Piccadily Sugar Plans to Set Up 3 KLPD Grain Based Distillery
Industrial Directory Of India
RELEASED : ISSUE DECEMBER 01/13
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Piccadily Sugar Plans to Set Up
3 KLPD Grain Based Distillery
Piccadily Sugar & Allied Industries Limited plans to set up a 3 KLPD Grain Based Distillery at IMT Bawal Industrial Estate in Rewari District, Haryana.
It will produce ENA (Extra Neutral Alcohol) in the above plant.
Capacity :
Distillery : 3 KLPD
Bottling Plant
(3000 CASES /Day)
By Prouct : CO2 will be generated during fermentation
process which will be collected and sold to authorized vendor.
Location : Sector 3, Phase II, IMT Bawal Industrial Estate
Rewari District, Haryana.
As on December 03, 2013 : The Project is under Planning Stage.
The unit would come up on about 1.945 Acre (7875 Sq. Meter) of Land .
About 30% of the area will be developed as Green Belt.
IMPORTANT: As per the the discussion we had
on 15.11.2013 with Piccadily Sugar & Allied Industries Limited
the Project is under Panning Stage.
The company is now waiting for Environmental clearances .
The project work is likely to start in April, 2014.
The Project is Scheduled to be Completed
by March, 2015.
=======================================
So, this is the RIGHT TIME to contact and Follow Up at following address
to obtain the detailed Enquiry of each product in time and to
submit your quotation subsequently.
The Main Scope of Supply includes:
Boiler : *1 TPH
Fuel : Coal/Rice Husk
Heat Exchanger, Air Pre-Heater/ Economiser
===============================
Steam Requirement (*Break Up):
Liquefaction : 70 Kg/Hour
Multi-pressure Distillation : 440 Kg/Hour
Evaporation (Integrated) : 70 Kg/Hour
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Total : 580 Kg/Hour
===============================
Raw Materials :
- Grains : 10 MT/day
- Antifoam Agent : 2 kg/day
- Yeast (Active Dry Yeast/ : 3 kg/day
Distiller’s Yeast
- Sulphuric Acid : 10 kg/Day
- Sodium Hydroxide (Caustic) : 30 kg/Day
For Main Process Plant (35% Strength)
- Liquefying Enzyme : 3 kg/day SC 120 KNU
- Saccharifying Enzym : 3 kg/day Spirizyme fuel 720 AGU
Air Pollution Control Equipment :
Electrostatic Precipitators/ Bag Filter
To control the particulate emissions from Coal/Rice Husk Fired boiler will be controlled by Bag Filter and emissions will be dispersed through a Stack of adequate Height .
Flue gases after super heating
the steam will pass through Economizer where they will Pre-Heat the boiler Feed water before it
enters the boiler drum. After Economizer, flue will pass through Air Pre-Heaters where
they will heat the air which will be
fed to the boiler furnace for burning the fuel.
After Air Pre Heaters flue gases will pass through Bag Filter.
Single
Chimney
Fuel system
Cooling Tower
=======================
Manufacturing Process:
GRAIN CLEANING, MILLING AND FLOUR HANDLING :
Grains are received from trucks in gunny bags. These bags will be unloaded manually on receiving platform & then to the receiving hopper. Receiving hopper will be provided with De dusting system to avoid dusting in the receiving area. Hopper will be equipped with Safety Grill, Manual slide gate to regulate flow to bucket elevator.
The Bucket Elevator shall feed the grains to the Pre-cleaner.
The Pre-cleaner is provided of double deck type to remove oversize and undersize impurities. The dust and light impurities are separated with blower and cyclone of the Pre-cleaner. In the Pre-cleaner oversize, undersize impurities along with light dust and farm waste will be removed.
From the Pre-cleaner clean grains are further fed to Bucket Elevator to feed the silo. The Silo diverter will be provided at the outlet of elevator to feed the desired silo. Y chute will be provided for feeding the silo. The Bucket elevator will be provided with supporting structure with ladder up to top and intermediate platforms. .
Liquefaction :
In liquefaction process, starch will be hydrolyzed to dextrin. The Liquefaction will be carried out in Single Liquefaction Tank. Feedstock Flour will be transferred to Pre-masher and mixed with Recycle Streams and liquefying enzyme. Slurry from Pre-masher will be taken to Liquefaction tank where temperature will be maintained by means of steam. Necessary retention time will be maintained in the Liquefaction Tank. Slurry pH will be maintained by supplying dilute caustic solution. Contents in Slurry Tank will be kept in suspension by Agitation. The Liquefied Slurry will be then cooled in Slurry Cooler using cooling water supply and transferred to Pre-fermentation and Fermentation section.
