Professional consultancy to industries

 

Other professional consultancy provided

1. Running or recently commissioned distilleriey plants facing any engineering problems.
2. Any operational and maintenance problems of boilers and its auxiliary plants and machineries.
3. Improvements in performance of boilers and distilleriey plant machineries and equipments.
4. Identification of bottle necks in such as undersized machineries while initial project planning and commissioned. 
5. Any process plants facing recurring problems can be identified and proper suggestions are provided for over come such problems at once.
6. Any process plants and distilleries facing operational and maintenance problems can approach us for solutions.

For further information one can always contact us by mail or phone given below.

K GOPALAN.
9420663740/9108956202.
kgopalan1956@gmail.com.

Approximate project cost (section wise)

 

approximate cost (section wise)
considering 100 klpd ethanol/ena plants.

1. Grain silos & millsection =6cr (4.3%)
2. Liquefaction & Fermentation =15cr (10.71%)
3 .Distillation &Evoppration=28cr(20%)
4.DDGS Drier(1no)=8cr(5.71%)
5. WTP &ETP=5.5cr(3.93%)
6. Fire fighting systems =5cr(3.57%)
7. Boiler with ESP & Fuel handling plant =10cr(7.15%)
8. steam turbine =5cr(3.57%)
9. Decanters 3nos=2cr(1.43%)
10. Receivers & Storage tanks =6cr(4.3%)
11. Electrical motors & Pumps =5cr(3.57%)
12. pipelines & fittings =3cr(2.15%)
13. Structural materials =12cr(8.57%)
14. civil works =15cr(10.71%)
15. Fabrication, Erection & Commissioning =5cr(3.21%)
16. Electrical motors, panels, pumps =5cr(3.57%)
17. Admin office, store section & Toilet block =4cr(2.85%)
18. Structural painting & wall painting =3cr(2.15%)

It should be noted that 18% GST & Transportation costs are extra as applicable at the time of delivery.

For further information one can always contact me by mail or phone given below.

K GOPALAN
9420663740/9108956202.
kgopalan1956@gmail.com.

Tentative project cost

 

Tentative project cost.

Again we consider for 100 klpd plant.
The following are assumptions.

1. We consider only ss 304 m.o.c only for process plant equipments and storage tanks. (shell side)
2. All the tubes for heat exchangers and process columns are of ss316 m.o.c only.
3. All the process piping and  fittings are ss316, sch40 only.
4. All the water piping are m.s. C class heavy duty only.
5. All the steam and condensate piping are  c.s. A 106 grade only.
6. All the process pumps are fully CF8M construction only. and for water it is C.S.
7. All the electrical motors are squrel cage with F class insulation NFP/FP and 2 pole/4pole/6pole as per requirement.
8. All process and control valves are CF8M,
and class 150 only. All flanges are also of class 150 only.
9. All structural materials such as angles/Channels/Beams etc are medium duty class only.
10. All civil works are included.
11. All erection and commissioning jobs are considered.
12. The selection of thickness for  plates and tubes are as our customers requirement only.
13. The total project time from concept to commissioning will require a minimum of 18 months to 24 months.
19. The cost of getting DPR , EC, CFE, CFO, and other government licenses from various departments are not included in this proposal.
20. Similarly the Working capital also not considered in this proposal.
21. With above considerations the one can always rest assured the trouble free operation for minimum of 10 years barring normal wear and tear.

FINANCIAL COST FOR THE PROJECT IS COMES AROUND 1.3cr to 1.4cr per klpd of plant capacity.

For further information one can always contact me by mail or phone given below

K GOPALAN.
9420663740/9108956202.
kgopalan1956@gmail.com.

Raw materials and by products

 

raw materials and by products of grain based ethanol plant.
we again consider 100 klpd plant.

1. Grain based ethanol can be produced from various raw materials such as broken rice, maize, jawar, wheat, bazra etc.
2. Presently we consider only broken rice and maize only.
3. We can use broken rice and maize individually or combination of both.
4. When using broken rice only, it must consist of minimum 66% of starch. The yield will be around 470 ltrs of ethanol per ton of broken rice. When using maize only, it must consist of minimum 60% starch. the yield will be around 380 ltrs of ethanol for every ton of Maine.

5. We can use both maize and broken rice with various percentage of combinations. example 70%rice & 30%maize etc. The yield will be depending upon expertise how we operate the process plant.
6. The by products are mainly the DDGS/DDWS. That is either dry or wet sludge which can be marketed as cattle feed. The other by product is carbon di oxide CO2. Which can marketed as co2 liquid gas for industries.

