Detailed Feasibility Report
for 2G Ethanol Biorefinery
at Bathinda, Punjab
Hindustan Petroleum Corporation Limited
SECTION 1
EXECUTIVE SUMMARY
1.0 EXECUTIVE SUMMARY
1.1 INTRODUCTION
Hindustan Petroleum Corporation Limited (HPCL) is examining the feasibility of
setting up a Ligno-cellulosic ethanol production plant to produce 100 KL per day of
2G ethanol using domestic agro based lignocellulosic feedstock at Bathinda in the
state of Punjab. HPCL has taken M/s Praj Industries Limited as the licensor for this
biomass to 2G ethanol plant at Bathinda. The preliminary plot plan and project
schedule are also included in this report.
1.2 BACKGROUND FOR DFR
Bio-fuels are an alternative energy option as they are clean and have low sulfur
content thereby having positive environmental impact. Therefore need of the
hour is development of second generation biofuels using agricultural residues and
waste that can be harnessed as ligno-cellulosic bio-fuel source. This requirement
is also mandated in the National Bio fuel policy (NBP) 2009, where in ethanol
blending in Gasoline is to reach 20% by 2022.
The main reasons for the enhanced development of bio-ethanol are its use as a
favorable and near carbon neutral renewable fuel, thus reducing CO2 emissions and
associated climate change. Whether first, second, or third generation feedstock is
used, fermentation produces an alcohol-lean broth only, as such unusable in
industrial and fuel applications. The ethanol must hence be purified. Fractional
distillation can concentrate ethanol to 95.6 vol% (89.5mol %), corresponding to
the azeotropic composition with a boiling point of 78.2 oC. Remaining moisture is
captured in dehydration column to produce anhydrous fuel grade ethanol.
The practice of blending ethanol started in India in 2001. Government of India
mandated blending of 5% ethanol in petrol in 9 States and 4 Union Territories in
the year 2003 and subsequently mandated 5% blending of ethanol in petrol on an
all- India basis in November 2006 (in 20 States and 8 Union Territories except a
few North East states and Jammu & Kashmir). Ministry of Petroleum and Natural
Gas, on 1 September, 2015, has asked OMCs to target 10% blending of ethanol in
petrol in as many States as possible. Table 1.1 shows the ethanol requirement in
future for 5%, 10% and 20% blending in petrol.
Table-1.1: Ethanol requirement in future for 5%, 10% and 20% blending (In
Million Lt.)
Particulars
2017-18
2018-19
2019-20
2020-21
2021-22
Petrol Sale
Projection
(14 % CAGR)
33091
37723
43005
49025
55889
Ethanol Requirement
(@ 5%
blending)
(@ 10%
blending)
(@ 20%
blending)
1451
1655
1886
2150
2451
2794
2903
3309
3772
4300
4903
5589
5805
6618
7545
8601
9805
11178
Petroleum Planning & Analysis Cell (PPAC)
In view of meeting the ethanol requirement for blending in petrol, HPCL is exploring to
set up 2G Ethanol Plant at Bathinda, Punjab and has to prepare the DFR for the project.
1.3 TECHNOLOGY LICENSOR
HPCL has taken M/s Praj Industries Limited as technology licensor for the 2G Ethanol
plant at Bathinda.
1.4 BASIC STUDY PARAMETERS
1.4.1 Ethanol plant capacity
The Feasibility study is carried out for 100 kilo liters per day (KLPD) of 2G Ethanol plant
from rice straw (lignocellulosic biomass) which is locally available.
1.4.2 Objective of Study
The objective is to carry out a detailed feasibility of the project, including the
development of a plot plan, project schedule, financial analysis based on a project cost
estimate.
1.4.3 Product Specification:
The quality and standard as per Indian specifications (IS15464:2004) of anhydrous
ethanol for use in automotive fuel is as listed below:
Table-1.2: Product specification for fuel grade ethanol
S. No
Parameters
Value
1
Relative density at 15.6/15.6 °C, Max
0.7961
2
Flash point
16.6 oC
3
Ethanol content percent by volume at
Min. (excluding denaturant)
4
Miscibility with water
15.6/15.6°C
99.50
Miscible
5
Alkalinity
Nil
6
Acidity (as CH3COOH) mg/l, Max
30
7
Residue on evaporation percent by mass, Max
8
Aldehyde content (CH3CHO) mg/l, Max
60
9
Copper, mg/kg, Max
0.1
10
Conductivity µS/m, Max
300
11
Methyl alcohol, mg/litre, Max
300
12
Appearance
0.005
Clear and bright
1.4.4 Feed Specification
Considering that the plant should be designed with the flexibility in processing several
biomasses, the 2G Ethanol plant should be feed agnostic. It should be able to process
different biomass like rice straw, wheat straw, cotton stalk, sugarcane bagasse etc. as
feedstock. The Design feedstock for the proposed 2G Ethanol Plant is Rice straw.
Table-1.3: Composition of Design feed
Sl No
Parameters
Unit
1
Glucan
Xylan
Lignin
Arabinan
Ash
Acetate
Extractive
%w/w
Protein
Others
Total Solid
Moisture
%w/w
2
3
4
5
6
7
8
9
%w/w
%w/w
%w/w
%w/w
Values
36.41
19.07
14.95
2.94
11.04
%w/w
%w/w
%w/w
%
9.31
2.09
4.19
100
6.25
0
1.5
PROCESS FOR 2G ETHANOL GENERATION FROM LIGNOCELLULOSIC
BIOMASS
1.5.1 Ligno-cellulosic Biomass
It is important to understand ligno-cellulosic biomass, particularly its chemical
composition, is a prerequisite for developing effective pretreatment technologies to
destruct its rigid structure, designing enzymes to liberate sugars, particularly cellulose
to release glucose, from recalcitrant cellulose, as well as engineering microorganisms to
convert sugars into ethanol and other bio-based chemicals. Lignocellulosic biomass is
mainly composed of plant cell walls, with the structural carbohydrates - cellulose and
hemi-cellulose and heterogeneous phenolic polymer lignin as its primary components.
Cellulose is a polysaccharide composed of linear glucan chains which are held together
by intra-molecular hydrogen bonds as well as intermolecular van-der Waals forces. The
crystalline cellulose must be subjected to some preliminary chemical or mechanical
degradation before it can be broken down into glucose.
Hemicellulose consists of short, highly branched chains of sugars. It contains pentoses,
hemicelluloses chains are more easily broken down to form their simple monomeric
sugars than is cellulose because of their highly amorphous and branched structure. The
exact sugar composition of hemicelluloses can vary depending on the type of plant.
Lignin is a non-sugar-based polymer and cannot be used as feedstock for ethanol
production via microbial fermentation through enzymatic route. It exerts a significant
impact on the economic performance of the corresponding bioconversion processes. As
the second most abundant component in biomass after cellulose, lignin yields more
energy when burned, and thus is a good selection for combined heat and power
production in an eco- and environment-friendly mode of the bio-refinery.
Each of the above steps are briefly described as under:
1.5.2 Bio-Chemical Conversion
Typical biochemical conversion process of lignocellulosic biomass is carried out in four
stages
1. Physical or chemical pretreatment of the plant fibers to expose the cellulose
and reduce its crystallinity,
2. Hydrolysis of the cellulose polymer, with enzymes or acids, to convert it into
simple sugars (glucose),
3. Microbial fermentation of these simple sugars to ethanol and
4. Distillation and dehydration to produce 99.5% pure alcohol.
Pretreatment:
The pretreatment process converts most of the hemicellulose carbohydrates in the
feedstock to soluble sugars (xylose, mannose, arabinose and glucose) by hydrolysis
reactions. Acetyl groups in the hemicellulose are liberated as acetic acid. The breakdown
of biomass in pretreatment facilitates downstream enzymatic hydrolysis by disrupting
cell
wall structures, driving some lignin into solution, and reducing cellulose crystallinity and
chain length. The nature and extent of such changes are highly dependent on the
pretreatment chemistry and reaction severity (defined by residence time, temperature,
and enzyme & yeast consumption).
Hydrolysis:
Hydrolysis process generates fermentable monomeric sugars from hemicellulose and
cellulose content of lignocellulosic biomass. This can be accomplished by two different
processes, namely,
1. Acid hydrolysis
2. Enzymatic hydrolysis.
In acid hydrolysis, mineral acids such as sulfuric acid, hydrochloric acid, hydrofluoric acid
and nitric acid are widely employed for the hydrolysis of lignocellulosic biomass.
In enzymatic hydrolysis step cellulose is converted to glucose using cellulose enzymes.
This process is known as enzymatic saccharification or enzymatic hydrolysis. A cellulose
enzyme preparation is a mixture of enzymes (catalytic proteins) that work together to
break down cellulose fibers into cellobiose and soluble gluco-oligomers and ultimately
into glucose monomers. The resulting glucose and other sugars hydrolyzed from
hemicellulose during pretreatment are co-fermented to produce ethanol.
For higher conversion and use of lower grade metallurgy in equipment, enzymatic
hydrolysis is favorable over acid hydrolysis.
Fermentation:
Fermentation is the biological process to convert the hexoses and pentoses into
ethanol by a variety of microorganisms, such as bacteria, yeast, or fungi.
When using enzymatic hydrolysis, different integration methods of hydrolysis and
fermentation steps are proposed. These are separate hydrolysis and fermentation (SHF),
separate hydrolysis and co-fermentation (SHCF) and simultaneous saccharification and
co-fermentation (SSCF) are other possible alternatives.
Distillation and Purification:
From fermented mash, fuel grade ethanol is produced through distillation and
adsorption via molecular sieve. Desired separation specification of 99.5%vol ethanol
cannot be achieved by distillation alone because of the non-ideal solution behavior of
the water- ethanol mixture. An azeotrope is observed when the mixture reaches 95.5%
mole purity of ethanol. 95.5 % alcohol is passed through molecular sieve to produce fuel
grade ethanol.
1.6 PRAJ 2G ETHANOL PROCESS
Cellulosic ethanol technology developed by Praj Industries Limited is based on biochemical
conversion and achieves conversion for obtaining the desired ethanol yield.
The technology is feedstock agnostic and has been successfully used with various agricultural
feedstock such as rice straw, cotton stalk, corn cob, bagasse etc.
The typical process for conversion of ligno-cellulosic biomass to ethanol route is based on
enzymatic hydrolysis and comprises five main steps as given below:
1. Biomass size reduction and washing of ligno-cellulosic feedstock
2. Pre-treatment (steam explosion) of the feed in the proprietary digester.
3. Enzymatic hydrolysis
4. Co-Fermentation of C5 and C6 sugars.
5. Distillation & dehydration to obtain fuel grade ethanol
The schematic diagram of the process is sown in following Figure 1.1.
Figure-1.1: PRAJ 2G Ethanol Process
1.7 UTILITIES
Utilities requirement of the 2G Ethanol project shall be met through new utility systems.
The Following are the brief details of the utilities:
Raw water
Raw water for 2G ethanol plant shall be met from the nearby canal (at a distance of 2.5
km) and storage facilities of 7 days are considered. The details of raw water reservoir are
as given below:


