Technical Specifications of Plant & Machinery Comprising Process Plant for Alcohol from Molasses ...

140 Pages·2015·0.62 MB·English

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ANNEXURE I (B)
Technical Specifications of Plant & Machinery Comprising Process Plant for
Alcohol from Molasses, Steam Generation, Power Plant, Effluent Treatment Plant
& Other Utilities, to Produce :

30.0 KLPD of Total Spirit from molasses, 30 KLPD Absolute Alcohol from
Rectified Spirit along with Effluent Treatment Plant to give zero effluent discharge
comprising the following :
(cid:1) Evaporation Plant ( integrated or stand alone) for molasses spent wash
Clean in place (CIP) for process plant is provided so as to maintain hygienic
conditions in the process of fermentation steps, distillation and evaporation plant
cleaning schedules of continuous operation process plants.
1. PROCESS DESCRIPTION
The proposed distillery plant is to produce R.S. from molasses, followed by ENA and
Absolute Alcohol from R.S.. and bio-methanation followed by bio-composting for zero
liquid discharge.. The plant capacities shall be as given below :
ENA - 30 KLPD
Absolute Alcohol - 30 KLPD
Captive Power Plant - 600 kW
1.1 Fermentation
Basic spirit production is by fermentation of molasses using sacharamyces cervisiae or
equivalent yeast developed from slant supplied by vendor. Fermentation process shall
be batch or modified batch mode. Total fermentation comprises yeast development
from strain in three stages followed by pre-fermenter stage and then final fermentation.
At the end of fermentation , the wash , after due settling and mud washing , is pumped
to distillation section to recover alcohol.

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NFCSF/NIT for 30 KLPD of Total Spirit and Absolute Alcohol Plant for KSCM LTD., SATHIAON
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1.2 Distillation
Alcohol distillation section is designed to produce Rectified Spirit of min. 95% v/v
strength or high quality ENA ( 96%v/v) The impurities are removed as Heads/Technical
spirit/Impure spirit using extractive distillation technique and multiple distillation
operations. The whole distillation train is conducted in multi pressure vacuum distillation
mode in order to keep the temperatures low and also to conserve on steam
consumption. Adequate condenser capacities shall be provided in order to eliminate
alcohol losses. Products of distillation-RS / ENA/FO/TA-are collected in respective
receivers prior to transferring the same to storage.
The plant is designed for a wash strength varying from 7.5%v/v to 9% v/v strength
alcohol and also to be capable of producing Rectified spirit or on line ENA. The
distillation system generally comprises, but not necessarily exactly analyzer column with
degasser column, pre rectifier with exhaust column, hydro extraction column, rectifier
column, dealdehyde column, FOC or recovery column and Simmering Column. The
equipment list with specifications provided in this tender are indicative and any
variations are acceptable subject to necessary clarifications and mutual acceptability.
1.3 Absolute Alcohol ( Ethanol )
Production of Absolute alcohol (99.9%v/v ) from Rectified spirit of 95%v/v strength is
done by dehydration in molecular sieve beds where moisture is trapped while releasing
water free alcohol. This process called adsorption, is basically batch operation and the
sieve bed is regenerated by flushing with pure alcohol vapours . Alcohol from dilute
vapours from sieve bed is recovered by rectification where water is ultimately rejected
.The whole operation is made continuous by providing two or more adsorption towers
functioning in cyclic mode. The product vapours from molecular sieve beds are
condensed , cooled and transferred to storage via day receivers.
1.4 Captive Power plant
The distillery is furnished with a captive power plant of 600 kW based on biogas engine
with BIO gas from bio-digester of spent wash from distillation plant. The gas engine will
have waste heat recovery system to preheat make up boiler feed water from 30 C to
90 C using exhaust flue gases from the engine.
1.5 Steam generation
Steam is basically required in process plant and its auxiliaries. This is generated in low
pressure boiler at 10 ata pressure and saturated. Fuel will be basically mil wet bagasse
along with surplus bio gas after meeting the requirement of gas engine

