HAZOP STUDY– NOV-2020

DAURALA SUGAR WORKS

A Unit of DCM Shriram Industries Ltd. Distt: Meerut (UP)

NAME AND ADDRESS OF THE FACTORY WHERE HAZOP STUDY CARRIED OUT:

Mr. N. K. Jain

(OCCUPIER)

SITE:

DAURALA SUGAR WORKS

A UNIT OF DCM SHRIRAM INDUSTRIES LTD. SIGN & SEAL

DAURALA

DISTT: MEERUT (UP)-250221

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HAZOP STUDY– NOV-2020
DAURALA SUGAR WORKS
A Unit of DCM Shriram Industries Ltd. Distt: Meerut (UP)

1.0 ACKNOWLEDGEMENT

This Hazard and Operability (HAZOP) Report for M/s. Daurala Sugar Works - A Unit of DCM Shriram
Industries Ltd. Distt: Meerut (UP) is based on the studies carried out in the month of NOV — 2020 and the
information provided by the Management.

The Officials of the plant gave whole hearted co-operation during the studies and completion of the
report. All the observations could be made freely.

We express our sincere thanks to management of M/s. Daurala Sugar Works - A Unit of DCM Shriram
Industries Ltd. Distt: Meerut (UP) for providing unstinted support during the HAZOP Study without
which the HAZOP study could not have been possible. The courtesy extended to our team is highly
appreciated.

For BBC Tech Associates

Ashok Upadhyay
(Director)

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HAZOP STUDY– NOV-2020
DAURALA SUGAR WORKS
A Unit of DCM Shriram Industries Ltd. Distt: Meerut (UP)

7.0 INTRODUCTION OF THE UNIT

7.1 Facilities / System for process safety, transportation, fire fighting system and emergency
capabilities to be adopted following facilities and system will be installed/ implemented.

1. Total enclosed process system.

2. DCS operation plant.
3. Instrument & Plant Air System for control all parameters.
4. High level, low level, High pressure, low pressure, high temp, high flow, low flow indication and cut
off interlocking provided on storage as well as process reactors.
5. Safety valve, rupture disk provided on reactor and pressure storage tanks.
6. Static earthing and electric earthing (Double) provided.
7. Jumpers for static earthing on pipeline flanges of flammable chemical provided.
8. Flame proof light fitting installed where ever it is required.
9. Emergency handling equipments like SCBA sets, Fire extinguishers, Gas mask, PPEs, Chlorine
emergency Kit, chlorine hood, caustic pit, Air line respirator, provided.
10. Full fledge ETP plant made and it will take care of liquid effluent of the plant and final discharge
parameter will be maintained as per CPCB norms.
11. Scrubbers provided on all process vents and air monitoring carried out and parameters will be
maintained as per CPCB norms. Fire Water reservoir for fire hydrant and sprinkler system.
12. Storage tank area is away from the process plant and Separation Distance has been maintained.
Dyke wall provided to all above ground storage tanks, collection pit with valve provided.
13. Dyke wall provide to all above ground storage tanks, collection pit with valve provide.
14. Flame arrestor with breather valve is installed on flammable material storage tank vent.
15. Lightening arrestor on all chimneys and building provided
16. Fencing and caution notes and hazard identification boards displayed.
17. Only authorized person are permitted in storage tank farm area.
18. Safety permit for hazardous material loading unloading is prepared and implemented.
19. Static earthing provision is made at all loading unloading points of flammable chemical storage tank
farm area.
20. TREM CARD provided to all transporters and trained for transportation Emergency of Hazardous
chemicals.
21. Fire hydrant system and water sprinkler system installed at tank farm area.
22. Caution note, safety posters, stickers and emergency preparedness plan displayed.
23. Emergency facilities and medical emergency facilities are available at site. Occupational Health
centre facility generated at factory premises and paramedical staff is available round the clock.
24. Wind direction indicators are provided.

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HAZOP STUDY– NOV-2020
DAURALA SUGAR WORKS
A Unit of DCM Shriram Industries Ltd. Distt: Meerut (UP)

25. Safety Shower and eye wash are installed at acid/ alkali handling area.
26. Tele Communication system will be used in case of emergency situations for communication,
(Mobile Phone is restricted in Distillery unit.)
27. Emergency siren installed at main gate as well as in all plant.
28. Training programme is being conducted regularly and induction training are being provided to all
employees on chemical safety and process safety.

8.0 MANUFACTURING PROCESS

8.1 PROCESS DESCRIPTION OF DAURALA SUGAR WORKS, DISTILLERY DIVISION, MEERUT

Molasses is being used for producing Ethanol. Molasses obtained from the sugar factories as the raw
material, Record of molasses is maintained in MF-6 format of Excise Department.
The detail of process description is as under:
For production of Ethanol, molasses based distillery consisting Fed batch high brix fermentation and MPR
distillation process.