Total Capacity: 175640 (with CO2 plant 105 m2/hr) M3
No. of days of storage: 7 days
DM Water
An RO based DM water plant is considered based on the treated water as feed.DM water
in 2G Ethanol Plant is required for the boiler feed water make-up for the generation of
steam.
Cooling water
Cooling water systems of capacity 6600 m3/hr have been envisaged for meeting process
requirements.
Steam and Power
Total steam requirement for process is 42 TPH. 2 nos. of Boiler of 60% capacity each is
considered. The boiler and associated facility i.e. De-aerator etc. are considered inside
unit B/L as the water recycle and steam systems are process oriented.
Power shall be sourced from external grid. Considering distance of 6 km which will be
detailed during execution.
Flare
Flare is not envisaged in 2G ethanol unit, since there is negligible hydrocarbon
generation which can cause any relief to flare.
Compressed Air
Total installed design capacity estimated for process plant, OSBL section and Solid
liquid separation is 6000 NM3/hr. Air compressor with 2000 NM3/hr capacity each
considered with 3 +1 combination.
Based on the above the utility summary for 2G ethanol plant facilities are tabulated
below in Table1.4:
Table-1.4: 2G Ethanol Plant Utilities Summary
S.N0
1
System
Raw Water Treatment
Plant Capacity
Units
m3/hr
Capacity
120
2
DM Plant Capacity
m3/hr
40
3
Cooling water
m3/hr
6600
4
Instrument Air
Nm3/hr
6000
5
Plant Air
Nm3/hr
300
6
Steam
TPH
60
Please note that for the DFR, the following margins are considered on the utility values
specified by the Licensor:
a) DM water : 30 %
b) Raw Water : 15 %
c) Cooling Water: 10%
Additional Consideration
In the DFR report, cost estimations are done keeping in view that power and water
requirements are met at the plant gate. Power is being imported from the grid in the
present scenario.
As per the HPCL requirements, 33KV power grid at a distance 6 KM line is to be
envisaged. Also, water is to be supplied from the canal located at 2.5 KM form the HPCL
Bathinda plant contour. HPCL had provided that the water requirement is to be met via
the given canal and raw water storage of 7 days is to be met within the plant area.
1.8 CAPITAL COST
ESTIMATION
Key Assumptions:
The basic assumptions made for working out the capital cost estimate are as under:

Cost estimate is valid as of 2nd Quarter 2017 price basis.

No provision has been made for any future escalation

CENVAT benefit has been considered.

No provision has been made for any exchange rate variation.

It has been assumed that the project would be implemented on EPCM
mode of execution.

