EMP Lesous

Environmental Management Plan
for
Grain Based Fuel Ethanol Distillery Plant (120 KLPD)
along with Power Generation of 3.30 MW at Purnia,
Bihar
Project Proponent:
M/s. LESOUS API AND FORMULATIONS PVT. LTD.

Regd. Office- J-200/A Paharpur Road, Garden Reach,
Kolkata- 700024, WB, India
Works- Purnia, Bihar
Environmental Management Plan for Grain Based Fuel Ethanol Distillery Plant (120 KLPD)
along with Power Generation of 3.3 MW at Purnia, Bihar by M/s Lesous API and Formulations
Pvt. Ltd.
Contents
Sr. No. Content Page No.
1.0 PROJECT DESCRIPTION 1
1.1 Introduction 2
1.2 Environment Policy 2
1.3 Grain Ethanol Process Diagram 6
1.4 Environmental Impacts and Management During Construction Phase 22
1.5 Environmental Impacts and Management During Operation Phase 23
1.6 Disaster Management Plan 30
1.7 Measures for Improvement of Ecology 30
1.8 Concept of Waste Minimization, 3R’s (Reuse, Recycle & Recover 32
Techniques), Energy and Natural Resource Conservation
Measures
1.9 Budget for EMP 34
Annexures
1 10 Km Study Area Map 35
2 Land Use Details 36
3 Ambient Air Quality Monitoring and AAQ Modeling 37
4 Land Documents 39
5 Environmental Setting 40
6 Water Allotment Letter 41
Lesous API and Formulations Pvt. Ltd. i

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ENVIRONMENTAL MANAGEMENT PLAN
1.0 PROJECT DESCRIPTION

M/s Lesous API and Formulations Pvt. Ltd. the project proponent, proposes to install a green
field project of grain based distillery with Zero Liquid Discharge norms to produce fuel grade
ethanol for blending with petroleum. Since the location of proposed project site in agriculturally
prominent area of Assam, proponent intends to use grain as raw material. To meet the power
required for the proposed project, proponent wish to install own power plant also. For power
generation, fuel proposed is rice husk. The project site is located at Gut No. 2 B, 2P, Village
Dhing, Teshil Nagaon, Dist., Nagaon, Assam.
Table 1 - Plant Configuration

SL. No Facility Capacity
1 Grain Based Fuel Ethanol Distillery 120 KLPD
2 Co-Generation Power Plant (45 TPH) 3.30 MW
Table 2 - Salient Features of the Project
1 Name of the Company M/s Lesous API and Formulations Pvt. Ltd.
Plant Location:
Purnia, Bihar
2 Registered Office Registered Office
Plant & Admin Office J-200/A, Paharpur Road, Garden Reach, Kolkata- 700024, WB,
India.
1. Raghawendra Singh
3 Name of the Directors 2. Vijay Jaiswal
3. Dr. Ayan Chatterjee
Schedule: 5 (ga), Grain Based Distilleries Producing
4 Proposed Sector
Ethanol, Category -B2
5 Area of plant 18 Acres
7 No. of Shifts 3 Shifts of 8 Hours per day and operation 350 Days per annum
Grain Based Fuel Ethanol Distillery of 120 KLPD with Captive

8 Installed Capacity
Power Plant of 3.30 MW.
Final Product & By- Fuel Ethanol (120 KLPD)
10
Product DDGS- 70 TPD
CO2- 50 TPD
11 Cost of Project INR 212.78 Cr
12 Total Manpower 150 Persons
13 Total Power Requirement 3.30 MW (Source-In house CPP)
Lesous API and Formulations Pvt. Ltd. EMP 1

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Total Water Requirement = 4174 KLD
14 Total Water Requirement
Fresh water requirement= 1048 KLD
Damaged Grain Feed Stock, Broken Rice, Maize, Bajra
15 Major Raw Material
& Sorghum, Starchy Materials etc.
400 TPD
16 Quantity of Raw Material
1.1 INTRODUCTION
Environmental Management Plan consists of the set of mitigation, management, monitoring and
institutional measures to be taken during implementation and operation of a plant to eliminate
adverse environmental impacts or reduce them to acceptable levels. The present environmental
management plan addresses the components of environment affected during the different
activities forming part of the processes of plant.
Based on the evaluation of impacts and baseline conditions, an Environmental Management Plan
(EMP) has been delineated to mitigate the adverse impacts on environment of the area due to the
proposed project. The EMP is herein outlined after taking into account the various Acts, Rules and
Regulations/ Standards concerned with the environmental management.
Aims of EMP
➢ Overall conservation of the environment.
➢ Minimization of waste generation and pollution.
➢ Judicious use of natural resources and water.
➢ Safety, welfare and good health of the work force.
➢ Ensure effective monitoring of all control measures.
➢ Vigilance against probable disasters and accidents.
➢ Monitoring of cumulative and long-time impacts.
1.2 ENVIRONMENT POLICY

M/s Lesous API and Formulations Pvt. Ltd. has a well-defined policy to keep the Environment
clean and green. The company has decided that all effective steps shall be taken to ensure that
flow of information from working level to top level should flow in a smooth and coordinated
manner, so that in case any deficiency is noted, it is brought to the notice of top management
and preventive and corrective action is initiated in a systematic manner
M/s Lesous API and Formulations Pvt. Ltd. is committed to:-
❖ Follow the National laws and regulations related to Environment Protection and
Prevention & Control of Pollution.
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❖ Design, construct and operate the plant by adopting technology and process that are
sustainable and environmentally acceptable in the country.
❖ Adoption of State of the Art technology for prevention and control of impacts.
❖ Take steps to prevent, minimize and control releases to air, water and land of
substances which could adversely affect human health and the environment.
❖ Operate facilities and conduct activities taking into consideration the efficient use of
natural resources.
❖ Provide and maintain healthy and safe working condition for all employees.
❖ Ensure the protection of the health and safety of workers.
❖ Adopt measures to ensure that all its contractors and business associates also comply
with National laws and regulations related to Environment & Control of Pollution.
❖ Focus on continual improvement of environmental performance and ensure
involvement of employees at all levels by providing training & awareness.
For effective and efficient implementation of Environment Policy, Company shall:-
❖ Ensure the allocation of sufficient financial, human and technological resources along
with organizational infrastructure for its implementation.
❖ Prepare and maintain site specific, list of all the applicable regulations legal records,
compliance requirements and compliance status.
❖ Develop and implement innovative processes focused on reducing consumption of
energy and water and minimizing quantity of waste dispose.
❖ Review facilities and programs on a regular basis and establish monitorable targets,
quantified as appropriate for continual improvement of our environmental performance.
❖ As far as practicable, purchase products and services that will have minimum impact on
the environment.
❖ Communicate the environmental commitment and performance of the organization to
the stakeholders.
❖ Establish an organizational structure to oversee the effective implementation of
corporate environment policy. Define key responsibilities with the various levels of
organization for policy implementation.
1.2.1 Interaction with the State Pollution Control Board

EMC shall be in regular touch with SPCB and shall send them environmental monitoring reports
regularly in the prescribed format, as per the prevailing practice. Any new regulations considered by
State/Central Pollution Control Board for the Industry shall be taken care of by EMC.
1.2.2 Provide Training