For further information one can always contact me in the following email address and phone numbers

K GOPALAN
9420663740/9108956202
kgopalan1956@gmail.com

Utilities requirements.

 Utilities requirements. 

consider 100 klpd ethanol/ena plants. 

Water, Steam, Cooling towers, Copressed air, WTP/ETP are common utilities required for any process plants for its operation. Let us discuss each of these. 

1. Water is required for boiler operation, Cooling tower make up, process operation such as slurry preparation, product washing to get required quality and purity. As per E.C. norm the water consumption should be around 4.5 ltrs per ltr of spirit produced. however the ground reality is it may required 7 ltrs/ ltr of spirit produced. this is fresh water requirement. we should be having an ETP to recover around 65 of water consumed. So for a 100 klpd plant we require 7 lakh liters of fresh water. there fore it is utmost importance to know the source of raw water requirements before stepping into project planning. 

2. Steam required for captive power plant and process plants such as liquefaction, distillation, evaporation and driers. The average consumption of the steam is around 4 to 5 kg/ltr of spirit produced depending upon the product  I.e ENA/ETHANOL/or both. The steam requirement for electrical power generation (captive power plant) is around 11 to 12 % of total steam generation, remaining 88 % is used for process. Depending upon the capacity of the plant the steam turbine may be back pressure type or extraction cum condensate type turbine. without the captive power plant the distilleriey project is not viable considering high cost of electricity from state electricity boards. 35tph boiler @ 45 bar pressure and 450 degree super heat temperature and 3.5MW turbine is sufficient for a 100 klpd plant. 

3. Cooling tower is one more essential part of utilities which cools the warm water from heat exchangers before circulating back to heat exchangers. The cooling towers may be counter flow type or cross flow type with induced fan arrangements. it consumes 1 to 1.5% of total flow of water as make up to compensate evaporation, drift and blow down losses. For a 100 klpd plant a total of 5500 TR with  8 degrees delta T is required for a typical 100 klpd plant. 

4. compressor air is primarily used to operate different types of control valves and actuators installed. 100 to 120 CFM @7 bar pressure with suitable driers is sufficient for 100 klpd plant. It should be noted that a standby unit is absolutely necessary. 

5. WTP AND ETP. 

WTP the water treatment plant is necessary to treat the raw water to reduce its hardness and tds before proceeding to use in the process and boiler. this treatment is necessary to avoid unnecessary scaling and fouling of healing surfaces which may reduce the effectiveness of respective heat exchangers. softener, reverse osmosis and demineralising plants are normally used as WTP. 700 to 800 cu m. perday capacity is required keeping in mind for back washing and regeneration. 

ETP Effluents generated from process plant and process condensate are required to treat in ETP to recover 65%water for reuse.

Land requirement

 

Land requirement for ethanol plant.

For the time being let us consider a 100 klpd plant.

Having discussed in the earlier post about the details of statuary requirements for land selected for distilleriey plant we now know the area of land required to set up a 100 klpd plant.

1. The total build up area requirements is around 20 to 25 acres.
2. Out of which 33% should be left as green belt, a mandatory requirement to get the environmental clearance. That comes around  7 to 8 acres.
3. Internal roads require around 10%of total build up area. That is around 2 to 2.5 acres.
4. Parking area for vehicles consumes around 10%of total build up area.This again consumes around 2 to 2.5 acres.
5.The remaining 47% will be utilized for plant building. This includes plant and machineries for process plant, boiler and turbine house, ware house for final product storage, loading station, administrative office, raw materials godown, engg stores and mechanical workshop, toilet block, WTP and ETP,  electrical substation, coal yard etc which comes around 9.5 to 11.5.acres.

this is a minimum requirement in order to  set up a 100 klpd distilleriey project. anything more can be always had advantages particularly when we look for capacity expansion.

For further information any time one can contact me in the contact numbers and/or mail address given below.

K GOPALAN.
9420663740/9108956202.
kgopalan1956@gmail.com

Project site should not have

 

The proposed site for ethanol project should not have

1. Any defence installations within 10km radius.
2. Any archeological important place within 10km radius.
3. Any critically/severely polluted area within 10km radius.
4. Any Ecological sensitive zone within 10km radius.
5. Any reserved forest/protected forest/National parks/ wildlife sanctuary etc within 10km radius.
6.Any airports within 10km radius

The above points are taken into consideration before finalizing any project site proposal for ethanol projects.

for any further information one can always can contact me.

K GOPALAN
9420663740/9108956202

kgopalan1956@gmail.com.