All costs are reflected in INR and all foreign costs have been converted
into equivalent INR using exchange rate of 1USD=Rs. 64.54.
As indicated above, the estimated project cost for the identified scope and technical
details works out to as under:
Rs. In Lakhs
S. No
Foreign
Component
Fc
Indigenous
Component Ic
Total Cost
1
1135
108490
109625
1.9
ENVIRONMENT
IMPACT Solids Waste
The solid waste generated from the 2G ethanol plant, their quantity and proposed
disposal method are tabulated as below.
Table: Solid waste from 2G ethanol plant
Description
Quantity, TPD
Disposal
Mud from wet washing (60 – 70 %
8 - 10
Land filling
moisture)
Dewatered Sludge from process
condensate treatment plant
Ash from Boiler
2-3
110 - 125
As manure on agricultural
Field
May be sold to brick,
cement industries
Liquid Discharge
The proposed 2G Ethanol unit is a Zero Liquid Discharge process plant. The water from
blow-down of boiler and cooling tower will be treated through reverse osmosis and
recycled.
Gaseous emission
These gaseous emissions are from the boiler only, as the CO2 from the fermenters is
proposed to be collected and bottled.
1.10 PROJECT SCHEDULE
The project is expected to be completed within 27 months after Environment clearance.
1.11 OVERALL PLOT PLAN
The overall plot plan is developed as per licensor layout for the process facilities. The
utilities, Plant & Non-plant buildings as per requirements are provided. The safety
distances except ethanol storage for Process plant sections, utilities and plant buildings
like Control Room and Sub- station are adopted as per standard followed in 1G Ethanol Plant
execution. PESO and OISD-118 will be considered for ethanol storage as Class A product. The
Firewater storage & Pumping facilities are also provided. Green belt area as available
inside the boundary wall is shown.
1.12 SOCIAL BENEFIT
Increase in Biofuel production reduces the dependence of oil. Reduction in greenhouse
gas emission gives environmental benefits. Less valued feed stock helps for the
production of value added products and increase income for farmer and generates
employment in rural areas.
SECTION 2
INTRODUCTION
2.0
INTRODUCTION
Hindustan Petroleum Corporation Limited (HPCL) is a Government of India
Enterprise with a Navratna Status, a Forbes 2000 and Global Fortune 500
company, listed on the Bombay Stock exchange (BSE) and National Stock
Exchange (NSE), India. It is involved in the business of refining and marketing of
petroleum products in the country.
HPCL owns & operates two major refineries producing a wide variety of
petroleum fuels & specialties, one in Mumbai (West Coast) and the other in
Visakhapatnam, (East Coast). HPCL also owns and operates the largest Lube
Refinery in the country producing Lube Base Oils of international standards. HPCL
along with M/s Mittal Energy Investments Pvt. Ltd. owns and operates a Joint
Venture Refinery at Bathinda in Punjab and also holds equity in the Mangalore
Refinery and Petrochemicals Ltd. (MRPL). HPCL has the second largest share of
product pipelines in India and a vast marketing network.
HPCL intends to set up Lignocellulosic 2G Ethanol production plant at Bathinda,
Punjab in India of capacity 100 KL per day . While the technology is feed agnostic
other biomass feed stocks envisaged to be used are cotton stalk, Cotton hull/ husk
bagasse, Corn cob, wheat straw, maize stover. Rice straw shall be the design
feedstock.
2.1
OBJECTIVE
Production of 100 KLPD Fuel Grade Ethanol meeting Specifications
as per IS 15464: 2004
2.2
ELEMENTS
As part of this project, the following facilities will be established:
1. Biomass storage section
2. Ethanol Production unit
3. Storage of Enzymes/yeast, chemicals, intermediate products, ethanol
product and by products like CO2, Ash/Silica, Mud/silt etc.
4. Raw water storage and treatment plant including DM Plant
5. Process steam boiler (with lignin as fuel).
6. Environmental Control Units like Reverse Osmosis Treatment Plant,
Multiple Effect evaporation systems meeting zero liquid discharge
norms.
2.3
CONFIGURATION
The 2G Ethanol plant configuration is considered as given below:

Ethanol unit.
o Biomass Handling and Size reduction
o Biomass Pre-treatment Section
o Enzymatic Hydrolysis
o Fermentation
o Distillation for Ethanol Recovery

CO2 Recovery and liquefaction plant

Multiple Effect Evaporation and RO system (Zero Liquid Discharge).

Lignin fired process steam boilers. Two Process Boilers based on
Lignin fuel at 60 % of the required capacity. i.e. 2 x 42 TPH

Power required for the 2G Plant is imported from the grid.

Raw water is obtained from the canal.
SECTION 3
PROJECT LOCATION
PROJECT LOCATION
The proposed 2G Ethanol plant in Punjab is envisaged at Bathinda. The site is located
approximately at latitude 30° 13′ 48″ N, and longitude of 74° 57′ 7″ E.
The site is well connected by road network and rail network. The distance of the
project site from nearest station/port/airport/city are as given below:




Bathinda Railway Junction: 18 km
Kandla Port: 1198 km
Bathinda Airport: 40 km
Bathinda City: 15 km
The overall plot plan prepared for this project is attached as
Annexure. The project site as visualized in Google map which is
given below:
Figure 1: Project site of 2G Ethanol plant
Figure 2: Project site of 2G Ethanol plant (satellite picture)
SECTION 4
PROJECT DESCRIPTION
SECTION 4.1
PROJECT CONFIGURATION
4.1 PROJECT CONFIGURATION
Hindustan Petroleum Corporation Limited (HPCL) is exploring to set up lignocellulosic 2G
Ethanol production plant at Bathinda, Punjab in India of capacity 100 KL per day. The
proposed biomass feed stocks are rice straw, cotton stalk and Cotton hull/ husk however
the envisaged technology is feed agnostic and other biomass feedstock such as Napier
grass, bagasse ,Corn cob , wheat straw etc. can also be processed.
M/s HPCL intends to explore the viability of producing Fuel Grade 2G Ethanol based on
the selected technology (PRAJ) and mainly produce following :