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EMC would be responsible for the implementation of the EMP, needs to be trained on the effective
implementation of the environmental issues. To ensure the success of the implementation set up
proposed, there is a high requirement of training and skill up-gradation. For the proposed project,
additional training facilities will be developed for environmental control. For proper implementation
of the EMP, the officials responsible for EMP implementation will be trained accordingly.
To achieve the overall objective of pollution control it is essential not only to provide latest
pollution control and monitoring systems but also to provide trained manpower resources to
operate and maintain the same. Therefore, apart from the EMC, specific training will be provided to
personnel handling the operation and maintenance of different pollution control equipment.
In-plant training facilities will be developed for environmental control. The training will be given to
employees to cover the following fields:
➢ Awareness of pollution control and environmental protection to all.
➢ Operation and maintenance of specialized pollution control equipment.
➢ Organize field monitoring, maintenance and calibration of pollution monitoring
instruments.
➢ Laboratory testing of pollutants.
➢ Repair of pollution monitoring instruments.
➢ Occupational health/safety.
➢ Disaster management.
➢ Environmental management.
➢ Afforestation / plantation and post care of plants.
➢ Knowledge of norms, regulations and procedures.
➢ Risk assessment and Disaster Management.
1.2.3 Other Responsibilities of the Cell Will Include
MOEFCC approved lab will be retained to generate the environment quality data in respect of air, water,
noise, soil and meteorology and prepare the Environmental Report.
➢ Timely renewal of Consents & Authorization will be taken care of.
➢ Submitting environmental monitoring report to SPCB. The cell will also take mitigative or
corrective measures as required or suggested by the Board.
➢ Conduct and submit annual Environmental Statement to SPCB.
➢ Prepare and submit six monthly report on the compliance with the conditions of the
environmental clearance
➢ Keeping the management updated on regular basis about the findings / results of
monitoring activities and proposes measures to improve environmental performance.
➢ Conducting regular safety drills and training programs to educate employees on safety

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practices. A qualified and experienced safety officer will be responsible for the issues related
to occupational safety and health.
➢ Conducting safety and health audits to ensure that recommended safety and health
measures are followed.
1.2.4 SOP for Flow of Information
The Environmental Management Group would consist of executives and supporting staff headed
by senior official reporting to CEO. During the construction of the project, Project Review Team
(PRT) meetings will be held every month wherein officials from the project and corporate centre
will participate and discuss the progress and problems related to implementation of schedules of
activities for construction, completion and commissioning. It will be ensured that all pollution
control measures identified are implemented in a coordinated manner, linking the overall project
implementation plans.
Monthly Operation Review Team (ORT) meetings for the project will be held during project
operation. In these meetings in addition to routine Operation and Maintenance (O&M) problems
issues related to environment will also be discussed. Dedicated groups for operation &
maintenance of major systems like Bag Filters, Waste Treatment Plant, Solid Waste Utilization, etc.
shall be formed. The issues related to the compliance of environmental norms including problems
associated with the mitigation measures identified will be included in the agenda for quarterly
review meetings, wherein action plan for remedial measures will be drawn and monitored.
Company has developed Environment Policy and well laid Standard Operating Procedures to bring
in any deviation / violation of the environment norms as prescribed by regulatory authorities.
The Head-Environment will brief the ORT about the environmental performance of the plant and
all compliances/non-compliances are brought to the notice of MD. Action plan is drawn for
rectifying the NC, budget is sanctioned (CAPEX & OPEX) and approval is obtained in the meeting
itself. Minutes of the Meeting are prepared. In the next weekly review meeting, the action plan is
discussed and the NC is closed.
The MD includes Environmental Performance as an Agenda in the monthly Board Meetings and
circulates the MOMs. In this manner the Board of Directors are appraised of the Non- Compliances
and CAPA taken to address the NC’s. System of Reporting Environmental Non- Compliances /
Violations To The Board of Directors are shown below:

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1.3 Grain Ethanol Process Diagram

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1.3.1 - Process Description
Grain Distillery consists of the following important plant sections:

1. Grain Receiving, Pre-Cleaning and Handling
2. Grain Storage Silo
3. Grain Milling and Flour Handling
4. Liquefaction and Saccharification
5. Fermentation
6. Multi Pressure – Wash to RS Distillation
7. Molecular Sieve Dehydration (Fuel Ethanol Plant)
8. Ethanol PESO Storage
9. Water Treatment Plant
10. Cooling Towers
11. Decantation
12. Integrated Evaporation for Thin Slop
13. DWGS Mixing
14. DDGS Dryer
15. Biogas Boiler based on Renewable Energy Source (Agriculture Source – Rice
Husk/Bagasse)
16. Turbine
17. Steam Integration Piping
18. Transformers, DG SETS and Electrical

System
19. Fire Fighting System
20. Condensate Polishing Unit / ETP
21. Laboratory
Grain Receiving, Storage and Milling

Grain unloaded, is initially received by grain
receiving hopper. From receiving hopper, grain
is shifted to storage silo through screw conveyor

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and bucket elevator. The silo is well equipped with aeration facility so as to keep proper air
circulation inside the silo. Some part of the dust that is carried along with the incoming grains is
removed in this section. Capacities of Silos and Number of Silos are decided on the basis of Grain
Availability and types of grains, which are used.
Pre-cleaned Grains are fed in controlled rate to the hammer mill. In this unit operation, Grain is
broken down into small particles (flour) of required size distribution. Oversized particles are
segregated with the help of vibratory screen. They are then recycled back to the hammer mill
through the coarse bin. Flour from Vibratory screen is collected in the Hopper and then fed to the
Slurry Mixing tank at a controlled rate.
Number of Hammer Mills and their capacities are decided based on the operating philosophy.
Liquefaction
The starch from the slurry is liquefied for sugar
production. This is done in three steps viz.
Preliquefaction, continuous jet cooking and
postliquefaction. Heat stable enzymes are used
for the process. The cooking process is done at
high temperature to sterilize the slurry and to
get high yields of sugar.
This process is designed to maximize product
yields using minimum process water and is
based on classical concept of Simultaneous
Saccharification and Fermentation.
Hot Process water and recycled thin slop is added to Pre-masher to make slurry. The mixed
slurry is taken to the Initial Liquefaction Tank where additional quantity of water is added as
per requirement. Viscosity reduction Enzyme and stabilizing chemicals and a portion of
liquefying enzyme are also added at this stage. This slurry is then “cooked” in the jet cooker. The
slurry is continuously pumped to a steam jet cooker where high-pressure steam at 3.5 bar (g) /
147 deg. C rapidly raises the slurry temperature. The mixture of slurry and steam is then passed
through the Retention vessel for desired retention time at a given flow rate. The cooked mash
is discharged to a Flash Tank. The cooking process, accomplished in the above manner,
converts the slurry into a hydrated, sterilized suspension (as starch molecule is solubilized) and
is therefore susceptible to enzyme attack for liquefaction.
The gelatinized mash from the Flash Tank is liquefied in the Final Liquefaction Tank where
liquefying enzyme is added. The liquefied mash is cooled in Mash Coolers and transferred to
Fermentation section for further action.
Fermentation
The purpose of fermentation is to convert sugars into alcohol. Simultaneously Carbon dioxide is
produced in Stoichiometric proportions and is scrubbed before being discharged.

