N.S.EPC Consultants India Pvt. Ltd. an Engineering, Procurement, and Construction Company, has been leading the change in providing Green Energy Solutions to an extensive and diverse array of industry areas. Well equipped with large infrastructure, vast experience and expertise we have undertaken and accomplished large turnkey projects and variety of integrated comprehensive Design to Delivery solutions to diverse polymers, chemical and process industries with a major emphasis on the continuous improvement, development and application of Biodegradable products Biofuels, Bioethanol and Biomass driven processes. As turnkey project suppliers, we are single point solutions provider for the entire spectrum of Plant Design & Build; right from evaluation, assessment, planning of business opportunity and financing to pre-construction feasibility studies to complete installation including commissioning, operation & maintenance assistance. Here, flexibility is one benefit that we can deliver as our technical team is capable of developing a generalized engineering concept for working out unusual designs and in carrying engineering knowledge from one field to another. Technologically Driven Environmentally Sensitive Customer Centric High Quality Oriented Strictly adhering to our ethos, we strive to achieve excellence in project delivery and customer satisfaction! We provide overseas/ indigenous solutions for sourcing automatic machines for PE, PS and PU plants, Fuel Ethanol plants, Multi fiber based biodegradable table ware projects complete line with manufacturing of Pulp from many natural fibers N.S.EPC Consultants India Pvt. Ltd. has been extremely successful in all its State of Art projects which as a matter of fact is the outcome of continuous efforts, hard work and expertise of some of the best consultants in the Industry, Originated from India, we have now progressed and crossed the boundaries and now function and work together, in harmony with different teams across the globe. We deliver significant values to our clients and strive to achieve consistent customer satisfaction through a group of experienced technocrats across the nation providing quick response without delay after implementation of plants. N.S. Consultants was Co-founded by Mr. Sushil Sharma, M.A., M.B.A, who has excelled in Techno-Commercial interactions over a span of 28 years, holds Dynamic Knowledge Base in Machinery Sourcing & implemented many projects successfully, Mr. N. Nagaraja, a Polymer Technologist & Mentor, who holds vast 28 years experience in various Plastic Industries, possessing expertise in technical and project implementation field. Hundreds of these Consultant junior, Heading Big companies, both of these consultants created and educate the team of technocrats and empowered them. Educated the new customers/ company owners about technology. We are currently based in NewDelhi & Bangalore in INDIA, U.A.E.,BANGLADESH, DUBAI, CANADA,

1. ETHANOL BLENDING PROGRAM
WITH
DUAL-FEED DISTILLERIES
B.B. PATHAK AND SUSHIL SHARMA
N.S.EPC CONSULTANTS INDIA PVT. LTD.
Principal Consultants

2. CONTENTS
1. AGRIBUSINESS:FUTURE FOR SUGAR INDUSTRY AND FARMERS
2. SOME FACTS
3. INTERCROPPING SUGARCANE WITH MAIZE
4. DUAL FEED DISTILLERY WITH MOLASSES AND MAIZE
5. CURRENT SCENARIO FOR EBP-MOLASSES
6. CURRENT SCENARIO FOR EBP- GRAINS AND B HEAVY-MOLASSES
7. MAIZE USAGE IN INDIA
8. FUTURE SCENARIO
9. ETHANOL BALANCING FOR 20% EBP
10. FUTURE FORWARD
11. PROCESS TECHNOLOGY
12. ECONOMICS OF ETHANOL PRODUCTION
13. SWOT ANALYSIS
14. US ETHANOL PRODUCTION FROM MAIZE
15. 4-E MODEL
16. CONCLUSIONS
N.S. EPC CONSULTANTS INDIA PVT LTD.
CORPORATE OFFICE: SANSAD MARG, NEW DELHI