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NFCSF/NIT for 30 KLPD of Total Spirit and Absolute Alcohol Plant for KSCM LTD., SATHIAON
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1.6 Evaporation plant
As mentioned above spent wash from distillation is treated biologically to produce
biogas. However, In order to achieve Zero liquid discharge liquid after digestion is
consumed in bio composting operation using press mud from the parent sugar mill. In
order to balance the pres mud and waste liquid, the quantity of liquid is reduced by
evaporation.. This evaporation is done in a quintuple effect evaporation plant either as
a stand alone or integrated cum stand alone plant. Steam shall be available at 4 ata
and saturated for stand alone system. In the integrated evaporation, initial concentration
is effected by using the primary distillation column vapors in the distillation section if so
chosen.
The steam condensate from the evaporation plant is returned to boiler as feed water.
The process condensate from the evaporators is duly treated for removing the
BOD/COD to be suitable for recirculation to process steps.
1.7 Effluent treatment plant
Effluent treatment plant comprises 2 parts , one for the spent wash from distillation plant
and the other for process condensate from evaporation plant and other clear liquids like
spent lees and washings
Spent wash is treated in bio-digester followed by evaporation na d bio composting with
press mud from parent sugar mill
Process condensate and other liquids go through clarification followed by biological
treatment and micro filtration to make it suitable for recirculation in the plant as a
measure of water conservation.
1.8 Controls
The control system shall include the following instrumentation for the process plant and
the other plants. These are further detailed in individual sections of equipment
specifications.
(cid:1) Fermentation parameters measurement and controls
(cid:1) Distillation plants parameters measurement ,recording /indicating and
controls
(cid:1) Boiler instrumentation for measurement , indication and recording and
controls
(cid:1) Turbine instrumentation for measurement ,indication, recording and
controls
(cid:1) Bio methanation plant controls

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NFCSF/NIT for 30 KLPD of Total Spirit and Absolute Alcohol Plant for KSCM LTD., SATHIAON
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(cid:1) Evaporation plant control
(cid:1) On / Off indicators for pump, blowers etc
(cid:1) Safety systems and alarms
Following facilities shall be provided in the control panel Page 78.
PID Control
• Trends for parameters
• Set point control
• Over view
• Alarm summary
• History and trends
The various displays (Plant mimics) shall be available for the operation using keys on
the computer keyboard and shall also be made available on the group/area overview
page. The operator shall select any particular loop from the overview page or by typing
a tag number.
The report can be made available on hourly/shift basis and this will be available on the
background (non-controlling screen). The operator shall be able to parallel control the
plant and observe the real time trend, dynamic graphics etc. Based on sampling for
the real time trend and historical trend as defined by the operator.
The system shall be designed to carry out various operations in the distillation and
fermentation section effectively in an operator friendly manner. The system shall be
located in the control room and shall comprise of the following:-
2 N Pentium P C each with
* 1 N 20 GB hard disc & 1.44 MB floppy disc drive
* 2 N Serial Ports – 1 parallel port and 1 Mouse
* 1 N 19”inch SVGA color monitor
* 1 N color inkjet printer
* 1 N keyboard
1 N PLC/DCS System panel floor mounted, powder coated consisting of:
* I/O Rack 1 set

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NFCSF/NIT for 30 KLPD of Total Spirit and Absolute Alcohol Plant for KSCM LTD., SATHIAON
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* Digital I/P modules 1 set
* Digital O/P modules 1 set
* Analog I/P modules 1 set
* Analog O/P modules 1 set
* Power supply modules 1 set
* Processor Modules /CPU 1 No.
The PLC/DCS System panel shall be complete in respect of mounting, wiring and testing
of PLC/DCS System hardware.

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NFCSF/NIT for 30 KLPD of Total Spirit and Absolute Alcohol Plant for KSCM LTD., SATHIAON
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2. EQUIPMENT SPECIFICTIONS.
2.1 Rectified Spirit / ENA Plant
2.1.1. Fermentation Section :
A. Molasses Weighing Section
Dim./Thk
S.
Particulars Capacity M.O.C. (mm) straight; Qty Remark
No.
bottom; top

1 Molasses day 250 MT/ M.S. 6 / 6 / 6 1
storage tank No.
2 Automatic 10 MT/Hr M.S., Load ___ 1
Weighing system Cell type No.
for molasses with
duplex Strainer
3 Molasses 3 M3 M.S. 6 / 6 1
weighing No
(receiving) tank
4 Weighed 50 M3 M.S. 6 / 6 1
molasses tank / No.
Vertical, Cylindrical,
Flat bottom, open
Molasses
top
feed tank