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There are closed top Fermentation tanks with adequate external cooling system to maintain optimum
fermentation temperatures. Agitators are also provided to ensure mixing and suspension of substrate
in the tank. Anaerobic conditions are maintained to ensure high reaction rates and CO2.
Typically, 4 Nos. of fermenters are provided with Beer well of same capacity. After transfer process
is complete, empty fermenters is put to CIP cycle.
Yeast seed material is prepared in water-cooled vessels by inoculating sterilized mash with active
dry yeast. Optimum temperature is maintained by circulation of cooling water. The contents of the
yeast vessel are then transferred to Pre-Fermenter.
The pre-fermenters are filled with mash and loaded with contents of the yeast vessel. The purpose
of the aerated pre-fermentation is to allow time for the yeast cells to multiply and reduce the
chances of contamination in fermenters. When the Pre-Fermenter contents are transferred to the
main fermenters, the concentration of Yeast cells are high enough to substantially reduce the lag
time associated with yeast growth in fermentation.
Saccharifying enzymes are added in the fermenters. These convert the starch into sugars. This is
basically conversion of Dextrin into Dextrose. The purpose of fermentation is to convert the
fermentable substrate into alcohol. To prepare the mash for fermentation, it has to be diluted with
water.
The pH of the mash is adjusted primarily by recycled slops (which also provides for nutrients) or by
the addition of acid. Yeast is available in sufficient quantity to initiate fermentation rapidly and
complete it within 45 hours.
At the start of the cycle, the Fermenter is charged with mash and contents of the pre-Fermenter.
Significant heat release takes place during fermentation. This is removed by forced circulation

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cooling in external heat exchangers. The recirculating pumps also serve to empty the fermenters into
beer well. After the fermenters are emptied, they are cleaned with water and caustic solutions and
sterilized for the next batch. Six fermenters are provided for Grain operation.
CO2 evolved during fermentation carries along with it some entrained alcohol. This CO2 is taken to a
CO2 scrubber where it is washed with water to recover the entrained alcohol. The scrubbed CO2 can
then be taken to CO2 recovery plant.
Multi-Pressure Distillation for Wash to RS
Multi - pressure distillation scheme has three distillation columns. These columns operate under
different pressure conditions. Energy from column operating under high pressure is re- utilized by
column operating under low pressure to conserve energy.
The columns in order of flow are:
• Mash/Stripping Column
• Rectification Column
• Aldehyde cum Recover Column
Fermented wash is preheated in the Fermented Wash

Pre heater and fed at the top of the Mash/Stripping
column. This column is provided with Reboilers. Top
vapors of Mash/Stripping column containing all the
alcohol in the wash are sent to Rectification column.
Rest of the fermented wash flows down the
Mash/Stripping column and is taken out as spent wash
from column bottom.
In Rectification column, higher volatile ethanol
component is separated from ethanol+water binary
mixture. Rectified Spirit draw is taken from the top of
Rectification column, which is sent to Molecular Sieve
Dehydration Fuel Ethanol Plant.
In the Aldehyde cum Recovery column, fusel oils are
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are concentrated and then sent to decanter where these streams are diluted with water and fusel oil rich
layer is seperated. Technical alcohol cut is taken out and recycled into the system.
Molecular Sieve Dehydration (Fuel Ethanol Plant)
Molecular sieve dehydration system is based on pressure swing adsorption technique. Vapour of
Rectified Spirit at around 95% v/v are passes through a bed containing alumino-silicate adsorbent
bed material. This removes extra amount of moisture from spirit and output is Fuel Ethanol or
Absolute Anhydrous alcohol of more than 99.8% v/v which is suitable for blending in petrol and
also pharmaceutical applications.
Decantation Section
Spent wash/Thick Slops from Mash Column is pumped to Thick Slops Tank. Thick Slops is then fed
to Decanter Centrifuge through Decanter Feed Pump. In Decanter suspended solids from Thick
Slop are separated and removed as Wet Cake while Thin Slops is collected in Thin Slops Tank. Thin
slops from this tank are then fed to Evaporator for further concentration.
Thin Slop Evaporation
Thin slop evaporation plant is designed to concentrate thin slop coming out of decantation unit
from 5% to 30% w/w solid concentration. This evaporation plant is multi-effect forced circulation
type. Evaporation is integrated to distillation and DDGS dryer for energy conservation.
DDGS DRYER
Wet cake with 30% w/w solids concentration from decantation section and Concentrated

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Syrup with 30% w/w solids concentration produced in evaporation section are mixed together in a
DWGS mixer to get DWGS of 30% Solids Concentration. This DWGS is fed to a rotary steam Dryer
to produce DDGS.
Colorless effluent such as spent lees, process condensate, washings, blow downs are treated in a
Condensate Polishing Unit and recycled back to process.
Ethanol Storage
Product streams from the various sections are initially collected in respective daily receivers and
then transferred to bulk storage tanks. Separate vent condenser is provided for each bulk storage
tank. Entire fuel ethanol receivers, bulk storage and dispatch system is installed according to PESO
norms.
Utilities & Services

This comprises cooling tower and its system, instrument air and process air system, water
treatment system and steam generation facility. Instrument Air is dried air having due point

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(-) 40°C. Process air can be filtered air. The water treatment plant consists of sand filtration
followed by softening unit. The design of softening plant is dependent upon quality of raw water.
Boiler capacity is arrived considering a peak load requirement.
Biomass Boiler based on Renewable Energy & Turbine
A high-pressure steam is generated in boiler and passed through a Back pressure turbine to
generate indigenous power. Turbine exhaust steam is utilized for process.
1.3.2 Plant and Machinery Details
Sr. No. Plant Section

1 Grain Receiving and Pre-cleaning Station
Scope starting from grain receiving hoppers, pre-cleaning system to Grain Silo
Inlet.
System capacity - Suitable
Aspiration system
Inter connecting ducting
Structure for buckets elevators and manta Dust
extraction and collection system
Associated Electrical, Field Instruments and hook up to DCS Automation
2 Grain Storage Silo

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Flat bottom GI Corrugated Silo
Along with accessories such as sweet augur, catwalks, ladders etc.
Motorised discharge gates connected to Central DCS Systems Level
switches
Aeration system
Inter connecting ducting
3 Grain Handling, Milling, Flour Handling and Weighing
Scope starting from discharge gates of Grain Silos to Premasher in Liquefaction
section
Capacity - Suitable Hammer
Mills
Sifter, oversize recycle and classifier
System consisting of vibrating screens, magnetic separator, destoner, bucket
elevators, screw conveyors etc.
Flour storage bin capacity suitable in CS construction with bin activators
Flour weighing system with flour buffer hopper, weighting hopper, load
cell, receiving hopper etc. Inter connecting ducting
Dust extraction and collection system
4 Liquefaction Section
Scope starting from Premasher to Cooled Slurry at ambient temperature
Two / Three Tank system consisting of Slurry mixing and liquefaction tanks
along with central agitators in SS304 construction
Jet cooking, retention vessel, flash tank, vent condenser and hot water
recycle system
Mash Coolers wide gap PHE Enzyme
dosing system
Caustic Lye Storage and CIP system
Pumps, motor, piping, valves and accessories Insulation
and aluminium cladding
Associated Electrical, Field Instruments and DCS Automation
5 Fermentation Section