3. COMPATIBILITY
Farmers
Processing
Space
Manpower
Management
Technical Man
power
Land
Availability
Power &
Fuel
Storage
Finance &
Material
management
resources
Waste
Treatment
Plant
Off-season
availability
Communicatio
n System
Agribusiness Hub
AGRIBUSINESS:FUTURE FOR SUGAR INDUSTRY AND FARMERS
Sugar Complex can be
converted into Agri-
business Complex by
converting molasses based
distilleries to DUAL FEED
DISTILLERIES
(Molasses + Maize)
It would help farmers to
supply maize directly to the
sugar factories
Government’s 20% Ethanol
Blending Program (EBP) can
be achieved
N.S. EPC CONSULTANTS INDIA PVT LTD.
CORPORATE OFFICE: SANSAD MARG, NEW DELHI

4. Sugar Industry is CYCLIC…… EBP can be influenced by CYCLICALITY
Grain ethanol is not CYCLIC
SUGARCANE and MAIZE can be grown as INTERCROP
Ethanol from Sugarcane: 4900 L per hectare (12 month crop)
Ethanol from Maize: 3600 L per hectare (3 month crop)
SOME FACTS…..
N.S. EPC CONSULTANTS INDIA PVT LTD.
CORPORATE OFFICE: SANSAD MARG, NEW DELHI

5. INTERCROPPING SUGARCANE WITH MAIZE
Duration: 60-90 days
Production: 6-8 t/ha
Can be grown with
sugarcane in Autumn
and Spring season
Three crops of maize
can be grown in a year
Maize production in India is
increasing at CAGR of 5.5%.
In 2017-18 it was 219 Lakh Mt

6. DUAL FEED DISTILLERY WITH MOLASSES AND MAIZE
 Out of 360 distilleries in India only 25
are dual feed distilleries
 Dual feed distilleries producing
ethanol from molasses and grain can
offer availability of ethanol across the
years
 Maize and grain (Millets and broken
rice) based ethanol distilleries can
come up in different parts of country
 Maize and millets can be grown under
rainfed conditions. These crops
require much less irrigation compared
to sugarcane
N.S. EPC CONSULTANTS INDIA PVT LTD.
CORPORATE OFFICE: SANSAD MARG, NEW DELHI

7. S. No. Particulars Production UOM
Equivalent
Ethanol
Production
UOM
1 Sugarcane 355 MMT 24.85 Billion Liters
2
Sugar production 32.8 MMT
Molasses C grade 15.6 MMT 3.59 Billion Liters
3
Alcohol used for potable and other
purpose
1.96 Billion Liters
4
Ethanol available for EBP through C-
molasses
1.63 Billion Liters
5 Ethanol required for 10% Blending 3.29 Billion Liters
6 Ethanol required for 20% Blending 6.60 Billion Liters
CURRENT SCENARIO FOR EBP: C-MOLASSES
N.S. EPC CONSULTANTS INDIA PVT LTD.
CORPORATE OFFICE: SANSAD MARG, NEW DELHI

8. CURRENT SCENARIO FOR EBP- GRAINS AND B HEAVY-MOLASSES
1 Additional Ethanol made from B Heavy 0.29 Billion Liters
2 Ethanol made from Grains (Current) 0.50 Billion Liters
3 Total Ethanol available for EBP (Current) 2.42 Billion Liters
4 Short fall @ 10% 0.87 Billion Liters
5 Short fall @ 20% 4.18 Billion Liters
Number of Present Distilleries
Molasses based distilleries 360
Grain based distilleries 85
dual Feed Distilleries 25
This shortfall of 0.87 Billion Litres (10% EBP) and 4.18 billion litres (20% EBP)
will mainly come from maize/broken rice based distilleries
N.S. EPC CONSULTANTS INDIA PVT LTD.
CORPORATE OFFICE: SANSAD MARG, NEW DELHI

9. MAIZE USAGE IN INDIA
Beverage
7%
Directly
Consumed
20%
Starch
12%
Cattle
Feed 14%
Poultry
Feed 47%
Scenario after using 50% of Poultry and cattle feed
Present scenario
Directly
Consumed
20%
Starch
(12.00)
Cattle
Feed 7%
Poultry
Feed
23.5%
DDGS
18.19%
Ethanol
19.32%
N.S. EPC CONSULTANTS INDIA PVT LTD.
CORPORATE OFFICE: SANSAD MARG, NEW DELHI

