1137/1(12-10), 1138(29-10), 1139/1(13-10), 1139/2(11-10), 1140(25-0),

1141/1/1(8-5), 1141/1/2(3-2), 1143(25-0), 1144/1(13-0), 1144/2(11-0), 1144/3(9-6), 1144/4(1-14),
1145/2(3-18), 1145/3(21-2), 1146/1(16-13), 1146/2(24-13), 1151/1(12-10), 1151/2(7-0), 1151/3(2-10),
1151/4(2-10), 1152(25-0). Agricultural land has now been converted to industrial land use. The copy of
Change in Land Use (CLU) has been provided as Annexure III. The estimated production capacity of
the project is 2G Ethanol – 100 KLD and other By-products.

The commercial operation date (COD) is envisaged in 18 months reckoned from the effective
zero date.

The total project cost for the Proposed Installation of 2G Ethanol Plant is around Rs. 600 crores.
This includes the cost of land and land development, on lease from Govt. of Punjab as per lease
rentals/terms & conditions.

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Pre-Feasibility Report For Installation Of 2G Ethanol Plant at Bathinda
 2. INTRODUCTION

2.1 Project Proponent

Hindustan Petroleum Corporation Limited (HPCL) is a Government of India Enterprise with
a Navratna Status, and a Forbes 2000 and Global Fortune 500 company. HPCL has the second
largest share of product pipelines in India with a pipeline network of more than 3015 kms for
transportation of petroleum products and a vast marketing network consisting of 13 Zonal offices
in major cities and 106 Regional Offices facilitated by a Supply & Distribution infrastructure
comprising Terminals, Pipeline networks, Aviation Service Stations, LPG Bottling Plants, Inland
Relay Depots & Retail Outlets, Lube and LPG Distributorships.
Consistent excellent performance has been made possible by highly motivated workforce of over
11,000 employees working all over India at its various refining and marketing locations.
HPCL is committed to achieve the economic, ecological & social responsibility objectives of
sustainable development consistently through varied operations and activities. HPCL’s focus
areas are in the fields of Child Care, Education, Health Care, Skill Development & Community
Development, touching lives of weaker section of society.

2.2 Nature of Project

The technology is suited for both Indian and global needs and it is projected to be capable of
converting all types of agricultural residues like bagasse, rice and wheat straw, bamboo, cotton
stalk, corn stover, wood chips to ethanol in less than 24 hours, with optimum product yields The
Bathinda Bio-refinery will be utilizing agriculture residues for production of ethanol which may
be sufficient to meet the 26% of the ethanol blending requirement of the State. The proposed
Bio-refinery will generate employment. The project shall also help in reducing CO 2 emissions
from the paddy straw which currently is being burnt after harvesting. One of the major outputs of
this Bio-refinery shall be Bio-fertilizer which shall be incorporated into the soil for improving
soil fertility and overall productivity of farms in Punjab. The Bio-refinery shall also produce Bio-
CNG per annum which can cater to transport and clean cooking requirements.

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Pre-Feasibility Report For Installation Of 2G Ethanol Plant at Bathinda
 3. SITE INFORMATION

HPCL proposes to Installation of 2G Ethanol plant at Bathinda, Punjab. HPCL has acquired 15.1
ha (37.28 Acres) from Government of Punjab on a long term lease in the Village Nasibpura,
District Bathinda.

3.1 Environmental Setting

The Environmental Setting in 10 km radius of project site is presented in Table 3.1
Table 3.1: Environmental Setting
Sr. Particulars Details
No.
Plant location The Proposed project is located at Village
Nashibpur Tehsil Talwandi, District Bathida
Punjab
Approx site Centre point Lat : 30.054746°
Coordinates Long: 75.011549°
Climatic conditions
Maximum temperature 35oC
Minimum temperature 9 oC
Annual rainfall (total) 1200mm
Relative humidity Maximum- 85
Minimum- 17
Plant site elevation above MSL 686Ft
Plant site topography Plain
Present land use at the site Agricultural Land
Nearest highway SH-17 6.3 Km
Nearest railway station Bathinda Railway Station : 31.8 Km
Nearest Airport Ludhiana Airport : 180Km
Nearest major water bodies River towards south 200mters
Nearest village Nasibpura
Archaeologically important Nil
places
Protected areas as per Wildlife Nil
Protection Act, 1972 (Tiger
reserve, Elephant reserve,
Biospheres, National parks,
Wildlife sanctuaries,
community reserves and
conservation reserves)
Reserved / Protected Forests Nil
Defence Installations Nil
Seismicity The proposed project is located in Seismic Zone IV
as per IS: 1893 and all designs will be as per IS
Codes

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Pre-Feasibility Report For Installation Of 2G Ethanol Plant at Bathinda
The location map of the project site is as depicted in Figure 3.1, Connectivity Map is shown in
Figure 3.2 and Google Image is as shown in Figure 3.3.

