Pioneer Industries plans For Expansion of Distillery & Co-Generation Power Plant
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Pioneer Industries plans For Expansion of
Distillery & Co-Generation Power Plant
Pioneer Industries Limited plans to expand the production capacity of its Grain Based Distillery from 125 KLPD to 200 KLPD along with 5000 Cases/ Day of IMFL/PML Bottling Unit and to expand the capacity of its Biomass and Coal based Cogeneration Power Plant from 3.65 MW to 9.00 MW at its existing location at Industrial Growth Center, Ranipur Village, Defence Road in Pathankot District, Punjab.
Capacity Expansion :
Distillery : 125 KLPD to 200 KLPD
Co-Gen Power Plant : from 3.65 MW to 9.00 MW (Fuel : Biomass/ Coal)
Bottling Plant: 5000 Cases/ Day
By Prouct : CO2 will be generated during fermentation
process which will be collected and sold to authorized vendor.
Location : Industrial Growth Center, Ranipur Village
Defence Road in Pathankot District, Punjab.
As on April 20, 2016 : The Project is under Planning Stage.
The expansion would come up on its existing 33 Acres of Land .
IMPORTANT: As per the the discussion we had
on 18.04.2016 with Pioneer Industries Limited is under Panning Stage.
The company is waiting for Environmental clearances.
The Project is
Scheduled to be Completed in 15 to 18 Months from the date of commencement of project work.
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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 : 45 TPH (Fluidized Bed Boiler)
Fuel : Coal/Rice Husk)
Note: The industry plans to install additional 45 TPH capacity fluidized bed boiler (FBC) for steam and additional 5.35 MW of cogeneration of power.
Heat Exchangers, Air Pre-heater/Economiser) to be included in the Boiler.
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Existing Status of Heating Equipment:
Presently the company is operating Three Nos. of Boiler of following Capacity:
1. Boiler
Capacity : 25 TPH - 1 No.
Fuel : Coal/ Biomass
2. Boiler
Capacity : 12 TPH - 2 Nos.
Fuel : Coal/ Biomass
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TURBINE & GENERATOR : .
he industry would install 6.0 MW back pressure/extraction cum condensing turbine
for the Co-Generation Power plant.
..
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Air Pollution Control Equipment :
Electrostatic Precipitators/ Mechanical Dust Collector
To control the particulate emissions from Coal Fired boiler will be controlled by ESP and emissions will be dispersed through Stack Height 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 an Electro Static Precipitator where the Dust Particles will be collected on charged electrodes. After passing through ESP, clean flue gases with dust particle concentration also known as SPM level less than 50 mg/Nm3 through a Chimney of prescribed height.
The dust will be collected from the bottom of the ESP.
High pressure superheated steam from boiler will pass through a Steam Turbine and at the lower pressure will go to the condenser.
The part of the steam will be extracted from the extraction points provided on the turbine, which will be used for distillery.
The condensed steam will return to the steam boiler as condensate and will again be boiled as steam.
While passing through the turbine, the high pressure and temperature steam will rotate the turbine rotor and an Electric Alternator mounted on the same shaft.
Electric power will be generated by the alternator. This electric power generated will be consumed in house i.e. for running the distillery and utilities like boilers auxiliaries etc. and surplus power will be exported to the state grid.
Steam turbine
Coal handling system
Ash handling system
Ash handling System will be totally enclosed system. The ash handling system shall be designed to take care of 100% fuel burning. Ash collected from the bottom of furnace (bottom ash) and the ash collected in the air heater hoppers and ESP (air pollution control system) hoppers will be taken to an ash silo through a pneumatic conveying system.
Ash silo will have the capacity of storage for 1 day of ash. The ash from the silo will be unloaded through the ash conditioner and stored on land. This ash will be finally used for the making of flyash bricks within the premises.