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Scope starting from Mash Coolers in Liquefaction to Fermented Wash at the
outlet of pumps at Beer Well.
Fermentors Capacity – Suitable - 4 Nos. in SS 304 construction
Beer Well Capacity – Suitable - 1 No. in SS304 construction
Pre-Fermentos Capacity – Suitable - 2 Nos. in SS304 construction
Fermentors and Pre-fermentors shall be flat bottom with lateral
agitators, recirculation pumps, wash cooling system, 360 °C CIP cleaning
nozzles, safety system etc.
Wide gap PHE with online CIP from DCS control
Chemicals, Nutrients and Enzyme dosing system
Online CIP system
Pumps, motor, piping, valves and accessories
Electrical, Field Instruments and DCS Automation
6 Primary RS Distillation
Scope starting from beer well pumps outlet to production of Rectified Spirit
Multi pressure distillation
Mash column with grid trays in SS304 construction
All other distillation columns shall be with bubble cap trays in
SS304 construction PHE for slops
CIP system
Pumps, vacuum pumps, flame proof motors, piping, valves and accessories
Insulation and aluminium cladding
7 Fuel Ethanol Section - Molecular Sieve Dehydration

Scope of work starting from Rectified Spirit to Fuel Grade Ethanol
System comprising of Feed tank, Recovery column, superheater, preheaters,
associated heat exchangers in SS304 construction
Molecular sieve beds in SS304 construction
Vacuum eductor system
Online densitometer and strength monitoring connected to DCS automation
Pumps, flame proof motor, piping, valves and accessories
8 Ethanol PESO Storage Section

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Ethanol Storage strictly according to PESO norms.
Ethanol Daily Receivers - 3 Nos. in MS Construction (3 Days Storage
Capacity)
Ethanol Bulk Storage - 3 Nos. in MS Construction (One Month Storage
Capacity)
Fusel Oil Receiver - Suitable capacity in MS Construction
Fusel Oil Bulk Storage - Suitable capacity in MS
Construction Mass Flow Meters / PD Flow Meters - 2 Nos.
Ethanol tankers loading platform with
canopy Vent condensers, flame arrestors etc.
Pumps, flameproof motors, piping, valves and accessories
Associated Electrical, Field Instruments and connection to DCS Automation
9 Decantation Section
Capacity - To handle entire thin slop.
Decanter feed tank capacity - suitable in SS304 construction Thin
slop tank capacity - suitable in SS304 construction
DWGS Mixer and DWGS Hopper in SS304 Construction for truck loading Safety
/ control system for decanters
Pumps, motor, piping, valves and accessories Insulation
and aluminium cladding to tanks and piping
10 Thin Slop Evaporation Section

Zero Steam Evaporation System
Syrup concentration to 32% w/w minimum
Part 1 - Partially Integrated to Mash Column
Part 2 - Partially Integrated to DDGS Dryers
Pumps, vacuum pumps, flame proof motors, piping, valves and accessories
11 DDGS Dryer

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Capacity - Suitable
Steam tube rotary dryer with stationary shell and rotating tube bundle Ground
mount
Seamless tubes
Inspection doors
Suitability for Integrated Evaporation Dryer
internal temperature below 85 °C
No protein degradation and free flow DDGS
DDGS Coolers
DDGS Handling System
Conveyors, Mixers, Cyclones, Bag Filters, Wet Scrubber, Chimney DDGS
Storage Silo – Suitable capacity in CS Construction
DDGS Semi-Automatic Weighing & Bagging System - 2 Nos. Dust
extraction and collection system
12 Cooling Towers
Induced Draft Wooden, Paharpur Make Cooling Towers for following
sections
Liquefaction
Fermentation
Distillation
Fuel Ethanol MSDH
Evaporation Turbine
13 Boiler

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Superheated steam flow rate at MSSV – Suitable capacity
Superheater steam pressure at MSSV - 45 kg/cm2 (g) minimum
Superheated steam temperature at MSSV - 440 °C minimum
Multi-Fuel Boiler suitable for Rice Husk / Bagasse
Steam Drum with internals. Water
Drum
ESP – to comply with outlet emission norm of 50 mg/Nm³
De-aerator
Drain, Soot Blower Feed Water Piping
Screw feeders for Rice Husk with VFD
Fans with Drive - FD / ID and SA
VFD for ID, FD & SA, Feed water pump & fuel feeders, Soot blowers Ducting,
hopper, casing, fixture & holders with expansion joints, dampers.
Instrumentation for boiler including DCS
Sample coolers
Rice husk Silo
Mechanical/Pneumatic ash handling system with MS Ash Silo for 8 Hours storage
Fuel handling system (Suitable Capacity) for Rice Husk Bagasse
Bail Breaker / Return Bagasse Breaker Conveyor Structure,
platform, ladders, railings
Blow down arrangement with CBD tank Piping,
Valves & fittings
Silencer for start-up vent & SH safety valve
Boiler feed water Pumps - 2 nos. (1W + 1S)
Refractory Work, Insulation and Cladding
MS Fabricated Chimney (self-supporting type) of suitable diameter and
minimum 60 m height
MCC, MCC cables from MCC panel to motors, VFD Panels
Motorised valves, Dust Extraction System
Closed structure building for boiler along with canopy and painting Electrical,
instrumentation and connection to central DCS automation
14 Turbine

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Turbo Generator - Suitable Steam
flow - Suitable
Inlet Pressure - 68 ATA 480°C
Exhaust Pressure – 5 ATA
Multistage, Nozzle governed, Horizontal spindle, two bearings, Back Pressure
Type Steam Turbine with
- Hydraulically operated Stop & Emergency Valve with integral
steam strainer for inlet
- Hydraulically operated Throttle/Governing valves for inlet steam flow
control & extraction steam flow control
Gearbox
Coupling
Lubrication system with first fill of turbine oil Accessories
such as_
Base plate for turbine and gearbox
Insulation for Turbine hot parts (lagging & cladding) Set
of foundation bolts
Set of special tools & tackles for maintenance Motorized
barring gear arrangement
AC Generator
EOT Crane for turbine maintenance
Instrumentation and control
Turbine control panel and connection to central DCS automation
15 Steam Integration and Distribution for entire project
Entire steam integration and distribution piping including Boiler
and Turbine
Turbine bypass along with PRDS Steam
distribution header
Steam to various process sections along with suitable PRDS Steam
traps, loops, drains
Radiography and stress analysis as per IBR
Steam condensate, blow downs pipelines etc.
16 Power Integration, Distribution and Electricals for entire project

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Transformers
PCC, EMCC, Express Feeder, DG, TG, Synchronisation Panels, Various MCC
Cables, cable trays, junction boxes and other electrical accessories
Lightning arrestors at minimum 3 tallest points such as boiler chimney,
distillation, milling etc.
High mast lamps - 1 Nos. Aviation
lamp on Boiler Chimney Plant
lighting for entire project
Yard lighting for entire plant lay out Earthing
above ground work
17 Instrumentation and DCS Automation for entire project