2G Ethanol

Carbon Di-Oxide
The Detailed feasibility study of 2G Ethanol plant at Bathinda, Punjab has been carried out
considering following process units:
Table-1: Process Units
S.No
Unit Name
Capacity
1
2G Ethanol Unit
100 KLPD
2
C02 Recovery Unit
45 TPD
UTILITY AND OFFSITES SYSTEMS
For the proposed configuration, following are main facilities envisaged in the utility block.
a) Raw water (partial requirement)
b) DM Water
c) Recirculating Cooling water
d) Compressed Air
e) Steam, Power and Boiler feed water
f) Fire Water system
Following offsite facilities have been envisaged:
a) Biomass storage and transfer facilities
b) Product Tankage (for Ethanol and CO2)
c) By-product storage (for Ash/Silica)
d) Intermediate Tankage
AUXILIARY AND NON PLANT FACILITIES
Other Facilities considered in Complex are:
 Fire and Gas detection Alarms
 Electrical substation / MCC
 Switch yard
 Loading/ Unloading Gantry
RECEIVING, DISPATCH FACILITIES AND STORAGE
Bio mass for feed shall be sourced externally through truck unloading and biomass
storage/transfer shall be part of biomass handling section. The storage of five days for feed
and two days for supplementary fuel are envisaged.
The main products from the bio refinery are Fuel Grade 2G ethanol and CO2. Ethanol shall
be stored in ethanol day storage tanks and two finished product storage tanks (after excise
check) whereas CO2 shall be stored in liquefied form in two tanks of 45 Ton Capacity
(each). Ethanol and CO2 shall be dispatched through road tankers. Ash/ Silica and mud/silt
shall be stored in the storage yard and dispatched from the complex through trucks.
SECTION 4.2
PROCESS DESCRIPTION
4.2 INTRODUCTION
Cellulosic ethanol is chemically identical to first generation bioethanol (i.e. CH3CH2OH). However,
it is produced from different raw materials via a more complex process (cellulose hydrolysis).
In contrast to first generation bioethanol, which is derived from sugar or starch produced by food
crops (e.g. wheat, corn, sugar beet, sugar cane, etc), cellulosic ethanol may be produced from
agricultural residues (e.g. straw, corn stover), other lignocellulosic raw materials (e.g. wood chips)
or energy crops (miscanthus, switchgrass, etc).
These lignocellulosic raw materials are more abundant and generally considered to be more
sustainable. However they need to be broken down (hydrolysed) into simple sugars prior to
distillation. This may be achieved using either acid or enzyme hydrolysis.
The main reasons for the enhanced development of bio-ethanol are its use as a favorable and near
carbon neutral renewable fuel, thus reducing CO2 emissions and associated climate change.
Whether first, second, or third generation feedstock is used, fermentation produces an alcohollean broth only, as such unusable in industrial and fuel applications. The ethanol must hence be
purified. Fractional distillation can concentrate ethanol to 95.6 vol% (89.5mol %), corresponding
to the azeotropic composition with a boiling point of 78.20C. Remaining moisture is captured in
dehydration column to produce anhydrous fuel grade ethanol.
Table-1: Product specification for fuel grade ethanol
S. No
Parameters
1
Relative density at 15.6/15.6 °C, Max
2
Flash point
3
Ethanol content percent by volume at
15.6/15.6°C Min. (excluding denaturant)
Value
0.79
16.6 oC
99.5
4
Miscibility with water
Miscible
5
Alkalinity
Nil
6
Acidity (as CH3COOH) mg/l, Max
30
7
Residue on evaporation percent by mass, Max
8
Aldehyde content (CH3CHO) mg/l, Max
60
9
Copper, mg/kg, Max
0.1
10
Conductivity µS/m, Max
300
11
Methyl alcohol, mg/litre, Max
300
12
Appearance
0.005
Clear and bright
Understanding of Ligno-cellulosic Biomass
Understanding ligno-cellulosic biomass, particularly its chemical composition, is a prerequisite for
developing effective pretreatment technologies to destruct its rigid structure, designing enzymes
to
liberate sugars, particularly cellulase to
release glucose, from cellulose, as well
as
engineering
microorganisms
to
convert sugars into ethanol and other
bio-based chemicals. Ligno-cellulosic
biomass is mainly composed of plant
cell
walls,
with
the
structural
carbohydrates cellulose and hemiFigure 1: Schematic diagram of plant
cellulose and heterogeneous phenolic polymer lignin as its primary components. However, these
contents vary substantially, depending on the species, variety, climate, soil fertility and fertilization
practice, but on average, for agricultural residues such as corn stover, wheat and rice straw, the
cell walls contain about 40% cellulose, 30% hemi- cellulose and 15% lignin on a dry weight basis.
The distinctive feature of plant cell walls is their two-part structure, as illustrated in Fig. 1. Primary
cell wall is developed with cell division, and enlarged during cell growth to a fiberglass-like
structure, with crystalline cellulose microfibrils embedded in a matrix of polysaccharides such as
hemicelluloses. The primary wall of adjacent cells is held together by a sticky layer, called the
middle lamella, composed of pectins, to form the conducting tissue system arranged in numerous
vascular bundles. On the other hand, when cells cease to grow, a secondary cell wall is gradually
deposited between the plasma membrane and the primary cell wall for better mechanical strength
and structural reinforcement through the incorporation of lignin for the bulk of ligno-cellulosic
biomass that can be converted to fuels and chemicals. The development of the conducting tissue
system with the rigid secondary cell wall is a critical adaptive event in the evolution of land plants,
which not only facilitates the transport of water and nutrients as well as extensive upright growth,
but also raises its recalcitrance to degradation due to the interaction and cross-linking of cellulose,
hemicelluloses and lignin as shown in Fig.2.
Cellulose
Cellulose is a polysaccharide composed of linear glucan
chains that are linked together by β-1,4-glycosidic
bonds with cellobiose residues as the repeating unit at
different degrees of polymerization depending on
resources, and packed into micro-fibrils which are held
together by intra-molecular hydrogen bonds as well as
intermolecular van-der Waals forces. Hydrogen bonds
hold
Fig 2: Schematic
diagram of
the long cellulose chains tightly together in a crystalline structure rendering the cellulose insoluble
to hydrolysis. The crystalline cellulose must be subjected to some preliminary chemical or
mechanical degradation before it can be broken down into glucose.
Hemicelluloses
Hemicellulose consists of short, highly branched chains of sugars. It contains pentoses, five-carbon
sugars such as xylose and arabinose, hexoses, six-carbon sugars such as glucose, galactose, and
mannose, and small amounts of other chemicals. Hemicelluloses chains are more easily broken
down to form their simple monomeric sugars than is cellulose because of their highly amorphous
and branched structure. Since pentose sugars comprise a high percentage of the available sugars
in plants, the ability to recover and ferment them into ethanol is important for the efficiency and
economics of the process. The exact sugar composition of hemicelluloses can vary depending on
the type of plant.
Lignin
Although lignin is a non-sugar-based polymer and cannot be used as feedstock for ethanol
production via microbial fermentation, it exerts a significant impact on the economic performance
of the corresponding bioconversion processes, since most inhibitors of microbial growth and
fermentation come from this compound during the pretreatment that is needed to render
cellulose amenable to enzymatic attack. Meanwhile, as the most abundant component in biomass
after cellulose, lignin yields more energy when burned and can be used for power production in
an eco- and environment-friendly mode of the bio-refinery. Moreover, lignin is an excellent
starting material for various products including transportation fuels and value-added chemicals,
which may add credits to the bioconversion processes and make bio-ethanol more economically
competitive.
In addition to the three major components, cellulose and hemicelluloses that can be hydrolyzed
to sugars for ethanol fermentation, and lignin left after fermentation, other components like
proteins and ashes also affect the process economics. For example,
fermentation nutrients are usually needed to nourish ethanologenic microorganisms, either
Saccharomyces cerevisiae or Zymomonas mobilis that can be engineered for ethanol production
from lignocellulosic biomass, due to insufficient nutrition in the feedstock, which raises a concern
about the supplementation of nutritional components to satisfy the basic requirements for cell
growth and ethanol fermentation.
PROCESSES FOR ETHANOL GENERATION FROM LIGNO-CELLULOSIC BIOMASS
Ligno-cellulosic biomass can be converted into bio-ethanol using following two technological
routes as shown in the Fig.3