Air Cooled Condenser
Power plant stack
Single Chimney
Fuel system
Cooling Tower
The maximum process and power plant cooling water requirement will be 2000 m3/hour for the additional 100 KLPD distillery plant and 5.0 MW cogeneration power plant. The cooling tower will be counter/cross flow induced draft cooling tower with total capacity of about 2000 m3/hr capacity divided into four cells. The cooling tower shall be designed for a cooling range of 6°C, and an app roach of 5°C while operating under the atmospheric wet bulb temperature of about 27°C. The cooling tower shall be carefully sited such that there is no re-entertainment of the vapors into the cooling tower. Evaporation and drift loss will depend on season and an average figure will be about 1.00 %. The cooling tower blow-downs will be approximately 0.1%. Whole of the quantity lost will be made-up by adding fresh water/treated condensate from the process.
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Manufacturing Process:
GRAIN CLEANING, MILLING AND FLOUR HANDLING :
The grain is 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 elevator 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.
SLURRY PREPARATION & LIQUEFACTION :
Grain flour and process water is fed at controlled rate to Initial Liquefaction tank. 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 rapidly raises the slurry temperature. The mixture of slurry and steam is then passed through the Retention Vessel. The retention vessel has sufficient capacity to provide the 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 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 (alpha-amylase) is added. The liquefied mash is cooled in Mash Cooler and transferred to Saccharification cum fermentation section. This
process initiates the formation of sugar.
The gelatinized mash from the Flash Tank is liquefied in the Final Liquefaction Tank where liquefying enzyme (alpha-amylase) is added. The liquefied mash is cooled in Mash Cooler and transferred to Saccharification cum Fermentation section.
HIFERM-NM SACCHARIFICATION AND INSTANTANEOUS FERMENTATION :
Yeast seed material is prepared in water-cooled Yeast Activation Vessel by inoculating sterilized mash with Active Dry Yeast. Optimum temperature is maintained by cooling water. The contents of the Yeast Activation Vessel are then transferred to Fermenter.
Saccharification & Instantaneous Fermentation:
The Liquefied starch slurry comprising Dextrins is partly taken for Yeast development in Yeast Activation vessel and majorly transferred into the Fermenter. Amyloglucozydase and other nutrient Enzymes are first added to Saccharify the Starch Slurry causing formation of Sugars. Immediately, the Active Yeast is 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.
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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.
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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 :
500 KVA – 1 No ( New - optional)
will be installed
for emergency power Back-up during power failure.
Existing : The unit has 4 Nos. of of DG sets of 500 KVA capacity and 1 nos. of 1200 KVA capacity as backup power supply.
Stack Height (above roof level) : As per CPCB/SPCB norms
Pollution Control Equipment Measures : Adequate stack height/ Acoustic
Water Treatment Plant
Oxidisation Chamber, Pressure Sand Filter / IRF, R.O. DM Plant,
Tube Settler
Pumps Valves, Custom Pipeline Work.
DM Water Treatment Plant : 1000 m3/Day
Total water requirement for the above project will be
1669m³/Day .
Details of Water Consumption
Process & dilution water : 415 m3/Day
Cooling water : 850 m3/Day
Washing : 25 m3/Day
Water Treatment Plant : 50 m3/Day
Water Requirement for Cerala Plant : 311 m3/Day
Domestic : 18 m3/Day
________________________________________________________
TOTAL WATER REQUIREMENT 1669 m3/Day
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Effluent Treatment Plant :
The industry would be generating less than 200 m3/day (193 m3/day) of effluent from different streams from the proposed 200 KLPD distillery unit. The effluent would be having organic impurities which need to be treated before its disposal on land for irrigation purposes.
The overall effluent generation from the industry after expansion from the distillery unit would be less than 500 m3/day (including effluent from cereal based products unit). The industry has already installed an ETP that is sufficient to handle effluent more than 500 KL/day.
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 33 % 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 :
Pioneer Industries Limited
Chhoti Nehar, Malakpur
Pathankot 145025, Punjab, India
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Tel : +91-186-2345352/ 2345353/ 2345354/ 2345355
Fax : +91-186-2345351
Email : heado...@pioneerindustries.org
Website : www.pioneerindustries.org
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