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Pre-Feasibility Report For Installation Of 2G Ethanol Plant at Bathinda
 Figure 3.1: Project Location

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Pre-Feasibility Report For Installation Of 2G Ethanol Plant at Bathinda
• Connectivity
The project site is aerially located at 6.3 Km from SH 17 Highway. The nearest Railway station is Bathinda Railway Station: 31.8 Km
and The nearest airport is Ludhiana Airport: 180 Km

Figure 3.2: Aerial Image of the Project Site

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Pre-Feasibility Report For Installation Of 2G Ethanol Plant at Bathinda
 Figure 3.3: Google Image of the Project Site

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Pre-Feasibility Report For Installation Of 2G Ethanol Plant at Bathinda
 4. PROJECT DESCRIPTION
4.1 Process Description
The proposed 100 KLPD plant is based on the DBT-ICT 2G Ethanol technology developed
indigenously at the DBT-ICT Centre for Energy Biosciences (CEB), Mumbai. The CEB at the
Institute of Chemical Technology (ICT), Mumbai is one of India’s leading multidisciplinary
research facilities specializing in Bioenergy and Industrial Biotechnology.
The project is designed to produce 100KL fuel grade ethanol per day, primarily from rice straw
and will use approximately 400 tons of rice straw per day for the process. An additional 50 tons
of straw per day will be used for supplementary fuel for steam generation. The process employed
here uses rice straw as feed stock to convert into its cellulose, hemi cellulose and lignin fractions.
The cellulose and hemi cellulose fractions are then converted into respective sugars through a
process called saccharification.The sugars are then converted into dilute ethanol by fermentation
using appropriate yeasts. The dilute impure ethanol stream is then purified and concentrated to
fuel grade ethanol. The Figure 4.1 depicts the process outline. The rectangular blue blocks
represent the main processing sections in the plant. Aside from these, there are ancillary sections
like biomass size reduction, steam/steam /power/water supply systems, raw material and finished
goods storage yards etc.

Figure 4.1: Process Flowchart

The plant has been designed as a zero-liquid discharge plant. The final products will be fuel
grade ethanol, silica, mixed solid salts and liquid carbon dioxide.

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Pre-Feasibility Report For Installation Of 2G Ethanol Plant at Bathinda
4.2 Manufacturing Process

The Figure 4.2 schematically represents the basic process outline. Biomass (rice straw/cotton
stalk/Napiergrass) obtained in the form of bales, is size reduced and then converted to sugars
that are fermented to ethanol via two step alkali and acid treatment steps.
The overall site consists of the following sections:
• Size reduction
• Fractionation to cellulose, hemicelluloses and lignin
• Saccharification to C6 and C5 sugars
• Fermentation to Ethanol
• Distillation and Dehydration of ethanol
• Purification, Compression and Bottling of CO2
• Utilities(power, steam, cooling water)

Figure 4.2: Basic Process

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Pre-Feasibility Report For Installation Of 2G Ethanol Plant at Bathinda
The Site layout of the proposed project is as shown in Figure 2.3.

Figure 4.3: Project Site Layout

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Pre-Feasibility Report For Installation Of 2G Ethanol Plant at Bathinda
The plant is designed for the products as listed in the Table 4.1. The plant and Machinery have
been designed with required specification considering volume of reaction, material of
construction and are located at appropriate positions. Adequate ventilation, air conditioning and
Air Filtration systems have been planned to prevent environmental hazards. The raw materials
required for the proposed production is listed in Table 4.2.

Table 4.1: Proposed Product List

Products Rice Straw (TPD) Cotton Stalk (TPD) Napier Grass (TPD)
Ethanol 80.00 65.00 84.00
CO2* 80.00 65.00 84.00
Silica 53.00 - -
Fusel Oil 0.30 0.30 0.30
Total 213.30 130.30 168.30

Table 4.2: Proposed Raw Materials

Cotton Napier
Raw Materials Rice Straw (TPD) Stalk Grass
(TPD) (TPD)
A. BIOMASS
Biomass (dry basis) 373.00 373.00 373.00
Chemical characteristics Lignocelluloses (with 15% w/w moisture
maximum)
Physical characteristics Supplied as 15-25 kg rectangular bales
B. CHEMICALS
Nitric Acid (60% w/w 4.30 4.30 4.30
fuming liquid)
Sodium Hydroxide (40-50 5.20 5.20 5.20
w/v aqueous lye)
Enzymes (liquid protein 1.12 1.12 1.12
solution with stabilizers)
C.FUEL
Biomass 40.00 Nil Nil
D.OTHERS
Salts 1.90 1.90 1.90
Total 425.52 385.52 385.52

The main features of the plant are as follows:

• Both C5 and C6 sugar (glucose) can be obtained separately and converted to ethanol by
fermentation either independently or combined.
• The plant is fully automated and DCS/SCADA controlled

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Pre-Feasibility Report For Installation Of 2G Ethanol Plant at Bathinda
 • The plant is supported by an equipped QC/QA laboratory
• Sugars produced are fermented using specific yeast strains
• Enzyme and chemicals required to be procured from recommended suppliers
• The plant does not produce and create liquid effluent
• Solid byproducts generated are ash, salts (sodium nitrate) and silica that will be sold in
market