Field instrumentation and central DCS control system Air
compressors with dryers, air piping
Hook up of entire control panels at central DCS for monitoring
18 Diesel Generators
1500 kVA, 1 No. along with all accessories, heat recovery system and
chimney
19 Water Treatment Plant
Conventional WTP with pre clarification, multi grade filters, ion exchange
resin beds, transfer pumps, for Process water, Soft Water and DM Water ,
Acid and Caustic Storage
20 Condensate Polishing Unit

Conventional CPU with equalisation, neutralisation, anaerobic, aerobic,
clarification, multi grade filters, RO to ensure treatment of spent lees, process
condensate, vessel washings, drains, PHE and Decanter washings, Cooling
Tower and Boiler Blowdown and WTP Rejects. To achieve zero
liquid effluent discharge.
21 Pollution Control Equipment and Online Monitoring System
Online monitoring system complying to MOEF & CC norms
Flowmeters at ETP
Stack monitoring system at Boiler
Noise reduction equipment, acoustic covers
Dust extraction system at Milling, Dryer, Boiler etc. CCTV
at ETP
22 Fire Fighting System

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In compliance with firefighting norms
Main electric pump, diesel pump and jockey pump Fire
hoses, hydrants, risers and extinguishers
23 Laboratory
Laboratory equipment, glasswares, chemicals and reagents required for grain
distillery laboratory analysis
24 Weigh Bridge
60 MT capacity along with electrical connections, computer and printer
25 Structure for entire project
Entire plant structure including structural building, staircases, platforms,
railing, gratings, chequered plates, toe guards
Piperack’s and supports Final
painting for structure
26 P & F and Transportation
Packing, forwarding, transportation to project site and transit insurance
27 Equipment Erection, Project Construction, Piping, Painting
Material unloading at site, storage, accommodation for skilled and unskilled
manpower, local conveyance, food, security, shifting, erection, erection
insurance, piping connections, final painting etc
28 Project Commissioning and Performance Trials

Commissioning of entire project and demonstration of performance for each
plant section as per rated capacity, efficiency and quality.
29 Engineering
Design engineering, heat and mass balances, technical specifications,
equipment and bought outs specifications, process flow diagrams, P & I
Diagrams, single line diagrams, DCS control logic, operating and maintenance
manuals for main process sections, bought outs, package items etc.
Civil and Structural Construction Drawings for entire project along with
stability certificate.
30 Statutory Permissions, Compliances and Approvals

Various statutory permissions, government approvals, environment
clearance, IBR, factory inspectorate, safety etc.

Pvt. Ltd.
1.4 ENVIRONMENTAL IMPACTS AND MANAGEMENT DURING CONSTRUCTION PHASE
The total area of land is 6.07 ha. During construction this land will be used for installation of
plant and machineries, storage sheds for raw materials, construction of internal roads, parking
area and temporary storage of construction materials including oil and chemicals, domestic
waste etc.
The impacts due to construction activities will be limited to above area only.
Construction activities will have cumulative impact on environment due to impact on land, soil,
air, water and noise environment as follows:
1.4.1 Land Environment
The site for project is flat and already levelled, hence no levelling is required. Earth excavated
during civil foundations will be reused for raising the plinth and backfilling the columns. Dust
generated due to earthwork including excavation and transportation activities, especially during
dry weather conditions, will be controlled by water sprinkling.
1.4.2 Air Environment
Dust will be generated during clearing of ground vegetation, leveling of site, dumping of earth and
fill material generated from site during drilling for ground water extraction, construction of
foundations waste pit construction and other grading activities. During ground excavation site
preparation in readiness for construction work may require vegetation clearance stripping off of
overburden material, ground leveling and compaction. These activities will open-up the ground
to wind action and will result in dust generation.
Impact on Air Quality -The air quality in the project area may slightly deteriorate for the time
being during construction due to poorly paved service lane, excavation, delivery of building
materials, mixing of construction materials, construction of temporary structures etc.
Movement of trucks bringing plant and machinery shall also generate dust and noise. During
construction phase, dust generation will be the main pollutant, which would generate from the
site development activities and vehicular movement on the road. However, concentration of NOx
and CO may slightly increase due to increased vehicular traffic movement.
1.4.3 Water Environment

Temporary drainage work will be maintained, removed and reinstated as required, and all other
precautions will be taken for avoidance of damage by flooding and silt. Sedimentation pit of
sufficient capacity will be constructed to trap silt-laden water during monsoon. The wastewater
will be reused for dust suppression.
1.4.4 Noise Environment

Pvt. Ltd.
The noise generated during the constructed phase will be due to the movement of vehicles and
construction equipment. Construction equipment and transport vehicles will be properly
maintained so that noise generation is minimized. Regular maintenance schedule will be adopted
for all construction equipment and vehicles
1.4.5 Solid Waste Management
Careful design, planning and good site management would minimize waste of materials such as
concrete, mortars and cement grouts. Construction waste will be segregated as much as possible
at site itself to increase the feasibility of recycling concrete and masonry as filling material and
steel pieces as saleable scrap.
Muck shall be generated from drains and sedimentation pits. The muck shall be collected daily
and stored at earmarked place. It shall be finally disposed within the plant premises for plinth
raising purpose. Litter disposal and collection points shall be established around the all
construction work sites. Construction waste shall be segregated as much as possible at site itself
to increase the feasibility of recycling concrete and masonry as filling material and steel pieces as
saleable scrap.
1.4.6 Sanitation & Safety Measures of Construction Workers
Construction workers will be taken from surrounding villages. They will be made aware of
possible hazards and safety measures that need to be taken during construction activities
through organized training. Personal Protective Equipment (PPEs) such as dust masks, goggles,
earplugs/ earmuffs, safety gloves, safety belts, safety shoe with toe protection, gumboots will be
made available at construction site. Construction workers and vehicle drivers will be provided
with drinking water, canteen and toilet/washroom facility. Rest room facility for truck drivers will
be provided.
1.4.7 Maintenance of Vehicles
One should be very careful in selecting the site for vehicle maintenance, so as to prevent the
ground water contamination due to the spillage of oil. Both diesel and petrol engine vehicles will
be maintained properly. Unauthorized dumping of waste oil will be prohibited. Wastes will be
disposed off to the SPCB approved vendors.
ENVIRONMENTAL IMPACTS AND MANAGEMENT DURING OPERATION PHASE
Air Pollution Dispersion Modeling Studies

Air Quality model has been used to predict the impact on air quality. The model uses regulatory
defaults options and meets the guidelines developed by CPCB (PROBES/70/1997- 1998). In the
present study, one season Feb.2022 met data generated at site has been used. The mixing height has
been taken from the atlas of hourly mixing height.
Meteorological data - One monthly, Hourly data on wind speed, wind direction, calm,
Pvt. Ltd.
atmospheric temperature, etc were used. In the present study, one season i.e. summer season
meteorological data has been used for modeling purpose. The mixing height for study period and
area is built-in the software.
DG set of 1500 KVA with stack height of 30m will be used for power backup & Boiler capacity
at MCR (100% Load)- 45 TPH at 45kg/cm2:
Incremental load has been identified for Particulate Matter (PM10), NO2, SO2,. The Maximum
GLC predicted for PM10 is 1.5 µg/m3. Maximum GLC predicted for SO2 is 1.6 µg/m3, Maximum
GLC predicted for NO2 is 3.2 µg/m3. The details are attached as Annexure -3.
Table 3 Emission Details