Bio chemical conversion

Thermochemical conversion
In biochemical conversion the plant fiber is separated into its components cellulose,
hemicelluloses and lignin. The cellulose is then further broken down to simple sugars that are
fermented to produce ethanol.
Lignin is a byproduct of this process, and this can be used as a boiler fuel or processed
Fig.3: Technologies for Ethanol Generation
from Lignocellulosic Biomass
into specialty chemicals. Hydrolysis and fermentation can be conducted simultaneously in one
stage but simultaneous saccharification and fermentation (SSF) is yet to be implemented
commercially, significant advances are being made in this area.
PROCESS DESCRIPTION OF PRAJ
Praj industries limited has executed 1 TPD pilot plant to produce bio-ethanol from ligno- cellulosic
biomass is in operation since 2009 to till date consistently. A 12 TPD integrated smart bio refinery
demonstration plant in the state of Maharashtra is under operation since March, 2017.
Praj industries limited has divided their technology in different sections which are listed below and
shown in Figure. 6.6
1. Biomass Preparation Section
A. Biomass Storage
B. Biomass Handling & Milling
2. Main Process Plant
A. Pretreatment
B. Enzymatic Hydrolysis
C. Co‐Fermentation
D. Distillation
E. Dehydration
3. Utilities & Auxiliaries
A. Boiler
B. Water Treatment Plant
C. Chemical Storage
D. Cooling Tower
E. Raw water treatment
F. DM water
G. Air Compressor
H.
Enzyme Storage
4. Residue Handling Section
A. Solid Liquid Separation
B. Evaporation
C. Process condensate treatment plant
5. Off‐Site Packages
A. Fire Fighting System
B. Control System
C. Weigh Bridge
MATERIAL HANDLING & WET WASHING SECTION
The purpose of this section is to outline the technical specifications for feed stock handling system for
conveying the feed stock, de-stoning and screening, magnetic particle separation, intermediate
storage, necessary safety controls and instrumentation for automatic operation, weighing system,
vibratory screen system with rated capacity as per layout and parameters mentioned in these
specifications.
The feed stock handling system shall be designed for all feed stock materials mentioned in technical
specifications and for the levels of moisture mentioned in the feed stock.
The complete installation will be outdoor type. All components in system, instrumentation, motors,
gearbox, etc shall be suitable for outdoor installation.
From storage, raw material will be fed to the feed conveyor of feed stock handling system with the help
of front end loaders etc for further processing of size reduction, stones separation, and removal of
foreign particles, intermediate storage and further conveying.
A permanent magnet type metal separator shall be installed on feed conveyer to remove metallic
foreign particles from the feed stock. A proper access will be provided to the magnetic separator for
easy removal of separated metallic particles.
The milling unit will be supplied to crush biomass up to 10 – 30 mm particle size and integrated with
upward and downward conveying system including interconnecting chutes bellows, hoods for dust
extraction system etc. are included in the handling system. The controlled flow rate from the silo shall
be fed to the wet washing system for further processing.
Washing is done at ambient conditions. The wet washed, sized feed stock shall be conveyed from wet
washing system to pretreatment section with belt / chain conveyor and washed water will be sent to
clarification section for recycle. The clarified water will be recycled back to washing section and clarifier
bottom will be sent for water recovery to evaporation section.
MAIN PROCESS PLANT
Pre-treatment section:
In this section, C5 hydrolysis is done (i.e. conversion of Xylan to Xylose) in a reactor. The mixed acid
solution is continuously fed as per the requirement. The slurry is treated at high temperature and
pressure. The slurry from reactor is flashed in a flash vessel and then pumped to enzymatic hydrolysis
section. Water from the steam flashing shall be recycled back to process.
Enzymatic hydrolysis section:
The pretreated slurry is fed to the pre-hydrolysis reactor. Reaction conditions maintained are pH in
the range of 5.0 to 5.5, temperature of about 48 to 55 oC at atmospheric pressure before enzyme
addition. Enzyme shall be added to the reactor as per required dose. The reaction will continue in the
pre-hydrolysis reactor for few hrs and then the contents are transferred to main hydrolysis reactor for
further processing.
Fermentation Section:
The sugar rich slurry from hydrolysis reactor is then cooled to normal temperature and fed to the
fermenter. Pre-fermenters are provided for yeast propagation and different nutrients are added as
per the required dosages. The pre-fermenter volume is transferred to main fermenter for
fermentation process.
Distillation Section:
Once the desired alcohol is achieved, fermented wash is transferred from fermenter to beer well and
from beer well to distillation section. The fermented mash from the co- fermentation section is
distilled and dehydrated to get Fuel grade ethanol.
Dehydration Section:
The process drives the rectified feed through a system of molsieve beds. To allow for molsieve
bed regeneration in continuous operation, twin beds are provided of which one is in dehydration
mode while the other is in regenerating mode. Depending on feed and product specifications, the
dehydration regeneration exchange takes place based on set time cycle. As the regeneration process
releases the adsorbed water together with ethanol content, it is recycled back to system for
reprocessing.
The feed is pumped to evaporator column after preheating in feed pre-heater. The overhead vapor of
evaporator column is superheated to the required operating temperature and circulated to sieve bed
one. After passing through the molsieve, the vapor is condensed, cooled and sent to storage.
The regeneration operation forces the release of the moisture from the molsieve, making the sieve
bed 2 ready for the next cycle. The whole stillage generated in distillation shall be pumped to biomethanation.
UTILITIES & AUXILIARIES Boiler:
The solid fuel fired boiler package is envisaged for steam requirements of plant. The high pressure
steam generated in the boiler will be supplied to the process plant through steam distribution
network. Pressure Reduction DeSuperheater (PRDS) system is used to reduce the steam pressure
whenever required. The condensate from process plant will be partly returned back to the boiler
package.
The boiler package comprises the complete boiler system (combustion system, water tube boiler,
super‐heaters, evaporators, economizers, air pre‐heaters), the boiler feed water system (pressurized
de‐aerator tank, boiler feed water pump, chemical dosing systems), fuel and ash handling system,
pollution control system, chimney and balanced draft system, electrical and instrumentation system
for fully automatic operation of the boiler package.
The wet biomass cake (lignin cake) produced in the process is blended with supplementary fuel such as
rice straw in appropriate percentage. This well blended mixture will be supplied to boiler as fuel along
with concentrated syrup produced from evaporation system.
RESIDUE HANDLING SECTION Solid-Liquid Separation:
Spent wash generated from the bottoms of the distillation section is transferred to solid liquid
separation section. Series of filter press system is used to separate lignin rich solid stream from liquid.
The solid stream is used as a feed to boiler and the liquid stream (Thin slop) shall be sent to
evaporation section.
Evaporation Section:
The thin slop is further concentrated by water evaporation in evaporators to produce the
concentrated syrup which will be mixed with solid stream generated from solid liquid separation
before being fed to boiler. Evaporation (water evaporated) process condensate will be partially
recycled back to process and remaining will be sent to polishing unit for further treatment.
Process Condensate Polishing Section:
The process condensate from evaporation plant will be treated through anaerobic followed by aerobic
biological process in addition to separation in condensate polishing unit. The treated process
condensate then will be sent OSBL (outside battery limit) for utility makeup.
4.3
MATERIAL BALANCE
Overall material balance of the 100 KLPD 2G ethanol unit on dry basis
Table : 6.4 In and out flow from main Ethanol Unit (Dry basis)
Inlet Flows, TPD
Outlet Flows, TPD
Feed Stock
390
CO2 vent
Acid-1
7.39
2G Ethanol
Acid-2
1.86
TA
1.8
Chemical-1
6.5
FO
0.3
Chemical-2
11.6
Lignin
Enzyme & Yeast
3.21
Concentrated Syrup
103
Nutrients
3.46
Losses
11.23
Biogas
2.5
Others Molasses and 53.81
Rejects from ETP for
Treatment
Total
477.83
Total
1264
Total
78.4
79.6
201
477.83
1264
The percentage of solid content of feed and by products are tabulated below.
Table : 6.5 Solid content in feed, lignin & conc. syrup
Solid content (wt%)
Feed
93.75
Wet lignin
50
Concentrated syrup
60
SECTION 4.4
WATER BALANCE
SECTION 4.5
UTILITIES DESCRIPTION
4.5 UTILITY DESCRIPTION:
This section provides details of utility requirements and description of utility system
envisaged for 2G ethanol plant.
The following utility systems are reviewed for DFR:
1.
Raw Water System
2.
De-mineralized Water System
3.
4.
5.
6.
7.
Bearing Cooling Water (BCW) System
Cooling Water System
Compressed Air System
Steam, Power & Boiler Feed Water (BFW) System
Condensate System
The utility consumption and the facilities required have been done based on estimation of
utility consumption of the process units based on the following.