HIFERM-NM SACCHARIFICATION AND INSTANTANEOUS FERMENTATION :
Yeast seed material will be prepared in water-cooled Yeast Activation Vessel by inoculating sterilized mash with Active Dry Yeast. Optimum temperature will be maintained by cooling water. The contents of the Yeast Activation Vessel will be then transferred to Fermenter.
Saccharification & Instantaneous Fermentation:
The Liquefied starch slurry comprising Dextrins will be partly taken for Yeast development in Yeast Activation vessel and majorly transferred into the Fermenter. Amyloglucozydase and other nutrient Enzymes will be first added to Saccharify the Starch Slurry causing formation of Sugars. Immediately, the Active Yeast will be introduced in the system for simultaneous Fermentation. The process of fermentation is to convert the fermentable substrate into alcohol.
The carbon dioxide evolved during the process is vented to atmosphere after recovery of alcohol in a scrubber..
MULTI PRESSURE DISTILLATION :
This process utilizes following columns namely the Analyser, Degassifier, Pre-Rectifier Column, Stripper, Rectifier cum Exhaust, Extractive Distillation (ED) Column, Recovery Column and Simmering Column in ideal heat integration in order to reduce the energy consumption.
The Analyzer, Degassifier & Extractive Distillation Columns are operated under Vacuum whereas the Simmering, the Recovery Columns are operated under Atmospheric condition. The Pre-Rectifier, Rectifier-cum-Exhaust Columns are operated under Pressure.
The energy requirement for Analyser, Degassifier Column is met by Rectifier Column top vapours.
The Distillation Plant shall be designed for use of Grain starch route only.
ALCOHOL (ENA & TA) DAILY RECEIVERS & BULK STORAGE :
The Extra Neutral Alcohol & Technical Alcohol (Impure Spirit) is first taken to Daily receiver storage tanks, which is based on the State Excise laws, storage for three days considering the weekly holidays of two days. Thereafter, the alcohol is transferred to Bulk Storage Tanks after taking the daily receiver Dip. This is transferred using flameproof pumps. Final dispatch of alcohol is metered and again
is carried out using special flameproof pumps.
The Bulk Spirit Storage is proposed to be set up for 30 days.
*************************************
Details of Material Handling for Distillery:
Bucket Elevators, Vibrating Screen,
Hammer Mills, Screw Conveyor
GRAIN STORAGE : Pre-Cleaning and to store in Storage Silos.
GRAIN STORAGE : The grain has to be lifted in Bucket Elevators,
screened followed by removal of stones and iron matter.
Cleaned Grains are then milled using dry milling process in Hammer Mills.
The flour is fed through the Bucket Elevators and conveyed to the Batch Tipping Machine through a Screw Conveyor.
The flour addition is metered through the Batch Tipping Machine with load cell arrangement, before transferring the flour to the Slurry Tank through another Screw Conveyor (pre-masher) for slurry preparation process.
=======================
Cooled Condenser :
Use of Air Cooled Condenser to be used to reduce water consumption.
All the Conveyors will be covered with GI sheets to prevent the fugitive dust emission into the atmosphere.
DG set :
250 KVA – 1 No
will be installed
for emergency power Back-up during power failure.
Stack Height (above roof level) : As per CPCB/SPCB norms
Pollution Control Equipment Measures : Adequate stack height/ Acoustic
will be installed for emergency power Back-up during power failure:
Water Treatment Plant
Oxidisation Chamber, Pressure Sand Filter / IRF, R.O. Plant,
Tube Settler
Pumps Valves, Custom Pipeline Work.
Total water requirement for the above project will be 103 m3/day ( For First Run).
33 m3/day Fresh Water will be sourced from HSIIDC (Haryana State Industrial & Infrastructure Development Corporation Limited).