Particular Stack 1 Stack 2
(Attached to Boiler) (Attached to 1500
kVA DG)
Height of Stack (m) 60 30
Diameter of Stack (m) 2.5 1.2
Temperature of Flue Gas (oC) 130 140
16
Velocity of Flue Gas (m/s) 18
23.5
Volumetric Flow Rate (Nm3/sec) 23.5
Particulate matter at outlet @ 30 mg/Nm3 1.11
0.8
(gm/sec)
SO2 (gm/sec) 1.05 0.9
Oxides of Nitrogen (gm/sec) 2.22 1.8
1.5 .1 Air Pollution Management Plan
Stack emissions
➢ Online stack monitoring system will be provided to keep a check on emissions and
implement proper measures in case of any failure or violation of prescribed standards.
➢ Regular cleaning, inspection and maintenance of air pollution control equipment will be
carried out.
➢ Workers will be trained regarding emergency actions to be taken during equipment
failure.
➢ The whole distillery unit will be provided with facility of inter locking so that any failure of
equipment or APCE will result in instant shut down of the complete process.
1.5.2 Action Plan for Control and Monitoring of Fugitive Emissions

The fugitive dust (PM) emissions occur from road, raw material unloading and loading, vehicle
movement leading the re-suspension of settled dust, etc. Following mitigation measures are
recommended for its control:
Pvt. Ltd.
1.5.2.1 Apply water to suppress dust generation namely use of Anti-smog guns, Water canons,
Water sprinklers and Hydrant and hoses connected to water reservoir/tank
1.5.2.2 Use of dust suppressants namely liquid polymer emulsion, agglomeration chemicals
(lignosulphonates, polyacrylamides), cementitious products like lime and calcium
sulphate, Petroleum based emulsions, Chloride salts (Mg and Ca)
1.5.2.3 Use of scaffolding sheets /nets, wind fencing for dust control
1.5.2.4 Stabilised concreted earthworks with stone, soil, geotextiles, vegetation, compacting.
1.5.2.5 Use enclosures – covering for stockpiles – tarpaulin, plastic, fences, screens
1.5.2.6 Keep proper shape of stockpiles (avoid steep slopes and faces)
1.5.2.7 Remove muck from truck tyres an under bodies prior to leaving the plant premises
1.5.2.8 Minimize the drop height of raw materials
1.5.2.9 All road surfaces for permanent movement of trucks shall be paved (Concreted)
1.5.2.10 Apply water spray in conjunction with cutting, grinding, drilling
1.5.2.11 Provide enclosure around mixing process
1.5.2.12 Use mechanical road sweeping machine for regular cleaning of roads
1.5.2.13 Use industrial vacuum cleaner for cleaning all shop floors and roofs.
1.5.2.14 Monitoring of fugitive dust emissions
1.5.3 Noise Pollution Management Plan
During proposed project, the major noise-generating source will be machinery and equipment.
The proposed equipment of the proposed plant would be designed for noise levels not exceeding
75 dB (A) at plant boundary.
In general the following methods will be adopted to control the noise pollution.
1.5.3.1 The use of barricades
1.5.3.2 The use of vibration insulation techniques at foundation of fans and other moving
machinery.
1.5.3.3 The use of mufflers, and acoustic louvers in DG sets.
1.5.3.4 Proper plantation of trees.
1.5.3.5 Providing earmuffs and earplugs to the plant personnel.
1.5.4 Water Pollution Management

Plan Water Requirement:
One Time Total water requirement for the project will be 4174 KLD which will be further reduced
through recycling & reuse to 3126 KLD. The total fresh water demand for proposed project will be
1048 KLD which will be sourced from Surface water. The applications for permission of withdrawal
of water has been submitted to Department of Irrigation.

Pvt. Ltd.
Table No. 1.4 Water Demand
Water use Total (KLD) Recycle (KLD) Fresh Water (KLD)
Process water 2020 1722 298
DM +Soft water 380 0 380
Vacuum sealing 50 50 0
Floor washing 56 56 0
Domestic 12 0 12
Total (A) 2518 1828 690
Ratio 3.45KL/KL Ethanol
Water budget for 4 MW Cogen plant having rice husk fired 45 TPH boiler
Utility Requirement
Boiler 840 632 208
Cooling 816 666 150
Total (B) 1656 1298 358
Total (A+B) 4174 3126 1,048
Water Quality Management

The entire wastewater from the plant will be reused and there will be no discharge of
wastewater outside the plant premises under normal circumstances. Following measures will be
followed:
1.5.4.1 Online monitoring System consisting of flow meter and camera to analyse ETP/CPU
effluent quality will be installed. Proper maintenance of state of the art ETP/CPU will be
carried out.
1.5.4.2 Regular testing of samples at every outlet of ETP/CPU will be carried out to monitor the
outcome after every treatment process.
1.5.4.3 Regular monitoring and maintenance of equipment/machineries will be done and
records maintained.
1.5.4.4 Periodic checking to find out any leakages or areas susceptible to leaching will be
undertaken in order to save the ground water contamination.
1.5.4.5 Regular cleaning of all equipment and machineries will be done in order to avoid water
clogging areas or any corrosion in the machinery and equipment.
1.5.4.6 Grain Slops will be taken through Decanters Centrifuge for separation of Suspended
Solids separated as Wet Cake. Thin Slops from the Decanter Centrifuge will be partly
(20%) recycled back to Liquefaction Process), partly (20%) used in Analyser Column
Reboiler for flash steam generation under vacuum and the balance (60%) taken to Multi
Effect Evaporation Plant for concentration of thin slop to form a Syrup. This Syrup as
Condensed Distillery Solubles (CDS) is mixed with the Wet Cake coming out of Decanter
Centrifuge and the mixture is known as Distillers Wet Grain with
Pvt. Ltd.
Solubles (DWGS). DWGS will be fed to Dryers operating on steam and is dried to
make it DDGS – Distillers Dried Grain with Solubles.
Action plan to control ground water pollution
The proposed distillery will be based on “Zero Liquid Discharge”. The following measures will be
adopted to prevent groundwater pollution:-
• During operation phase, spent wash will be treated and will not be discharged on
soil/water.
• Treatment of secondary streams like spent lees, condensates, blow downs, etc. shall be in
closed loop & any discharge outside the distillery shall not be done.
• Spillage of chemicals/ oils/ etc. will be avoided as best possible.
• The spent wash holding tank will be made up of RCC & steel.
• Regular checking of spent wash storage lagoon will be carried out in order to check for any
leakages or leaching.
• Monthly monitoring of ground water will be done in and around spent wash storage lagoon
under environmental monitoring program and parameters will be checked in correlation
with drinking water standards IS 10500-1991.
• In case of accidental spillage, proper measures will be undertaken immediately in order to
prevent the substance from entering into ground water route.
• Storm water drains will be made along the plant boundary. Sedimentation pits will be
provided along the storm water drains. The runoff will be discharged to municipal sewer.
• Garland drains will be provided along the raw material stock yard. The water will be
collected in sedimentation tank, treated and then reused for dust suppression.
Table No. 5 Inlet and Outlet Characteristics of Treated Process Effluent