The following are the expected Plant Performance figures:

• C6 (glucose) sugar yield on biomass (dry): 80% of maximum

• C5 (xylose) sugar yield on biomass (dry) : 80% of maximum
• Ethanol yield on C6 (glucose): 0.50 L/kg
• Ethanol yield on C5 (xylose): 0.40 L/kg
• Ethanol Production per day: 0.45L/kg total sugars
• Overall maximum possible yield of ethanol on dry biomass: 300L/ton biomass

4.3 Land Use and Land Ownership

HPCL has already signed Land agreement with Punjab Government (Village development and
Panchayat Department) on Lease for a period of 33 years

4.4 Water Requirement

The total water requirement for the proposed project will be 100m3/day; Table 4.3 shows the
distribution of the water requirement
Table 4.3: Proposed Water Requirement
Sr. No. Water Requirement TPD
1 Process water 200
2 Cooling water 870
3 Boiler 144
4 Drinking water 6
5 Domestic water Blow down water will be used for domestic purpose
6 Green Belt 270 (Blow down water will be used)
7 Floor Washing Blow down water will be used for floor washing

4.5 Power Requirement

Total power requirement (connected load and maximum demand) and source, power exported
during season and off-season will be 5 MW. Emergency power required for boiler, distillation
system, cooling water circulation, membrane system and water pump for reactor flushing is 1.6
MW. Thus, the capacity of the DG set will be 2MW.

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Pre-Feasibility Report For Installation Of 2G Ethanol Plant at Bathinda
4.6 Manpower Requirement
The estimated manpower requirement during operation phase will be around 120 personnels. The
details of the same are provided in Table 4.4.
Table 4.4: Proposed Manpower Requirement
Persons for operation of plant in three
1 45
shifts
2 Persons for maintenance of the plant 45
3 Persons for lab-Chemist, Microbiologist 25
4 Managers 5

4.7 Waste Management

The details of the Non Hazardous Solid Waste are as provided in Table 4.5 and Hazardous
Waste is as provided in Table 4.6.

Table 4.5: Non-Hazardous Solid Waste

Feed stock Total Solid waste – Ash + Silica (TPD)
Rice Straw 60.61
Cotton Stalk 31.57
Napier Grass 32.33

Table 4.5: Hazardous Waste

Cat. Type of waste Source Qty. Method of Disposal
34.3 Sch – I ETP Sludge ETP 5 MTM CHWTSDF
5.1 Sch – I Used Plant & 0.5 MTM CHWTSDF
Lubricants Machineries
33.3 Sch – I Used Raw Material 1200 Decontamination &
Containers Storage (Nos.) Re-use or sell to
(Metal & Scrap vendors
Plastic)
HDPE/ LDTE/ Raw Material 2000 Decontamination &
Gunny Bags Storage (Nos.) Re-use or sell to
Scrap vendors

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Pre-Feasibility Report For Installation Of 2G Ethanol Plant at Bathinda
 5. ENVIRONMENT CONTROL MEASURES

• During construction phase there will be fugitive emissions due to movement of

equipment at site, dust emitted during the levelling, grading, earthworks, foundation
works and other construction related activities. These impacts will however, be marginal
and temporary in nature.

• The DG sets shall be acoustically insulated resulting in reduction of noise as per limits
prescribed by State Pollution Control Board. The exhaust pipe from DG sets shall be
taken above the building as per State Pollution Control norms

• All conditions & pre-requisites of water and air consents together with certificate to
handle hazardous products issued by State Pollution Control Board shall be strictly
adhered to.

• During operation phase, there shall be air pollution being generated due to the Boiler.
Following stack as mentioned in Table 4.6 is as proposed.

Table 4.6: Stack Details

Sr. No. Stack Emission Details Details
1 Number of stacks 1
2 Number of flues per stack 2
3 Physical stack height (m) 25
4 Sack diameter (m) 30
5 Flue gas exit velocity (m/s) 4
6 Flue gas exit Temperature (˚C) 150
7 Flue gas density (kg/m3) 0.75
8 Emission rate per flue of
SPM (kg/h) 98.0
SO2 (kg/h) 3.50
NOx (kg/h) 9.0
10 Pollution control device and its efficiency SOx and NOx absorption (95%
efficiency) and solid disposal

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Pre-Feasibility Report For Installation Of 2G Ethanol Plant at Bathinda
 6. PROJECT SCHEDULE AND COST ESTIMATES

6.1 Project Schedule

The commercial operation date (COD) is envisaged in 18 months reckoned from the effective
zero date.

6.2 Project Cost Estimates

The total project cost for the Proposed Installation of 2G Ethanol Plant is around Rs. 600 crores.
This includes the cost of Land and land development, on lease from Govt. of Punjab as per lease
rentals/terms & conditions

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Pre-Feasibility Report For Installation Of 2G Ethanol Plant at Bathinda