10. Ethanol made from Molasses 1.92 Billion Litres
Ethanol made from Maize 3.20 Billion Litres
Ethanol made from Broken Rice 1.35 Billion Litres
Ethanol made from other Raw Mat. 0.13 Billion Litres
Ethanol required for 20% Blending 6.60 Billion Litres
Approximately 250 distilleries are about to be modernized and newly set up. However,
the molasses quantity will remain the same. The option is dual feed distilleries.
FUTURE SCENARIO
N.S. EPC CONSULTANTS INDIA PVT LTD.
CORPORATE OFFICE: SANSAD MARG, NEW DELHI

11. 6.60 BL
Ethanol
required for
20% EBP
Molasses
(1.92)
B Rice
(1.35)
Others
(0.13)
Maize
(3.20)
Ethanol balancing for 20% EBP
Figures in Billion Litres
N.S. EPC CONSULTANTS INDIA PVT LTD.
CORPORATE OFFICE: SANSAD MARG, NEW DELHI

12. FUTURE FORWARD
 Only few states like Uttar Pradesh, Maharashtra and Karnataka supplies
molasses based Ethanol to OMCs.
 Tender for year 2019-20 targeted for 5.11 billion liters whereas bidding from
distilleries made only of 1.66 billion liters, shortage of 3.45 billion ltrs.
 Almost 6.6 billion litres of Ethanol is required for 20% targeted EBP by 2022
onwards. Present capacity of molasses based distilleries can produce 1.93
billion litres of Ethanol, even after considering B-Heavy Molasses.
 Even 250 distilleries are to be put up, thus there will be severe shortage of
molasses.
 If dual feed distilleries will come up, the Ethanol production and EBP can be
met.
N.S. EPC CONSULTANTS INDIA PVT LTD.
CORPORATE OFFICE: SANSAD MARG, NEW DELHI

13.  Govt. of India extended EBP to J&K and North-East States, it is therefore:
 Transportation cost will be increased if Ethanol is taken from UP and Bihar for OMCs to North
East States , Chhattisgarh, Jharkhand and Orissa etc.
 It is therefore make commercial sense to put up Grain Based distilleries for EBP nearer to
North East States like Assam and West Bengal.
 To cater up to 20% EBP the state where sugarcane is not grown, suitable size of Ethanol Plants
using Maize and Rice and other coarse grains as raw material can be put up.
 It is also relevant in states like MP, Chhattisgarh, Orissa, Jharkhand and Telangana.
 Installation of Grain based Ethanol distilleries will save on logistic cost and also cater to over
all Ethanol availability to OMCs for EBP.
Contd…..
N.S. EPC CONSULTANTS INDIA PVT LTD.
CORPORATE OFFICE: SANSAD MARG, NEW DELHI

14. PROCESS TECHNOLOGY
N.S. EPC CONSULTANTS INDIA PVT LTD.
CORPORATE OFFICE: SANSAD MARG, NEW DELHI

15. Reused
Spent Wash Recycle
Water Molasses
Exhaust
Fermentation Section
Multi Pressure Distillation
Evaporation
Concentrate Slop
MSDH
Yeast Sludge
CO2 Emissions
Steam Condensate to Boiler
Process Condensate
Ethanol
Spent Wash
Condensate Polishing Unit
ETP Sludge
Spent Lees
Incineration Boiler
Fuel + Concentrate
Spent Wash
Steam
Power
To Incineration Boiler
Diluter
Yeast Propagation
Decantation
Power
PROCESS FLOW: MOLASSES BASED DISTILLERY
N.S. EPC CONSULTANTS INDIA PVT LTD.
CORPORATE OFFICE: SANSAD MARG, NEW DELHI