The main processes for the production of Ethanol are:

1) Fermentation
2) Distillation
3) Integrated Multi Effect Evaporator
4) Bio-Composting under Covered Premises
5) Wastewater Treatment cum recycling unit

The various sections involved in the process for manufacture of Alcohol are:
(a) Molasses Storage and handling section
(b) Fermentation section
(c) Distillation for production of Rectified spirit / Ethanol
(d) Integrated Multi-Effect Evaporator
(e) Bio-Composting under Covered Premises
(f) Wastewater Treatment cum recycling unit

Molasses Storage & Handling and Distribution:

In Daurala Sugar Works (Distillery division) there are 5 nos. of Molasses storage tank having total storage
capacity approx. 218554 Quintals. This is sufficient for 25 days of its consumption. Molasses is pumped to
molasses receiving tank in the fermentation section.

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DAURALA SUGAR WORKS
A Unit of DCM Shriram Industries Ltd. Distt: Meerut (UP)

Molasses Fermentation
(a) Yeast vessel section
(b) Pre Fermenter
(c) Fermenter

a. Yeast Propagation
Yeast propagation section comprises of four culture vessels, pasteurization and cooling facility. During
fermentation start up, yeast is grown in culture vessels.

b. Pre Fermentation (Two Nos.)

The grown yeast is transferred to pre-fermentation stage for further propagation (yeast activation tank).
The pre-Fermenter is having capacity 45000 Litres each.

c. Fermentation —
Fermentation is a biochemical reaction in which the conversion of one compound to another takes place
by the action of microorganism, such as Yeast."
Yeast is a microorganism which is used in fermentation to produce alcohol from sugar content present in
molasses
In Aerobic fermentation, oxygen is basic requirement, supplied for growth of yeast. Maximum yeast
biomass is formed during this process.
In Anaerobic stage the conversion of sugar in to ethyl alcohol and carbon dioxide takes place. —

INVERTASE
𝐶12 𝐻22 𝑂11 + 𝐻2 𝑂 − − − − − − − − − − − −𝐶6 𝐻12 𝑂6 + 𝐶6 𝐻12 𝑂 6

(Glucose) (Fructose)
ZYMASE
𝐶6 𝐻12 𝑂6 − − − − − − − − − − − −2𝐶2 𝐻5 𝑂𝐻 + 2𝐶𝑂2 + 𝐻𝑒𝑎𝑡
(Mono saccharine) (Ethanol)

Molasses from the storage tank is pumped to the molasses weighing system where exact weighing of
molasses going in the fermentation system is achieved. Weighed molasses is then pumped to a static
molasses dilutors attached to each Fermenter where it is mixed with water / fermentation wash so as to
achieve proper concentration of fermentation of fermentable sugars in the dilute molasses. This is a
Thirteen Fermenter system. Four Fermenter are open and nine fermenters are closed vessel.

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HAZOP STUDY– NOV-2020
DAURALA SUGAR WORKS
A Unit of DCM Shriram Industries Ltd. Distt: Meerut (UP)

Process water is used to scrub the total outgoing carbon dioxide so as to recover the alcohol vapour in
CO2. This water is then recycled in the Fermenter. Temperature of the individual Fermenter is
maintained in the desired range of 33 to 35°C by recalculating the fermented wash through the
individual plate heat exchangers (PHE). The temperature of fermentation is being maintained by
recirculation of cooling water (through fermentation cooling tower).
The fermented wash with 10 -10.8 % v/v alcohol is then fed into the degasifying column top for
distillation. Average fermentation time is about 22-24 hrs. The advantage of using this system by
distillery is that, inferior quality of molasses can also be used to achieve higher efficiencies, good quality
of spirit with lower steam consumption.

Distillation

"Distillation is a physical process in which the various components of a mixture are separated by virtue of
their difference in boiling points. "

The industry is using multi-pressure distillation ([Link].) system for production of rectified spirit. This
process consist of three columns namely analyzer/ degasifying, Aldehyde and rectifier cum exhaust
column. The distillation is integrated with MEE.

The analyzer vapor and the rectified vapors are operated the integrated MEE, Accordingly steam is
saving. The fermented wash, which is fed to top of degasifying column, is operated under vacuum. The
wash is then fed to analyzer column and the vapors from the top of the analyzer column are used to
operate the falling film no. 2. The vapor of the falling film no.2 is used to operate the falling film no. 1.
Rectifier cum exhaust column is operated under pressure. The steam is given to rectifier cum exhaust
column through re-boiler (live steam). The rectifier vapor is used to operate to heat the force
recirculation no. 3 & 2 and the vapor generated from recirculation no. 3 & 2 is used to heat the force
recirculation no 1 and the vapor generated from the force recirculation no. 1 is used to heat the analyzer
bottom.

Alcohol is enriched towards the top and is drawn out as rectified spirit at about 95% v/v concentration
from rectifier cum exhaust column. Fusel oil build up is separated in the rectifier cum exhaust column by
withdrawing outside steams (fusel oils). These are sent to the fusel oil decanter where these streams are
diluted with water and fusel oil rich layer is separated. The fusel oil wash water is recycled back to the
column.