Licensor Data

In-house data as applicable
2G ETHANOL PLANT UTILITIES SUMMARY
The utility summary for 2G ethanol plant facilities are tabulated below in Table 6.7: Table
6.7: Utilities Summary for 2G Ethanol Plant
S.N
1
2
System
Raw Water Intake
Treated Raw Water for
Distribution
Units
Normal Capacity
m3/hr
95
m3/hr
95
3
DM Water
m3/hr
28
4
Bearing Cooling Water
m3/hr
45
5
Cooling water
m3/hr
6600
6
Instrument Air
Nm3/hr
6000
7
Plant Air
Nm3/hr
220
8
Boiler Feed Water
TPH
53.6
9
Steam for main process
plant
TPH
51
RAW WATER SYSTEM:
Raw water will be pumped to the various consumers in the plant to meet its process and
other requirements.
Raw water shall be used as follows for 2G ethanol plant facilities:
 As make up to the cooling water system
 As feed for process water make-up
 As feed to the DM water system
 As feed to drinking water system and
 As service water for operating hose stations for various miscellaneous uses in the
plant.
 Treated water required for CO2 plant is additional requirement and considered in
the overall design.
Days Cover: Raw water reservoir should be utilized for storing the raw water required for 2G
ethanol plant. Following are the details of reservoir:
Total Capacity: 17640 m3
No. of days of storage for 2G ethanol plant: 7 days (#)
DE-MINERALIZED (DM) WATER SYSTEM:
DM water in 2G ethanol plant is required for Boiler feed water make-up.
DM water storage:
Two fixed roof type DM water tanks of 12 hrs storage shall be provided & 80% of the operating
volume. Normally one tank will be receiving DM water from the DM plant and the second tank
will be supplying DM water to consumers. DM water system is designed considering guaranteed
DM water consumption of 28 m3/hr as provided by licensor.
COOLING WATER SYSTEM:
The cooling water system will meet total cooling water demand of all the 2G
ethanol plant facilities.
Table 6.10: Cooling Tower
Unit Name
Capacity (m3/hr)
2G Ethanol Plant
6600
Total
6600
COMPRESSED AIR SYSTEM:
Compressed air is required for following main requirements:
-
As instrument air to operate the various instruments in the facility and also for the purging
of some control panels.
-
As service air for operating hose stations for various miscellaneous uses in the plant,
including providing breathing air to personnel during vessel entry, etc.
Compressed air required for all the above uses is generated at a centralized location in the
plant and distributed to the various users through headers. Two qualities of compressed air
are produced and distributed.
a) Plant air comprising compressed air cooled to ambient temperature. Quality of plant air
and service air are same. This air though not containing any entrained water droplets is
saturated with the water vapours at supply condition.
b) Instrument air comprising compressed air cooled to ambient temperature and dryer to
remove water vapour to meet stringent atmospheric dew point requirements.
STEAM, POWER & BOILER FEED WATER (BFW) SYSTEM:
Steam Requirement:
Total steam requirement for boiler operation is 60 TPH including de-aeration steam. 2
nos. boiler of 42 TPH capacity each is considered.
Power Requirement: Power requirement for ISBL+OSBL is 11.5 MW
Emergency power requirement is to be supplied by DG system by 2.75 MW
which will be accommodated by 2 days storage of diesel.
Boiler Feed Water System:
Boiler feed requirement of various units is given in Table 6.16. The values have
been arrived at from the steam generation figures (excluding the steam generation
from the back pressure drives) and considering 3% blow down losses.
CONDENSATE SYSTEM:
Condensate is recovered from all the process heat exchangers.
WATER TREATMENT SCHEME:
RAW WATER TREATMENT PLANT
Raw water received in the complex shall be stored in a raw water reservoir and
then pumped for treatment in a Raw Water Treatment Plant (RWTP). The design
capacity of the Raw Water Treatment Plant shall be 95 m3/hr of treated raw water.
The design feed raw water quality at inlet to the RWTP shall be as follows:
Table 6.17: Inlet Raw Water Feed Quality
Inlet Raw Water
No.
Parameters
Unit
1.
pH
--
Quality
7.2
2.
Mineral Oil
ppm
<0.01
ppm
-
NTU
<1.0
ppm
303.9
3.
Total Suspended Solids
5.
(TSS)
Turbidity
Total Alkalinity as CaCO3
6.
Total Hardness as CaCO3
ppm
227.7
7.
Total Iron as Fe
ppm
<0.01
8.
Total Dissolved Solids (TDS)
ppm
9.
Calcium
ppm
79.2
10.
Magnesium
ppm
7.1
11.
Chlorides
ppm
15
12.
Sulphates
ppm
21.8
4.
550 (as per ionic
balance)
The treated raw water quality at outlet of the RWTP shall be as follows:
Table 6.18: Treated Raw Water Quality
Treated Raw Water
No.
Parameters
Unit
1.
pH
--
7.5-7.8
ppm
<1.0
NTU
<1.0
ppm
82.0
ppm
132
Total Suspended Solids
2.
4.
(TSS)
Turbidity
MO Alkalinity as CaCO3
5.
Total Hardness as CaCO3
3.
Quality
6.
Total Iron as Fe
ppm
<0.1
7.
ppm
240
8.
Total Dissolved Solids (TDS)
Ca Hardness as CaCO3
ppm
96
9.
Mg Hardness as CaCO3
ppm
36
10.
Sodium
ppm
13.2
11.
Potassium
ppm
5
12
Chlorides
ppm
16
13.
Sulphates
Reactive Silica as SiO2
ppm
58
ppm
<15.0
14.
The treated water shall be stored in treated raw water tanks from where it will be
pumped to various consumers in the complex to meet their requirements. Treated
raw water shall be used to meet the following requirements:

Cooling water make-up

Process water for 2G Ethanol Project

DM plant feed

Service water

Potable water including safety showers, eyewash and
drinking water
DM WATER PLANT:
Feed to the DM plant shall be treated raw water from the Raw Water Treatment
Plant. The design capacity of the DM Water Plant shall be 28 m3/hr of net DM water
production. DM water shall be stored in DM water tanks from where it will be
pumped to 2G Ethanol plant to meet its DM water requirement.
The DM water quality to be met at the outlet of DM Water Plant is as follows:
Table 6.19: DM Water Quality
No.
Parameters
Unit
DM Water Quality
1.
pH
--
6.7-7.3
2.
Micromho/cm
<0.2
3.
Conductivity
Total Hardness as CaCO3
ppm
Nil
4.
Total Silica as SiO2
ppm
<0.01
5.
Turbidity
NTU
Nil
6.
Total Chlorides as Cl
ppm
Nil
7.
Total Iron as Fe
ppm
<0.01
8.
Total Copper as Cu
ppm
<0.003
9.
Oil Content
ppm
Nil
ppm
<5
ppm
<0.01
10.
11.
KMnO4 Consumption @
100oC
Na + K as Na
RECYCLE PLANT
The backwash/regeneration effluents from RWTP & DM Plant along with CTBD &
blow-down from 2G ethanol project will comprise the feed to the Recycle Plant.
Treated water from the Recycle Plant (complying to the treated raw water quality
as indicated earlier) shall be sent to RWTP for being utilized as treated raw water
in the complex.
SEWAGE TREATMENT PLANT (STP)
MBR (Membrane Bio-reactor) based Sewage Treatment Plant (STP) is envisaged.
The design capacity of STP shall be 10 KLD (10 m3/day). The scheme consists of the
following stages:

Screen chamber with bar screen & debris retaining grid, and oil & grease trap
in the STP inlet channel.