16. Additional cost
for 60 KLPD
Distillery is INR
approx. 10-11
Crores
Revenue per day
from DDGS is
INR 9-10 Lakhs
Reused
Exhaust
Flour Handling Section
Grain Cleaning, Milling Section
Slurry Preparation and Liquefaction
Section
Fermentation Section
Multi Pressure Vaccum Distillation
Decantation
Wet Cake
DWGS
Dryer
DDGS Rich in Protein use as Cattle feed
Evaporation
Concentrate Syrup
MSDH
CO2 Emissions
Steam Condensate
Process Condensate
Ethanol
Spent Wash
Condensate Polishing Unit
ETP Sludge
Spent Lees
Thinslop
Boiler
Fuel
Steam
Power
Rejects
Rejects
Water
*Incineration in case of Molasses
Active Dry yeast
PROCESS FLOW: GRAIN BASED DISTILLERY [60 KLPD]

17. Additional cost
for 60 KLPD
Distillery is INR
approx. 10-11
Crores
Revenue per day
from DDGS is
INR 9-10 Lakhs
Reused
Exhaust
Flour Handling Section
Grain Cleaning, Milling Section
Slurry Preparation and Liquefaction
Section
Fermentation Section
Multi Pressure Vaccum Distillation
Decantation
Wet Cake
DWGS
Dryer
DDGS Rich in Protein use as Cattle feed
Evaporation
Concentrate Syrup
MSDH
Yeast Sludge
CO2 Emissions
Steam Condensate
Process Condensate
Ethanol
Spent Wash
Condensate Polishing Unit
ETP Sludge
Spent Lees
Thinslop
Boiler
Fuel
Steam
Power
Rejects
Rejects
Molasses + Water
Incineration*
*Incineration in case of Molasses
Yeast +
Nutrients
PROCESS FLOW: GRAIN/MOLASSES BASED DISTILLERY [60 KLPD]

18. ENVIRONMENT
Grain based distilleries offer ZLD as DDGs are produced
Process Condensate
and Spent Lees
Thin Slops @5% w/w Solids
Partly Recycled to Process
Product (Alcohol)
Distillation
Spent Wash Decanter Evaporation Condensate Treatment
Plant
Treated Water to Cooling Towers
Thick Syrup
Wet Cake
DWGS Dryer
Dryer inlet @20-25% w/w
Solids
DDGS @88-90% w/w Solids
ETP SLUDGE
N.S. EPC CONSULTANTS INDIA PVT LTD.
CORPORATE OFFICE: SANSAD MARG, NEW DELHI

19. Figures in INR
Cost of raw material (INR/Mt Maize) 14,000 16,000 17,000
Cost of Raw Material (INR/Liter Ethanol) 35.90 41.03 43.59
COVERSION COST PER LITER OF ETHANOL
Process Chemicals 1.60 1.60 1.60
Boiler Chemicals 0.40 0.40 0.40
Steam and Power 7.01 7.01 7.01
Effluent treatment cost 0.20 0.20 0.20
Finance cost 2.40 2.40 2.40
Salary and Overheads 2.95 2.95 2.95
Plant maintenance/ boiler 0.30 0.30 0.30
Sub Total 14.86 14.86 14.86
EXTRA REVENUES
DDGS 10.65 10.65 10.65
CO2 0.69 0.69 0.69
Fusel Oil 0.03 0.03 0.03
Total (Extra Revenues) 11.37 11.37 11.37
TOTAL(Raw Material + Conversion cost) 39.39 44.51 45.99
Selling Cost Ethanol 47.13 47.13 47.13
Margin per Liter 7.74 2.62 1.14
ECONOMICS OF ETHANOL PRODUCTION FROM MAIZE
N.S. EPC CONSULTANTS INDIA PVT LTD.
CORPORATE OFFICE: SANSAD MARG, NEW DELHI

