Grain Based Fuel Ethanol Plant 30 KLD with 500-800 KW Co-Generation Plant and Generation of Co2 for 16 TPD
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GRAIN BASED FUEL ETHANOL PLANT 30 KLD WITH 500-800 KW CO-GENERATION PLANT AND GENERATION OF CO2 FOR 16 TPD
[EIRI/EDPR/4705] J.C.: 2925XL
INTRODUCTION
The energy demand in our country is rising due to an expanding economy, growing population, increasing urbanization, evolving lifestyles and rising spending power. About 98% of the fuel requirement in the road transportation sector is currently met by fossil fuels and the remaining 2% by biofuels. Today, India imports 85%2 of its oil requirement. The Indian economy is expected to grow steadily despite temporary setbacks due to the COVID pandemic. This would result in a further increase of vehicular population which in turn will increase the demand for transportation fuels. Domestic biofuels provide a strategic opportunity to the country, as they reduce the nation’s dependence on imported fossil fuels. In addition, when utilized with appropriate care, biofuels can be environmentally friendly, sustainable energy sources. They can also help generate employment, promote Make in India, Swachh Bharat, doubling of farmers’ incomes and promote Waste to Wealth generation.
Ethanol is one of the principal biofuels, which is naturally produced by the fermentation of sugars by yeasts or via petrochemical processes such as ethylene hydration. It has medical applications as an antiseptic and disinfectant. It is used as a chemical solvent and in the synthesis of organic compounds, apart from being an alternative fuel source.
Achieving energy security and the transitioning to a thriving low carbon economy is critical for a growing nation like India. Blending locally produced ethanol with petrol will help India strengthen its energy security, enable local enterprises and farmers to participate in the energy economy and reduce vehicular emissions. The Government of India notified the National Policy on Biofuels –2018 (NPB–2018) on 4.06.2018 wherein, under the Ethanol Blended Petrol (EBP) Program, an Indicative target of 20% blending of ethanol in petrol by 2030 was laid out.
In the processing of ethanol, alcohol, maltodextrin and other items with broken rice as raw materials, we can use our technology to separate the rice protein first, then use the starch to get ethanol maltodextrin, etc., in this way, you can get High-quality food grade purity more than 80% rice protein, which has no allergens, non-genetically modified, the ability to absorb more than soy protein and other proteins.
Ethanol is the IUPAC name for their chemical. The name alcohol is a generic name derived from two Arabic words, al and kohl.
COST ESTIMATION
Plant Capacity 30 KL/Day
Land & Building (15 Acres) Rs. 12.50 Cr
Plant & Machinery Rs. 35.85 Cr
Working Capital for 1 Month Rs. 7.58 Cr
Total Capital Investment Rs. 59.19 Cr
Rate of Return 29%
Break Even Point 52%
CONTENTS
INTRODUCTION
OVERVIEW OF ETHANOL IN INDIA
ENERGY SECURITY
COMPATIBLE VEHICLES
IMPACT ON EMISSIONS
GLOBAL EVIDENCES
NATIONAL POLICY ON BIOFUELS
PROPERTIES
SOURCES OF ALCOHOL
USES/APPLICATIONS
INDIAN MANUFACTURING INDUSTRY
INTRODUCTIONA
MARKET SIZE
INVESTMENT
SOME OF THE MAJOR INVESTMENTS AND DEVELOPMENTS IN THIS SECTOR IN THE RECENT PAST ARE:
GOVERNMENT INITIATIVES
IN THE UNION BUDGET 2023-24:
IN THE UNION BUDGET 2022-23:
ROAD AHEAD
ETHANOL SUPPLY PROJECTION IN INDIA
ETHANOL PRODUCTION CAPACITIES
MODIFIED INTEREST SCHEME TO ENHANCE PRODUCTION CAPACITY OF ETHANOL
AVAILABILITY OF FEED-STOCK FOR ETHANOL IN THE COUNTRY (IN LAKH TON)
ESTIMATION OF SUPPLY & CAPACITY AUGMENTATION
YEAR WISE & SECTOR WISE ETHANOL PRODUCTION PROJECTIONS
ETHANOL CAPACITY REQUIREMENT BY YEAR AND RAW MATERIAL
ETHANOL CAPACITY AUGMENTATION (20% BLENDING BY 2025-26)
AVAILABILITY OF FEED-STOCKS FOR ETHANOL PRODUCTION
FUEL ETHANOL DEMAND IN INDIA
GROWTH IN VEHICLE POPULATION