WATER REQUIREMENT FOR GRAIN BASED OPERATION
PROCESS WATER IN LIQN & FERMENTATION : 17 KLD
DM WATER IN DISTILLATION
FOR RS DILUTION : 27 KLD
SOFT WATER FOR CT MAKEUP : 12 KLD
DM WATER AS BOILER FEED : 22 KLD
BLENDING ( BOTTLING) : 15 KLD
DOMESTIC USAGE : 2 KLD
SOFT WATER FOR ANALYSER FLASH TANK : 5 KLD
SOFT WATER FOR PUMP SEALING & VACCUM PUMP : 3 KLD
________________________________________________________
TOTAL WATER REQUIREMENT (A) : 103 KLD
TOTAL WATER OUTPUT
STEAM CONDENSATE : 21 KLD
SPENT LEES PR : 4 KLD :
SPENT LEES RECTIFIER :27 KLD
WATER IN SPENT WASH : 19 KLD
WATER IN IMFL PRODUCT : 15 KLD
SOFT WATER FOR VACUUM PUMP & OTHERS : 3 KLD
CT EVAPORATION & DRIFT LOSSES : 12 KLD
DOMESTIC CONSUMPTION : 2 KLD :
________________________________________________________
TOTAL (B) : 103 KLD
RECYCLING & UTILIZATION STREAM
LEES RECYCLE FOR RS DILUTION : 22 KLD
STEAM CONDENSATE RECYCLE FOR BOILER : 21 KLD
SPENT LEES (PR) – PROCESS : 4 KLD
THIN SLOPS RECYCLE TO LIQN PROCESS : 6 KLD
PROCESS CONDENSATE TO PROCESS : 3 KLD
TREATED CONDENSATE TO CT MAKEUP : 6 KLD
VACUUM PUMP RECYCL : 3 KLD
RECTIFIER LEES RECYCLE TO PROCESS : 5 KLD
________________________________________________________
Total Recycling of water per day (C) : 70 KLD
TOTAL FRESH WATER INPUT (A- C) : 33 KLD
* Water requirement for first run would be 103 m3/day
Total Fresh Water Requirement : 33 KLD
************************************
Effluent Treatment Plant :
Treatment of Effluent: Grain Route
Grain Slops (Spent Wash) will be taken through Centrifuge Decanters for separation of Suspended Solids separated as Wet Cake.
Thin Slops from the Decanter Centrifuge are partly recycled back to process (30-35%) and partly taken to Thins Slops Evaporation Plant for concentration of remaining solids to form a Syrup. This Syrup is mixed with the Wet Cake coming out of Decanter Centrifuge and forms part of Cattle Feed. (Also known as Distillers Wet Grain Solubles - – Collectively known as DWGS).
The process condensate is cooled and collected into a neutralization tank with sufficient residence time. After Neutralization, this process condensate will be recycled into process and is used for green belt development within the complex.
Two streams of low BOD lees (White Effluent) comes out is partly used as fermenter washing and then sent for Cooling, treatment and utilized for RS dilution. The second part requires only cooling and can be used as Cooling
Tower water makes up directly.
The sewage generated from the sanitary blocks will be treated in septic tanks and applied on to soak pits and used for irrigation.
In the study area ground water is utilized for industrial, agricultural and domestic activities. Rainfall data shows that the area is having sufficient rainfall. Recharging capacity of ground water is good due to good rainfall.
Effluent Treatment Plant in detail
Other Equipments:
Material Handling Equipment : Conveyor, Hydraulic Equipment/Cranes,
DG Set, Air Compressor. DC/VFD Drive, Gear Box, Insulation, Valves, Pipes & Tubes, Cables, Automatic Weighing Machines for Bulk & Liquid Materials. Straight Line Steam Tunnel, Pneumatic Piston Filler, Pressure Filler,Storage Tank, Cooling Tower/ Plant, Air Conditioning Plant, Complete Laboratory Equipments etc
Fire Fighting System shall be as per the TAC Norms and cover all areas where alcohol is produced, handled and stored.
Provision of Foam System for Fire Fighting to control fire from the alcohol storage tank.
Green Belt Development plan in 30 % area and a scheme for Rainwater Harvesting have to be put in place.
Scope Of Entire Civil & Construction Work:
Construction of Office Building, Factory Shed- Boiler House, Substation-Control Panel- Electrical Work, Plumbing Work, Structural Steel fabrication and Erection Work, Fabrication Storage Tank, Vessels etc. etc.
Companies/ General Industries/ Contractors/ Sub Contractors/ Manufacturers of Boiler, Material Handling Equipment , Water Treatment Plant, Effluent Treatment Plant, Air Pollution Control Equipments, Cooling Tower, Blowers, Cranes, Hydraulic Equipments, Water line Valve, Pump, Pipeline etc. related to Distillery Plant may Contact for Specified Enquiry at :
Piccadily Sugar & Allied Industries Limited
Jakhal Road , Patran Distt. Patiala
Punjab - 147001, India
-------------------------------------
Tel : + 91- 176 – 4242500/ 4242027 / 4243249
Email : piccadil...@rediffmail.com
Website : www.psailpatran.com
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