20. Details At different Rice price regimes
A Cost of broken Rice per MT 16000 17000 18000 19000
B Cost of Raw Material per Liter 35.16 37.36 39.56 41.76
C Coversion Cost
1 Process Chemicals/ Ltr 1.6 1.6 1.6 1.6
2 Boiler Chemicals 0.4 0.4 0.4 0.4
3 Steam and Power/Ltr 7.01 7.01 7.01 7.01
4 Effluent treatment cost 0.2 0.2 0.2 0.2
5 Finance cost 2.4 2.4 2.4 2.4
6 Salary and Overheads 2.95 2.95 2.95 2.95
8 Plant maintanance/ boiler 0.3 0.3 0.3 0.3
9 Sub Total 14.86 14.86 14.86 14.86
D Gains
DDGS 10.65 10.65 10.65 10.65
CO2 0.69 0.69 0.69 0.69
Fusel Oil 0.03 0.03 0.03 0.03
Sub Total 11.27 11.27 11.27 11.27
E Total cost of Ethanol (B+C-D) 38.75 40.95 43.15 45.35
F Saling Cost Ethanol 47.13 47.13 47.13 47.13
G Margin/Liter (F-E) 8.48 6.28 4.08 1.88
ECONOMICS OF ETHANOL PRODUCTION FROM RICE
N.S. EPC CONSULTANTS INDIA PVT LTD.
CORPORATE OFFICE: SANSAD MARG, NEW DELHI

21. Strengths
 Dual feed distilleries are
economically viable over
single molasses feed
distilleries
 Strong demand of ethanol
for 10% and 20% blending
for EBP
 Environmentally sound
Weaknesses
 Maize and grain pricing
vis-à-vis ethanol pricing
 Food Vs. fuel
controversies
 Additional investment
Opportunities
 Smooth EBP across years
 Scope for expanding EBP to
20%
 By-product through DDGS
Threats
 High preference to maize
and other grains for
Government programs
 Future preferences of OMCs
on grain based ethanol
 Preferences of OMCs for
molasses based ethanol
SWOT
ANALYSIS
N.S. EPC CONSULTANTS INDIA PVT LTD
CORPORATE OFFICE: SANSAD MARG, NEW DELHI

22. Particulars 2011 2012 2013 2014 2015 2016 2017
Total maize Production
(M Mt)
312.7 273.3 351.3 361.2 345.4 384.6 370.8
Maize used for ethanol
production
(M Mt)
127.0 117.9 128.3 131.3 132.6 137.9 142.2
Ethanol produced from Maize
(Billion Liters)
49.5 46.0 49.0 51.2 51.7 53.8 55.5
Total Ethanol production
(All grains) (Billion Liters)
52.8 50.4 50.4 54.3 56.1 58.0 59.8
US ETHANOL PRODUCTION FROM MAIZE
N.S. EPC CONSULTANTS INDIA PVT LTD.
CORPORATE OFFICE: SANSAD MARG, NEW DELHI

23. INDUSTRIAL SECTOR AGRICULTURE SECTOR
LAND RESOURCES
SYSTEM MANAGEMENT
ETHANOL
FROM JUICE
ETHANOL
FROM C
MOLASSES
ETHANOL
FROM GRAINS
ETHANOL
FROM B
MOLASSES
DUAL FEED
DISTILLERIES
4EMODEL
TECHNOLOGY UPGRADATION IS KEY TO GROWTH
N.S. EPC CONSULTANTS INDIA PVT LTD.
CORPORATE OFFICE: SANSAD MARG, NEW DELHI

24. CONCLUSIONS
Maize can give 400 L ethanol/ Mt compared to 72 L/ Mt Sugarcane
Maize require less water and can be grown as intercrop with sugarcane
Zero liquid discharge
Maize can be used in molasses based distilleries with some modifications
Maize can be used independently, anywhere in the country
Ensures Ethanol availability throughout the year
20% EBP can be achieved
N.S. EPC CONSULTANTS INDIA PVT LTD.
CORPORATE OFFICE: SANSAD MARG, NEW DELHI

25. Thank
you
N.S. EPC CONSULTANTS INDIA PVT LTD.
CORPORATE OFFICE: SANSAD MARG, NEW DELHI