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HAZOP STUDY– NOV-2020
DAURALA SUGAR WORKS
A Unit of DCM Shriram Industries Ltd. Distt: Meerut (UP)

Less Yeast A) Less Yeast mixed in A) Fermentation not A) Operation delay A) Check the
vessel occur properly percentage of Yeast
Less Temperature A) Molasses at low A) Fermentation not A)Temperature gauge A) To be calibrate
temperature occur properly provided temperature gauge
B) Ambient temperature B) Fermentation not B) Temperature gauge B) To be calibrate
very low occur properly provided temperature gauge
3 Reverse Reverse flow of A) Not possible as storage A) None A) None A) Inspection will be
Molasses tank is filled from the top done
of the tank
4 As well as Flow of foreign A) Flow of other product A) No Hazardous A) To be check the A) Checking to be
material along with along with molasses consequences. Quality of material before done as per
molasses Molasses reduced unloading started established procedure
5 More More Temperature A) Gas maybe liberate at A) Pressure build-up in Vent provided A) Checking of vent
storage tank storage tank Provision for cooling of and cooling system
tank provided will be done
A) Molasses at High A) Fermentation not A) Temperature gauge A) To be calibrate
temperature occur properly provided temperature gauge
A) Molasses at low A) Fermentation not A) Temperature gauge A) To be calibrate
temperature occur properly provided temperature gauge
More Yeast More Yeast mixed in Wastage of Yeast Mixed the Check the yeast
vessel appropriate quantity percentage
of yeast

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HAZOP STUDY– NOV-2020
DAURALA SUGAR WORKS
A Unit of DCM Shriram Industries Ltd. Distt: Meerut (UP)

TABLE - 4
RESULTS OF HAZARD AND OPERABILITY STUDY
UNIT: DISTILLATION OF FERMENTED WASH
SR. GUIDE DEVIATION POSSIBLE CONSEQUENCES ACTION STATUS
NO. WORD CAUSES REQUIRED
1. None No Flow Steam discharge I. No transfer of steam & I. Temperature & I. Ensure opening of
valve closed required temperature of Pressure gauge discharge valve.
column will not be achieved installed. II Test and
II. Pressure build-up in II SRV installed in calibrate SRV at
boiler boiler regular interval
Steam discharge I. No transfer of steam & I. Temperature & Preventive
valve seat jammed required temperature of Pressure gauge maintenance to be
column will not be achieved installed. ensure regularly
II.. Pressure build-up in II SRV installed in
boiler boiler
2. Less Less Flow Discharge valve of Improper transfer of steam Temperature & Preventive
steam line partially & required Temperature of pressure gauge maintenance to be
closed column will not be achieved installed ensure regularly
3. More More Flow Line pressurized Failure of Line Steam release valve Check and calibrate
installed at pipeline the steam valve at
regular interval

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HAZOP STUDY– NOV-2020
DAURALA SUGAR WORKS
A Unit of DCM Shriram Industries Ltd. Distt: Meerut (UP)

TABLE - 5
RESULTS OF HAZARD AND OPERABILITY STUDY
UNIT: FILLING OF TANK LORRY (ETHANOL)
SR. GUIDE DEVIATION POSSIBLE CONSEQUENCES ACTION STATUS
NO. WORD CAUSES REQUIRED
1. None No Flow B) Ethyl Alcohol line B) Fire and B) Stop filling and B) Necessary hydrostatic tests
Leakage explosion hazards repair leakage for pipeline are planned
patrolling desired
C) Filling point hose B) Fire and C) Proper maintenance C) Hoses will be subjected
rupture explosion hazards of hoses desired to hydrostatic, Pneumatic and
electrical
continuity testes once in four
(04) months

D) Filling gun D) Ethyl Alcohol D) Proper Functioning D) Self explanatory

detached from tank release and maintenance of
lorry filling gun required

2. More More Flow A) Not Possible A) None A) None A) Self explanatory

More Pressure A) Not Possible A) None A) None A) Self explanatory
More A) Some fire in the A) Pipeline may A) Ensure proper A) Fire fighting arrangements
Temperature vicinity causing higher rupture causing fire functioning of fire provided as per statutory
pressure on Ethanol and explosion. fighting systems requirements.
line connected to lorry

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DAURALA SUGAR WORKS
A Unit of DCM Shriram Industries Ltd. Distt: Meerut (UP)

3. Less Less Flow A) Some Leakage in A) If leakage persists A) Regular patrolling A) Regular patrolling of
pipeline for longer time fire / of pipeline desired pipeline will be done
explosion hazards
may occur
Less A) Very low ambient A) None A) None A) Self explanatory
Temperature temperature
Less Pressure B) Some leakage in B) Fire and B) Proper operation of B) Fire fighting arrangements
Ethanol line explosion hazard fire fighting systems have been provided as per
desired statutory requirements
4. As well as Flow of foreign A) Not Possible A) None A) None
material along
with Ethyl
Alcohol
5. Other Than Static Charge A) Static Charge may A) Fire Hazards A) Proper bonding / A) Proper bonding / jumper
be developed due to Jumper takes place on provided on each flange joints.
transfer of Ethyl each flange joints B) Earthing of
Alcohol B) Earthing of tanker tankers provided
6. Reverse Reverse A) Not Possible due to A) None A) None (A) Self explanatory
differential pressure
between Storage Tank
& Lorry

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