Industrial Engineering

Hazardous-Area & Greenfield Ethanol Electrification

Specialised flameproof (FLP IS 5571) electrical & automation systems for 60 to 330+ KLPD grain-based & molasses distilleries.

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330 KLPD

Top Single Plant Scope

Grain-Based Ethanol

IS 5571

FLP Flameproof Standard

Hazardous Zone 1 & 2

ZLD

Zero Liquid Discharge

BOP Instrumentation

24/7

Continuous Rating

Zero Unplanned Downtime

Industry Engineering Overview

Flameproof & Continuous-Duty Electrical Systems for 60 to 330+ KLPD Distilleries

Distillery and ethanol plants fail conventional electrical designs in three specific ways: alcohol vapour zones demand flameproof (FLP) and intrinsically safe equipment classified to IS 5571; washroom and fermentation areas expose panels and cable trays to sustained corrosive attack; and the process runs 24/7, so switchgear and MCCs are sized and rated for continuous duty with no planned downtime for maintenance access.

DEC has executed full substation-to-process electrification on this basis for major distilleries — from 330 KLPD installations for Radico Khaitan and Balrampur Chini to 280 KLPD ZLD projects for Grainfuel Distillery and active 2024-25 greenfield builds for Zuari Envien Bioenergy and Bhagoli Sugar.

Process Electrification & System Architecture

FLP & Hazardous Zone Distribution

Ex-d/Ex-i flameproof panels, push-buttons, and junction boxes certified to IS 5571 for alcohol vapour environments.

Corrosion-Resistant Stainless Routing

SS304/SS316 cable trays, sealed trunking, and IP66 enclosures through fermentation & wash areas.

Fermentation & Distillation SCADA

Redundant PLC & DCS automation with temperature, flow, and gravity loop control for 24/7 continuous distillation.

Spent-Wash Incineration Cogen

Boiler BOP electrical systems for spent-wash incineration cogen boilers with electrostatic precipitator (ESP) drives.

Technical Parameters & Design Standards

Distillery Capacity Range 60 KLPD to 330+ KLPD

Hazardous Area Certification Gas Group IIA, IIB, IIC (IS 5571)

Protection Rating IP65 / IP66 Flameproof & Weatherproof

Automation Platform Siemens / Rockwell PLC + SCADA

Prominent Client Partners in this Sector

Grainfuel Distillery Radico Khaitan Balrampur Sugar Zuari Envien Bioenergy Dalmia Sugar Bhagoli Sugar (Dalmia Group) L.H. Sugar Mill Triveni Engineering Avadh Sugar Olam Agri India Mohangold Breweries

DEC Engineering Scope

✓ IS 5571 Hazardous Area Flameproof (FLP) Switchgear & Distribution
✓ Grain Slurry, Fermentation & Multi-Pressure Distillation PLC/SCADA
✓ Spent-Wash Incineration Boiler & Zero Liquid Discharge (ZLD) Automation
✓ Stainless Steel SS304/SS316 Cable Tray & Corrosion-Proof Cabling
✓ Captive Power Plant & Turbine Synchronisation for Distillery Cogen
✓ 33kV Plant Substation Erection, Testing & Statutory PESO/Grid Approvals

Planning a Hazardous-Area Installation?

Send us your area classification drawings — that's where our review starts, before a single panel spec is discussed.

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Planning a Hazardous-Area Distillery Project?