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NFCSF/NIT for 30 KLPD of Total Spirit and Absolute Alcohol Plant for KSCM LTD., SATHIAON
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B. Process equipment
Dim./Thk
S.
Particulars Capacity M.O.C. (mm) Qty Remark
No.
S/B/T
Suitable
1. Molasses magnetic flow __ __ 1Nos. with -------
15 T/hr.
each
capacity
meter with totalizer
fermenter
and
prefermenter.
------ -----
2. Molasses diluter for SS-304 3 mm 01 Nos.
Pipe for each
pre-fermenter & fermenter
PF and
schedule
FER.
(static mixer with non-
40
clogging
mixing
mixing element)
element
3mm
I-0.5 M3
3. 2 trains of Yeast SS-304 3 mm Two each
propagation vessels II-1.5 M3 shell and
cylindrical / vertical, dish 4 mm
III-7.5 M3
ends dish.
(Culture vessels) – I, II, III
in each train with
sterilizing, cooling and air
sparging arrangement,
sight and light glass &
other necessary fittings.
4. Pre-fermenter cylindrical, IV-45 M3 S.S 304 4mm 2
vertical, dish with external shell
V-45 M3
PHE, air sparging
5 mm
arrangement & necessary

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NFCSF/NIT for 30 KLPD of Total Spirit and Absolute Alcohol Plant for KSCM LTD., SATHIAON
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fittings such as sight &
light glasses, manhole,
relief valves temp.
measuring systems, etc.
Capacit
5. Fermenters Type 300 M 3 Carbon 4 Nos.
y and
cylindrical /vertical shell each steel
number
with conical top and epoxy
s are
sloping bottom. with coated 8
tentativ
agitator assembly & air mm shell
e.
sparger, sight and light 10mm
glass, manholes, level bottom,6
indicators, mechanical mm top
pressure relief device
& other necessary fittings
& nozzles . Type
cylindrical /vertical shell
with conical top and
sloping bottom

6. Beer well with agitator, 330 M3 SS-304 8 / 10/6 1 No.
other details as above

Tray
7. CO2 scrubber & internals 800 mm 304 S.S. 4/5 1 No.
type
6 trays with 250 mm plate dia absorber.
spacing
M.S.
8. Wash Settling tank with Capacity 8 x 10 x 1 No.
sight & 200 M3 epoxy 6 .
coated
light glass, manhole, level 7 m Ø x 4
indicator, m st ht,
45°
& other necessary fittings
conical
& nozzles
bottom

9. Sludge Holding tank-1 with Capacity SS-304 3/3/ 1 No.
agitator 3M3
Cylindrical, open top

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NFCSF/NIT for 30 KLPD of Total Spirit and Absolute Alcohol Plant for KSCM LTD., SATHIAON
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10. Sludge holding tank with Capacity SS-304 3/3
agitator, Cylindrical, 3 m3
Vertical open top
Carbon
11. Sludge washing tank 80 m3 4/4/4/ 1 no.
steel
Carbon
12 Wash holding tank, vertical 100 m3 8/8/6
steel
,cylindrical, closed top

C. Other tanks & receivers
S. Dim/Thk/
Particulars Capacity M.O.C (mm) / Qty Remark
No S/B/T
1 Tank for antifoam agent 1.5 M3 MS 6/6/6 1 No
2. Nutrient mixing tank with 2 M3 SS- 3/3/3 1 No
agitator, gear box and motor 304
3 Conc. Acid Tank 3 M3 MS 8 x 8 x 8 1 No.
4. Acid dosing tank 1 M3 SS- 3 thk 1 No.
304
5. Biocide / Additive tank with 1 M3 SS- 3 thk 1 No
agitator 304
6. Cleaning – in – place tank 10 M3 SS- 3 thk 2 No
304

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NFCSF/NIT for 30 KLPD of Total Spirit and Absolute Alcohol Plant for KSCM LTD., SATHIAON
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D. Process pumps (with motor)
S. Head
HP/
Particulars M.O.C Capacity in QTY Remark
KW
No MLC
1. Molasses transfer Pump from Body – 20 MT/hr * * 1+1
main tank to day storage CI
Nos
tank,
Other
Rotary, Sino pump wetted
parts
SS-304
2 Molasses feed pump from Body – MT/hr. * * * 1+1
day tank to Weighing section CI
Nos
Other
wetted
parts
SS-304
3 Molasses feed pump from Body – MT /hr. * * * 1+1
Weighing section to diluter CI
Rotary, Sino pump Other
wetted
parts
SS-304
4 Fermenter and prefermenter * * * * 1 pump
wash circulation pumps for for each
cooling, Wetted fermenter
part with one
Type - Centrifugal SS304 common
(&F8) stand by.
And 1
pump for
each
preferme
nter with
common
stand by.
5 Pre-fermenter to fermenter SS 304 M3/hr. * * * 2+1

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NFCSF/NIT for 30 KLPD of Total Spirit and Absolute Alcohol Plant for KSCM LTD., SATHIAON