Sewage Collection Sump (RCC construction) with an effective capacity of 10 m3
and submersible MBR Feed Pumps (capacity 1.5 m3/hr each pump) (1 working
+ 1 standby).

Package Membrane Bio-Reactor Unit (including anoxic tank, aeration tank,
permeate transfer and backwashing pump system, air scouring blowers and air
diffuser system, and associated cleaning and chemical dosing facilities as
required as per MBR system supplier’s recommendations) to provide treated
sewage of the required quantity and quality.

The MBR permeate water shall be stored in Treated Sewage Tank/Sump of
RCC construction (effective capacity of 30 m3) and sent for use in horticulture
via permeate water transfer pumps (capacity 5 m3/hr each pump)

The bio-sludge generated from the STP shall be dewatered employing Bag
Filters and the filtered effluent water shall be recycled back to the Sewage
Collection Sump.

NaOCl dosing shall be provided at for the disinfection of the treated sewage
water.
Cycle of Concentration (COC)
Considering the quality of available water and efficiency of the inhibitor treatment
scheme it is recommended that the CW system shall be operated at COC of 5
Maximum.
SECTION 4.6
OFFSITES DESCRIPTION
4.6 OFFSITE SYSTEM
Storage and Transfer System
This section describes the storage and pumping facilities for feed/intermediate and
finished product based on the material balance, unit capacities, block flow diagrams and
storage & shutdown philosophy of 2G Ethanol Plant for the selected configuration.
Storage capacity is based on the process unit feed / products rates, criticality of operation,
turnaround schedules, emergency operation, etc.
The philosophy and facilities for storage and transfer is discussed below. Offsite facilities
are divided into three sections:

Biomass storage and transfer

Intermediate Feed / Intermediate product storage and transfer

Finished product storage
Biomass Storage and Transfer

Five days storage for feed biomass (rice straw) is considered inside the plant area.
Biomass will be stacked in open area and put in to a conveyor by mechanical loader
to feed to the 2G ethanol unit.

Two days storage for secondary fuel (Cotton Stalk) is considered inside the plant
area. Secondary fuel will also be stored in open area and put in to a conveyor by
mechanical loader to feed to the boiler unit.
Intermediate Storage and Transfer
Two intermediate product storage is considered for the proposed 2G ethanol plant.
1) Lignin rich wet cake: Lignin rich wet cake produced from solid – liquid separation unit
contains about 60% moisture and shall be feed to boiler as a fuel. One day intermediate
storage is consider to address start-up /shutdown and short term problem encounter
in plant operation. Wet lignin produced in a day about 400 MT shall be stored in this
area.
2) Thin slop will be stored for 1 days in a tank.
Product Storage and Transfer
Main product from this unit is fuel grade ethanol. Other materials come out from this
plant and required storage are
a) Ash from boiler
b) Mud/slit from wet washing
c) Dewatered Sludge from PCTP
d) Fusel Oil and Technical Alcohol from distillation
Ethanol Storage and Dispatch:
10 days ethanol storage is considered for this unit. Two tanks of equal capacity is used for
this purpos. More over three daily receiver tanks are also considered in view of Indian excise
rule.
Gantry:
The dispatch of product is considered through road tankers. The basis of dispatch facilities
by road (Tanker) for the product is considered based on Product ethanol flow for 100 KL per
Day:
Note: Ethanol being hygroscopic in nature, It has to be ensured that no moisture is present
in road tankers/loading arms, which would otherwise degrade the gasoline spec/quality.
No. of bays & gantries and gantry configuration are listed below:
Table-3: Gantry Details
S No.
Bay No.
No.
Of
Loading
Point Per Bay
Product
Loading
Type
1
2
1
Ethanol
Bottom
1
1
1
CO2
Bottom
Ash Storage:
Ash generated from boiler shall be stored for 2 day before disposal or take off by third
party. Ash is collected in ash pond/pit.
Mud/slit Storage:
Periodically mud/slit removed from the wet washing section is stored in site for 7 days. The
mud/slit is collected in a pit and removed periodically for land filing. The estimated
generation of mud is 8 - 10 MT per day with 70 – 75% moisture.
FO & TA Storage:
For fusel oil storage ~40 m3 storage tank is consider. FO generated from the plant at a rate
of 0.4 – 0.5 m3/day. Storage is sufficient for 15 day storage. FO can either sell to marked or
burn in boiler. For Technical Alcohol storage ~51 m3 storage tank is consider. TA generated
from the plant at a rate of 1.5 – 2.0 m3/day. Storage is sufficient for 15 day storage. TA can
either sell to marked or burn in boiler.
Off – Spec Storage:
For storing the off spec product, one off-spec receiver tank is considered. Off spec product
is pumped back to system to produce final product.
CHEMICAL, YEAST, ENZYME STORAGE.
ISBL chemical, yeast, enzyme etc. required for main 2G ethanol process are given
below.
Liquid chemicals stored in tanks as mentioned below.
Table 6.28: Liquid Chemical Storage
Sl
No
Description
Day of
storage
1
Chemical – I bulk
storage
15
2
Acid – I bulk
storage
15
3
Acid – II bulk
storage
15
4
Chemical – III
bulk storage
15
5
Molasses
15
Other chemical in solid form are stored in warehouse the quantity of storage as
tabulated below.
Table : Solid Chemical Storage
Sl
No
Description
Day of
storage
Quantity/ Pack
1
Chemical – II
15
25 - 50 kg
2
Nutrient – I
15
25 - 50 kg
3
Nutrient – II
15
25 - 50 kg
4
Nutrient – III
15
25 - 50 kg
Enzyme and Yeast Storage:
Enzyme shall be stored in cold room in enzyme container (Intermediate Bulk Container,
IBC), enzyme storage is considered for 15. Temperature to be maintained inside the cold
room is 8 - 10 OC.
Yeast will be stored in a closed packing in day form and the storage duration is considered
for 15 day.
RAW WATER STORAGE
Following are the details of raw water reservoir considered for proposed 2G ethanol:

Total Capacity: 17640 m3

No. of days of storage: ~ 7 days
Two raw water tanks are considered inside the plant.
LAGOONS
Two lagoons are consider in plant to divert the stream from evaporation section during
start-up, shutdown and abnormalities arises during plant operation.
DIESEL TANK
A diesel tank storage is considered for emergency DG set.
BUILDINGS
The following buildings as have been rationalized have been considered for DFR.
Table : Building area considered
Sl No
Name
1.
Administrative Building
2.
Warehouse(Chemical, Spares, Product, Cement)
3.
4.
5.
6.
Workshop
Canteen
Laboratory (1st floor above control room)
Control room with rooms for operating
Carpet Area in m2
200
200
100
200
160
160
supervisors (Ground floor)
200
1500
200
2 portable cabin
18
60
7.
8.
9.
10.
11.
12.
Training Center and conference rooms
Substations
Fire station
Operator Cabins
Security Cabins
Medical centre
13.
200
14.
Any other building as required (Shed for contract
worker, drivers etc.)
Cold enzyme Storage (8 OC)
15.
Inventory store
100
16.
Excise office
60
150
SECTION 5
ENVIRONMENT CONSIDERATIONS
5.0 ENVIRONMENT CONSIDERATIONS
The design of the Project will be on a minimum pollution basis and include all the features required to
ensure that control of all forms of pollution will comply with regulatory & governmental requirements.
The PROJECT is also designed to minimise emissions and the production of waste. The solid waste that
is produced during construction phase will be segregated to allow for safe disposal and preferably
recycle/reuse. Such wastes includes; sieves, activated carbon filters and ion exchange resins, as well as
oily sludge, sanitary sludge, maintenance wastes and spent batteries.
The solid waste that is produced during operation phase will be mostly used for combustion in boiler and
left out portion will be either sold as manure for agricultural fields or to brick and cement industries.
Any waste that must be disposed of off-site, shall be disposed of by an appropriately authorised
organisation recognised by Central Pollution Control Board/State Pollution Control Board.
During the operation phase, the treated waste water will be recycled using RO based recycle plant.
Backwash/ regeneration effluent generated from recycle plant shall be stored in the recycle plant and
then pumped for use as horticulture water, fire water make-up and for ash quenching.
Solids Waste
The solid waste generated from the 2G ethanol plant, their quantity and proposed
disposal method are tabulated as below.
Table : Solid waste from 2G ethanol plant
Description
Quantity, TPD
Disposal
Mud from wet washing (60 – 70 %
8 - 10
Land filling
moisture)
Dewatered Sludge from process
condensate treatment plant
Ash from Boiler
2-3
110 - 125
As manure on agricultural
field
May be sold to brick,
cement industries
Liquid Discharge
The proposed 2G Ethanol unit is a Zero Liquid Discharge process plant. The water from blow-down of
boiler and cooling tower will be treated through reverse osmosis and recycled.
Gaseous emission
Since lignin is burnt, the quality and quantity of the effluent gases will vary with the biomass. These
gaseous emissions are from the boiler only, as the CO2 from the fermenters is proposed to be collected
and bottled.
Strom Water Disposal –
Storm water for first 5 to 10 min from the main process plant pit will be transferred to ETP to recycle
effluent. After 10 min, it will be connected to common storm water collection header. The oil skimmer
will be installed on storm water collection pond and removed periodically. The oil free storm water will
be connected to common storm water nearest header outside plant boundary
Section -6
PROJECT COST
CAPEX
Sr. No.
Description
Capacity
Total Cost (Rs. Lacs)
Foreign
Component
1
LAND LEASE COST (DURING
CONSTRUCTION)
2
Indian
Component
Total
120
120
SITE DEVELOPMENT
1043
1043
3
PROCESS KHOW HOW,BASIC ENGG/START
UP ASSISTANCE & LICENSE FEES
2275
2275
4
EPCM SERVICES
5310
5310
CONSULTANCY SERVIES FOR CATEGORY-I
EQUIPMENT
236
236
0
8984
8984
1076
77060
78136
1076
77060
78136
4.1
0
SUB_TOTAL (1-4)
5
5.1
PLANT AND MACHINERY
UNITS
(Ethanol Unit + Utilities + Off-sites)
100 KLPD
SUB_TOTAL (5.1)
5.2
UTILITIES & OFF-SITES
Included in Sr.
No. 5.1
5.3
UTILITY BOILER
Included in Sr.
No. 5.1
5.4
CATALYST AND CHEMICALS
5168
5168
5.5
LAB EQUIPMENT
137
137
82366
83441
SUB_TOTAL (5) PLANT AND MACHINERY
1076
6
ROADS AND BUILDINGS
3792
3792
7
EMP
300
300
8
OFFICE EQUIPMENT AND FURNITURE
178
178
9
ENABLING ASSET (For Power & Water)
2478
2478
10
CONSTRUCTION SITE REQUIREMENT
405
405
11
OWNERS CONSTRUCTION PERIOD
EXPENSES
3512
3512
12
START UP AND COMMISSIONING
EXPENSES
1076
102014
103090
54
5101
5154
836
836
1129
107951
109080
1129
107951
109080
6
540
545
1135
108490
109625
Included
above in Sr.
No. 3 & Sr.
No. 5.4
TOTAL (1 to 12)
13
CONTINGENCY
14
WORKING CAPITAL MARGIN
TOTAL (1 to 14)
15
INTEREST DURING CONSTRUCTION
PROJECT COST
16
5%
Corporate Environment Responsibility
(0.5% of the Project cost)
TOTAL PROJECT COST
OPEX:
Item Description
Unit
Requirement /
Day
Annual
Quantity
MT
MT
Unit Rate
GST
Total
INR/MT
%
INR
Crore
Variable Operating Cost
Rice Straw (dry basis)
MT
541.45
162434
3771*
0.00%
61.26
Supplementary fuel - Rice Straw
MT
186.35
55904.15
3771
0.00%
21.08
Acid 1
MT
7.39
2217
6850
18.00%
1.79
Acid 2
MT
1.85
555
68000
18.00%
4.45
Chemical 1
MT
10.50
3150
30000
18.00%
11.15
Chemical 2
MT
11.59
3477
22500
18.00%
9.23
Chemical 3
MT
2.00
600
24744
18.00%
1.75
Nutrient
MT
3.48
1044
25000
18.00%
3.08
Enzymes
MT
2.96
888
276000
18.00%
28.92
Yeast
MT
0.03
9
2844000
18.00%
3.02
Molasses
MT
24.99
7497
3200
18.00%
2.83
Antifoam
MT
0.25
75
160000
18.00%
1.42
Utilities Chemicals - Balance of Plant
10.30
Denaturant
M3
0.20
60
150000
18.00%
1.062
Raw Water
M3
2280
684000
35
0
2.394
Power
MW
276.00
82800
6038
ED 15% + 5%
Cess
49.99
Land on Lease
Acres
51.65
45000/Acre
0.23
Fixed Operating Cost
Salaries & Wages
150 Operational Manpower
5.50
General Administrative
1.15
Selling Expenses
@0.5% of sales revenue
0.93
Repair and Maintenance
@ 2% of plant and Machinery cost
13.15
Insurance
@ 0.5% of Project cost
5.39
Total Operating Cost (A+ B)
240.09
* Various options are being evaluated to delink storage of biomass from procurement by setting up biomass
storage depots which may increase efficiency of biomass supply change and bring down biomass supply cost
to 2500 Rs/MT, considering which OPEX will be Rs. 212 Crs per annum.
Revenue:
Description
Unit
Annual Quantity
Unit Rate
INR/Liter OR INR/Kg
Total
INR Crore
Ethanol
Liter
30000000
59.48
178.440
CO2
Kgs
13500000
5.50
7.425
Total
185.865
Ethanol price has been considered as per CCEA notification and CO2 rates are considered as per DFR rate. The
additional revenue and opex on account of lignin valorization to produce ligno sulfonate has not been
considered.