PROJECTED ADDITION OF GASOLINE VEHICLES (IN LAKHS)
DEMAND PROJECTIONS OF GASOLINE
GASOLINE DEMAND PROJECTIONS
DEMAND PROJECTION OF FUEL ETHANOL
ETHANOL DEMAND PROJECTION
ADDITIONAL MODELING OF ETHANOL DEMAND SCENARIOS
CONSERVATIVE (LOW EVS) –
BUSINESS-AS-USUAL (BAU, MEDIUM EVS) –
LOW CARBON (HIGH EV UPTAKE) –
ETHANOL BLENDING PROGRAMME IN INDIA
NODAL AGENCY FOR ETHANOL PRODUCTION
FEEDSTOCK COST AND ETHANOL YIELD
QUANTITY SUPPLIED (ETHANOL) AND %BLENDING TRENDS
MANUFACTURERS/SUPPLIERS OF ETHANOL
TRADE AND TECHNICAL NAMES
TYPE OF YEAST
THEY ARE GROUPED TOGETHER IN THREE FAMILIES ARE: -
SHAPE AND SIZE OF CELLS
CONTENTS OF THE CELL
YEAST SPARES
BIS SPECIFICATION
MANUFACTURING PROCESS
PROJECT DESCRIPTION WITH PROCESS DETAILS
GRAIN BASED DISTILLERY:
FLOW CHART SHOWING GRAIN HANDLING AND MILLING
LIQUEFACTION SECTION
FLOW CHART SHOWING LIQUEFACTION PROCESS
FERMENTATION SECTION
MPR DISTILLATION
MOLECULAR SIEVE DEHYDRATION (MSDH) FOR ETHANOL
FLOW CHART SHOWING MSDH TECHNOLOGY
DECANTATION SECTION
INTEGRATED EVAPORATION
DWGS DRYER SECTION
EFFLUENT TREATMENT SCHEME:
FOLLOWING EFFLUENT STREAMS WILL BE GENERATED FROM THE PROCESS:
UNIT PROCESS & EQUIPMENT:
DECANTER CENTRIFUGE
MULTIPLE EFFECT EVAPORATION PLANT
AGITATED MINGLER:
EFFLUENT TREATMENT SCHEME
CHARACTERISTICS EFFLUENT FOR DESIGN PURPOSE
CAPTIVE POWER PLANT:
BOILER & AUXILIARIES
THE HIGH EFFICIENCY PLANT WILL INCLUDE FOLLOWING MAJOR SECTIONS:
TURBINE & AUXILIARIES
LIQUEFACTION
FERMENTATION
DISTILLATION
PROCESS FLOW DIAGRAM
SEQUENCES - ETHANOL PRODUCTION
PROCESS IN DETAILS FOR ALCOHOL PRODUCTION
ALCOHOL PRODUCTION FROM BROKEN RICE AND OTHER GRAIN
GRAIN HANDLING AND MILLING
MASHING
FERMENTATION
DISTILLAITON
TECHNOLOGY
ACID HYDROLYSIS OF DAMAGED RICE
INCUBATION AT VARYING CONDITIONS
ACID HYDROLYSIS AT VARYING TEMPERATURES
ACID HYDROLYSIS AT VARYING PHYSICAL TREATMENT
THERMO CHEMICAL PROCESS IN HYDROLYSIS
POLLUTION CONTROL
WASTE WATER TREATMENT
ENVIRONMENT MANAGEMENT PLAN
AIR QUALITY MANAGEMENT:
WATER QUALITY MANAGEMENT
NOISE MANAGEMENT
SOLID & HAZARDOUS WASTE MANAGEMENT
ODOUR MANAGEMENT
PLANT & MACHINERY (BROADLY)
AREA 1 – GRAIN RECEIVING AND STORAGE SECTION
AREA 2 – GRAIN HANDLING AND MILLING SECTION
AREA 3 – LIQUEFACTION SECTION
AREA 3 – FERMENTATION SECTION
AREA 4 – MULTIPRESSURE DISTILLATION SECTION
AREA 5 – ETHANOL DEHYDRATION SECTION
AREA 6 – DECANTATION SECTION
AREA 6.1: INTEGRATED EVAPORATION PLANT ON DISTILLATION COLUMN
AREA 6.2: DRYER VAPOUR INTEGRATION EVAPORATION PLANT
DDGS DRYER EQUIPMENT SECTION
LABORATORY EQUIPMENT’S (BROADLY)
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF BROKEN RICE
SUPPLIERS OF PLANT & MACHINERY
SUPPLIERS OF SILO
SUPPLIERS OF HAMMER MILLS
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF REACTORS
SUPPLIERS OF D.G. SETS
SUPPLIERS OF BOILERS
SUPPLIERS OF CONDENSER
FIREFIGHTING EQUIPMENTS MANUFACTURERS & SUPPLIERS
ELECRICAL GOOD & SWITCH MANUFACTURE
LABORATORTY EQUIPMENTS MANUFACTURERS
SUPPLIERS OF DISTILLATION COLUMN
SUPPLIERS OF SCRUBBER
ENGINEERING DESIGN CONSIDERATIONS
ETP FACILITY
ETP FLOW DIAGRAM (TYPICAL)
SEWAGE AND WASTE WATER EFFLUENT
STP FLOW DIAGRAM (TYPICAL)
ADDRESSES OF RELEVANT GOVERNMENT OFFICES
ADDRESSES OF FINANCIAL INSTITUTIONS
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
SPECIFIC FACTORS
6. TRANSPORTATION:
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TERM LOANS:
8. TOTAL LOAD:
9. LAND AREA/MAN POWER RATIO:
STATUTORY APPROVALS FROM GOVERNMENT
DOCUMENTS REQUIRED FOR LICENSES
LIST OF DOCUMENTS:
POLLUTION CONTROL MEASURES
AIR POLLUTION
WATER POLLUTION
NOISE POLLUTION
SOLID WASTE MANAGEMENT
DISPOSAL OF SLAG FROM FERRO ALLOYS:
PLANTATION
SELECTION CRITERIA OF PLANT SPECIES FOR GREEN DEVELOPMENT PLANT
SWOL ANALYSIS
STRENGTHS
OPPORTUNITIES
WEAKNESS
LIMITATIONS
IMPLEMENTATION SCHEDULE
ORGANIZATION CHART
PLANT LAYOUT
CONCLUSIONS
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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