Parameters Inlet characteristics Outlet characteristics
pH 6.5 - 8.5 6.5 - 8.5
TSS 50 - 200mg/l < 100 mg/l
Oil & Grease 10 - 35mg/l < 10 mg/l
BOD 10-125 < 30
COD 20-250 <250
Iron 1.0 - 6mg/l < 1.0 mg/l
Chromium 0.2 – 0.5 mg/l < 0.2 mg/l
Phosphates 5.0 – 15 mg/l < 5.0 mg/l
Water Conservation
The following measures will be adopted to minimize use of ground water-
➢ Maximum recycling and reuse of wastewater after treatment. Condensate water will
Pvt. Ltd.
be re used & recycled.
➢ Periodic preventive maintenance of water distribution system.
➢ Optimum use of process cooling water.
➢ Training and awareness on water conservation measures.
➢ Rainwater harvesting will be practiced.
Rainwater harvesting will be done at project site to harvest rainwater from the roof tops and use
for various activities at the plant site to conserve fresh water and reduce the water requirement
from other sources. Rain water will be collected through open channel & pipelines in to storage
tank.
1.5.5 Solid Waste Generation & Disposal
The following will be the solid waste generation from the existing plant, proposed expansion
project and method of disposal:-
1.5.5.1 Maximum re-cycling and utilization of generated solid waste shall be done as per the
guidelines.
1.5.5.2 Unit will prepare Hazardous waste disposal plan, as per applicable statutory conditions
under the Hazardous Wastes Act, 2016 and same will be implemented.
1.5.5.3 EMC will keep a record of quantity of solid and hazardous waste generated and their
proper disposal.
1.5.5.4 A separate designated storage area shall be provided with sign boards/labels for
storage of hazardous waste.
1.5.5.5 The concerned person will prepare a site manual on the total program and activities of
solid/hazardous waste management.
1.5.5.6 Regular training of employees engaged in solid waste management works.
1.5.5.7 The project proponent will explore possibilities of in-house brick manufacturing unit for
utilization of fly ash.
1.5.6 Hazardous waste generation, storage &
disposal Waste oil: 2.0 KL / Annum
This will be stored in covered HDPE drums in a designated area and will be given to SPCB approved
vendors.
Table 6 Municipal Solid Waste Generation & Its Disposal
Type of Municipal Solid Waste Proposed Method of Disposal

Construction debris (generated : Used for landfill within the plant site to the extent
during construction phase) possible and recyclables will be given to
authorized recyclers.
Canteen waste : ➢ Used in composting/Vermiculture.
➢ Used as manure for greenbelt development
within the premises.
Pvt. Ltd.
Recyclable materials : Given to SPCB authorized dealers.
➢ The lead acid battery or dry battery will be given to authorized recycler having authorization from
competent authority;
➢ E-waste generated from the plant will be given to authorized recycler having authorization
from competent authority;
1.5.7 Odour management
Odour Management Plan outlines the methods by which odorous emissions will
systematically be assessed, reduced and prevented potentially from the distillery unit.
1.5.7.1 A horticulturist will be employed to develop greenbelt according to CPCB
guidelines and plantation of such trees that are known to prevent odours.
1.5.7.2 Areas having odorous emissions will be covered from all
sides with greenbelt/plantation.
1.5 DISASTER MANAGEMENT PLAN
The Company will make provisions for on-site and off-site disaster management plan: For On- site
disaster management plan, following points will be taken into consideration:
➢ To identify, assess, foresee and work out various kinds of possible hazards, their places,
potential and damaging capacity and area in case of above happenings.
➢ Review, revise, redesign, replace or reconstruct the process, plant, vessels and control
measures if so assessed.
➢ Measures to protect persons and property of processing equipment in case of all kinds of
accidents, emergencies and disasters.
➢ To inform people and surroundings about emergency if it is likely to adversely affect
them.
For off-site disaster management plan, following points will be taken into consideration:
➢ The plan will identify an emergency coordinating officer who would take overall
command of the off-site activities.
➢ Proper co-ordination will be there between the company and outside regulatory
authorities.
1.6 MEASURES FOR IMPROVEMENT OF ECOLOGY
There is no ecologically sensitive area within 10 km radius of the proposed plant. No wildlife exists in
the vicinity of the project. Plantation programme will be undertaken at several areas.
1.7.1 Greenbelt Development
A greenbelt of 2.01 ha will be developed in the plant premises. 10m–20m wide greenbelt will be
developed around the plant premises.

Pvt. Ltd.
Site Preparation: The location earmarked for greenbelt shall be fenced. The soil quality of the plant
area is fit for plantation.
Plant propagation: Nursery raised saplings of 2–3 feet height of trees and shrubs will be
purchased from local nursery and Forest Dept.
Plantation: This will include digging pits with proper spacing, filling pits with prepared soil, plantation
of seedlings and watering. The size of the pit will be 1m x 1m x 1 m for trees and
0.5 m x 0.5 m x 0.5 m for shrubs.
The pits will be filled with soil mixture. The soil will be irrigated soaking wet prior to placing of
seedling. The water required for greenbelt development will be met from the treated effluents
generated during plant operation. During construction period water supply will be met from
available sources.
Plantation will start from the beginning of construction activity (after the site is made clear and
demarcating the green portion). Soil proposed to be filled in the pit after plantation will be mixed
with compost (1:1). Plantation will be done after first rainfall. Adequate protection will be ensured
for achieving high survival rate of the planted saplings. Water and nutrients / manure will be given
at appropriate intervals.
Total Trees required as per CPCB/MoEF&CC Norms@2,500/Ha = 2.01 x 2,500 = 5025 No’s
The species selection will depend upon type of soil and local species with good survival rate will be
selected.
Table: 7 List of Big Trees for Proposed Plantation is Given Below
S.No. Common Name Scientific Name Family

1. Pipal Ficus benghalensis Moraceae
2 Chatim Alstonia scholaris Apocynaceae
3. Ashwatha Ficus religiosa Moraceae
4. Akashmoni Acacia moniliformis Mimosaceae
5. Aam Mangiferaindica Anacardiaceae
6. Arjun Terminalia arjuna Combretaceae
7. Debdaru Polyalthia longifolia anonaceae
8. Ghora neem Meliaazedarch Meliaceae
9. Ashok Saraca asoca Fabaceae
10. Jarul Lagerstroemia speciosa Lythraceae
11. Karanj Derris indica Fabaceae
12. Krishnachura Delonix regia Caesalpinaceae
13. Neem Azadirachta indica Meliaceae
14. Pakur Ficus infectoria Moraceae
15. Radhachura Amaltas Caesalpinaceae
16. Tentul Tamarindus indica Caesalpinaceae
17. Sisso Dalbergia sissoo Papilionaceae

Pvt. Ltd.
Species has been selected on following basis:-

❖ Fast growth;
❖ Capacity to endure water stress and climate extremes after initial establishment;
❖ Tolerance to specific conditions or alternatively wide adaptability to eco
physiological conditions;
❖ Differences in height and growth habits;
❖ Pleasing appearances;
❖ Providing shade; and
Trees should be tall in peripheral curtain plantation, with large, spreading canopy in the primary and
secondary attenuation zones.

Pvt. Ltd.
1.7 CONCEPT OF WASTE MINIMIZATION, 3R’S (REUSE, RECYCLE& RECOVER

TECHNIQUES), ENERGY AND NATURAL RESOURCE CONSERVATION MEASURES
The company has always considered environment as important element which can be impacted by
the project activities. They believe in prevention than curing. They believe in concept of conservation
& waste minimization.
Waste Minimization – 3R’s
(A) Reuse
➢ Fly ash will be given to brick manufacturing unit.
➢ Yeast sludge will be added to wet cake.
➢ ETP sludge will be dewatered in filter press and will be disposed off as per applicable
norms
Recycle
➢ Spent Lees and PR lees will be recycled to fermentation column
➢ Recycling or usage of recycled water at every stage of the process
➢ The process water will be treated in CPU and recycled in the process and within plant
premises.
➢ Used oil and grease from machineries/equipment will be treated and used.
(B) Recovery
➢ Concentrated spent wash will be used for the recovery of DWGS followed by DDGS to be
used as cattle feed.
➢ CO2 generated during the fermentation process will be recovered by CO2 Scrubbers and
sold to beverage & packaging industry.
➢ Water conservation & recirculation system shall be installed for recovery of cooling
water.
Energy Conservation
The following measures will be adopted for reduction in specific energy consumption:-
➢ Installation of energy efficient lightings. Use of energy saving light fittings.
➢ Installation of LED/CFL lighting.
➢ Use of energy efficient electric motors complying IEE3 Standards.
➢ Use of DCS controls
➢ Use of highly efficient VFD, minimizing idle running of machines.
➢ Optimizing loads and periodic preventive maintenance & lubrication
Pvt. Ltd.
➢ Prevention of leakages of compressed air
➢ Optimized compressed air pressure.
➢ Periodic energy audit
➢ Training, awareness and motivational programmes.
➢ Layout is designed for gravitation flow.
➢ Plant is designed for very low steam and power consumption with the use of state of art
technology.
Natural resource conservation
➢ Power will be generated within plant premises and no external power supply required,
instead surplus power will be exported to grid.
➢ Usage of rice husk as main fuel.
➢ Water will be conserved by practising rainwater harvesting and maximum recycling
within plant premises.
1.8 BUDGET FOR EMP

The capital cost for environmental management of the proposed project is estimated to be Rs. 609
lakhs & Rs. 100 lakhs per year will be required as annual recurring expenses to meet the recurring
expenditure for implementing the measures. The break-up of the investment is shown in Table 8.
Table 8 Investment on Environmental Protection Measures (Rs. in Lakhs)
Annual
Capital Cost
S. No Particulars Recurring Cost
In Rs Cr.
in Rs lacs
1 Air pollution control system (ESP/Bag filter) 2.5 25
on 36 TPH rice husk fired boiler
Scrubbing system, compressing system,
2 liquefying system and storage for CO2 0.75 15
removal
Treatment system for spent wash, DWGS
3 centrifuge decanter, DDGS dryer for ZLD 2.10 12
system
Condensate Polishing unit for water
4 0.85 17
treatment and recycle
5 Rainwater harvesting systems 0.20 5
6 Occupational Health Management 0.09 4
7 Noise Reduction Systems 0.04 2
8 Green Belt Development 0.06 5

Pvt. Ltd.
9 Environment monitoring - 5
10 Environment management cell - 10
Total 6.59 100
1.9 CONCLUSION
As discussed, it is safe to say that the proposed project is not likely to cause any significant
impact on the ecology of the area, as adequate preventive measures will be adopted to
maintain the various pollutants within permissible limits. Greenbelt development around the
area would also be taken up as an effective pollution mitigation technique, as well as to
control the pollutants released from the premises of the company.
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Environmental Management Plan

M/s. LESOUS API AND FORMULATIONS PVT. LTD.

Lesous API and Formulations Pvt. Ltd. i

1.0 PROJECT DESCRIPTION

Table 1 - Plant Configuration

Table 2 - Salient Features of the Project

Grain Based Fuel Ethanol Distillery of 120 KLPD with Captive

Lesous API and Formulations Pvt. Ltd. EMP 1

1.2 ENVIRONMENT POLICY

1.2.1 Interaction with the State Pollution Control Board

1.2.2 Provide Training

Lesous API and Formulations Pvt. Ltd. EMP 3

Lesous API and Formulations Pvt. Ltd. EMP 4

Lesous API and Formulations Pvt. Ltd. EMP 5

1.3 Grain Ethanol Process Diagram

Lesous API and Formulations Pvt. Ltd. EMP 6

Grain Distillery consists of the following important plant sections:

12. Integrated Evaporation for Thin Slop

13. DWGS Mixing

14. DDGS Dryer

17. Steam Integration Piping

18. Transformers, DG SETS and Electrical

20. Condensate Polishing Unit / ETP

Grain Receiving, Storage and Milling

Lesous API and Formulations Pvt. Ltd. EMP 7

Lesous API and Formulations Pvt. Ltd. EMP 8

Lesous API and Formulations Pvt. Ltd. EMP 9

Multi-Pressure Distillation for Wash to RS

Fermented wash is preheated in the Fermented Wash

Thin Slop Evaporation

Lesous API and Formulations Pvt. Ltd. EMP 11

Utilities & Services

Lesous API and Formulations Pvt. Ltd. EMP 12

Biomass Boiler based on Renewable Energy & Turbine

1.3.2 Plant and Machinery Details

Sr. No. Plant Section

Lesous API and Formulations Pvt. Ltd. EMP 13

Lesous API and Formulations Pvt. Ltd. EMP 14

7 Fuel Ethanol Section - Molecular Sieve Dehydration

Lesous API and Formulations Pvt. Ltd. EMP 15

10 Thin Slop Evaporation Section

Lesous API and Formulations Pvt. Ltd. EMP 16

Lesous API and Formulations Pvt. Ltd. EMP 17

Lesous API and Formulations Pvt. Ltd. EMP 18

16 Power Integration, Distribution and Electricals for entire project

Lesous API and Formulations Pvt. Ltd. EMP 19

17 Instrumentation and DCS Automation for entire project

20 Condensate Polishing Unit

22 Fire Fighting System

Lesous API and Formulations Pvt. Ltd. EMP 20

28 Project Commissioning and Performance Trials

30 Statutory Permissions, Compliances and Approvals

Lesous API and Formulations Pvt. Ltd. EMP 21

1.4.3 Water Environment

Lesous API and Formulations Pvt. Ltd. EMP 22

Air Pollution Dispersion Modeling Studies

Table 3 Emission Details

1.5.2 Action Plan for Control and Monitoring of Fugitive Emissions

1.5.4 Water Pollution Management