DPR on Integrated Sugar & Cogen Power Plant at Selu, Tal-Gevarai, Dist-Beed
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PRE-FEASIBILITY REPORT
FOR
5000 TCD SUGAR PLANT 35 MW CO-GENEARTION POWER PLANT
ALONG WITH 80 KLPD DISTILLERY
AT
Village Selu, PO - Jategaon, Tehsil Gevarai,
District Beed, Maharashtra
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1.0 Project at a Glance
Pingale Sugar & Agro Products Private Ltd. (PSAPPL) is a Company registered in the State of
Maharashtra under the Companies Act, 1956.
PSAPPL has been taken over by Mr. Dilip Shankarrao Apet & Mrs. Shalini Dilip Apet by
purchasing shares & ETC on August 8, 2014. The promoters sensed the great availability of
sugarcane in the region of Gevarai tehsil and increasing demand of power & ethanol and keeping
in view, the needs of the local farmers, those cultivate sugarcane in the command area.
PSAPPL proposes to set up an integrated new sugar mill of 5000 TCD, eco-friendly 35 MW
capacity cogen power project for decentralized generation of exportable surplus power, mainly
from renewable sources of fuel, located near village Selu, 25 km from Gevarai, which is Taluka
headquarter.
PSAPPL, also proposes to set up a 80 KLPD capacity ethanol plant to produce ethanol, adjacent
to the propose sugar plant located at Village Selu, PO Jategaon,Taluka Gevarai, District Beed,
Maharashtra
The proposed ethanol plant project will produce fuel ethanol mainly on own molasses, molasses
available from the other sugar factories. The steam and power requirement for the proposed plant
will be made available from the new slop fired incineration boiler & back pressure turbine.
2.0 Project Rationale
The promoters have extensively and carefully analyzed the present and future scenario of sugar
and power industries. They studied carefully the present irrigation facilities and surplus cane
availability in the command area, as well as future potential of irrigation and additional cane
availability.
The command area falls in tehsils of Beed & Jalna Districts. Beed district is drained by
Godavari, Manjra and Sina rivers and their tributaries. Beed district is benefited by major
projects like Jayakwadi, Majalgaon & Manjara. Additionally, bore wells and open wells are also
used for the irrigation. Due to adequate irrigation facilities in the command area, sugarcane
potential is very good. Hence, required sugarcane of 8 lakh MT will be available within the
command area along with sustainable sugarcane development in future. At present surplus
sugarcane in the command area is around 12.10 lakh MT, which can easily support 5000 TCD
sugar plant.
To make the venture commercially viable and financially profitable, the capacity of the sugar
plant is decided and fixed at 5000 TCD sugar plant and a cogeneration plant of 35 MW.
DPR on Integrated Sugar & Cogen Power Plant at Selu, Tal-Gevarai, Dist-Beed
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PSAPPL will generate about 36000 MT of molasses from expected / sustained cane crushing of
8.00 lakh MT / year, with 4.50% molasses recovery.
The requirement of in –house molasses to run the ethanol plant for at least 160 days as per SDF
norm is 54,468 MT. PSAPPL will utilize 36,000 MT of own molasses and 22.14% or 12,400 MT
of B-heavy molasses required to be diverted, for meeting the shortfall quantity of 18,468 MT of
final molasses.
The total requirement of molasses for the 270 days operation of the proposed ethanol plant at
optimum level of operation will be around 91,915 MT. PSAPPL will utilize 54,468 MT of
own/B-heavy molasses & the balance 37,447 MT of molasses will be procured from nearby
sugar mills.
2.1 The Promoters & Project Preparedness
PSAPPL is promoted by:-
Mr. Dilip Shankarrao Apet, Chairman & MD
Mrs. Shalini Diliprao Apet, Director
The CMD of PSAPPL is highly educated and has 35 years of experience in the sugar industry.
His huge practical experience in sugar industry will be immensely helpful in executing and
operating the proposed ethanol project. The management is successfully operating a sugar unit,
M/s. Shambhu Mahadev Sugar & Allied Industries Ltd. at Village Havargaon, Tal - Kallam, Dist
- Osmanabad.
PSAPPL already has appointed a technical / managerial team of highly qualified engineers,
contract & arbitration experts, agricultural officers and managerial personnel for implementation
and operation of the captioned integrated project.
PSAPPL has already obtained IEM from the Ministry of Commerce & Industry, Govt. of India
for setting up 30 KLPD ethanol plant and has already applied for amendment of IEM for 80
KLPD ethanol plant.
3.0 Project in Brief
3.1 Sugar Mill (estimated capital investment of Rs.97.00 crore)
A sugar mill of 5000 TCD capacity will be installed for manufacture of white sugar of good
quality. The sugar market in India is quite up-beat and is expected to continue for a foreseeable
future. Command area has adequate sugarcane availability with sugar recovery of about 11.50%.
3.2 Cogen Power Plant (estimated capital investment of Rs. 103.00 crore)
DPR on Integrated Sugar & Cogen Power Plant at Selu, Tal-Gevarai, Dist-Beed
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The cogen power project of 35 MW capacity will mainly operate on mill bagasse during 160
season days of the sugar mill and saved bagasse for 15 off-season days. At designed levels, it
will generate about 131.72 million kWh and export about 97.31 million kWh through MSEDCL
grid for sale to MSEDCL, as per prevailing tariff (present MERC tariff is Rs 6.27 /kWh). All
steam and power requirements of the sugar mill and cogen auxiliaries and colony, both during
season and off-season periods, will be met internally from the cogen power plant.
It will employ extra high pressure and temperature configuration (110 Kg/cm2 and 540 C) boiler
& steam turbine, as well as ESP for emission control and DCS control system for efficient
operation.
The policy for sugar mill cogen plants, both at the Central Government and at the State,
Government of Maharashtra, are quite conducive. The MNRE has provided several financial
incentives in terms of capital grants and fiscal incentives till date and the same are continued
vide their order dated April 28, 2010. The proposed project will be eligible for these incentives
as well as other incentives like accelerated depreciation, income tax benefits, reduced import
duties for renewable energy projects.
3.3 Distillery Unit (estimated capital investment of Rs. 127.00 crore)
The proposed ethanol plant of 80 KLPD capacity will employ fermentation, multi pressure
distillation system, evaporation & slop fired incineration boiler. Sugar mill will supply molasses,
while the incineration boiler & turbine will supply steam & power to the proposed ethanol plant.
Highlights of the Project
Name and Address
Factory Site:
:
:
M/s. Pingale Sugar & Agro Products Private Ltd.
Registered Office:
C/o. Shambhu Mahadev Sugar & Allied Industries Ltd.,
Havargaon, Tal-Kallam, Dist-Osmanabad
Village Selu, PO Jategaon,Taluka Gevarai,
District Beed, Maharashtra
Constitution & Type : Limited Company
Products : Sugar,Co-generated Power, Distillery Unit
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Installed Capacities of
the Integrated Project
Sugar Plant
Cogen Power Plant
Distillery Unit
:
:
:
5000 TCD
35 MW installed capacity
22.38 MW (Avg. exportable power, Season 160 days)
31.43 MW (Avg. exportable power, Off Season 15 days)
80 KLPD
3.4 Financial Highlights
Project Cost for Sugar & Co-gen Power Plant
(Rs. in Lakh)
Total Project Cost Sugar Cogen Total
Land & Site Development : 175 75 250
Civil works & Buildings : 1464 796 2260
Indigenous Plant and Machinery : 6785 8303 15088
Miscellaneous Fixed Assets : 140 85 225
Prelim & Preoperative Expenses : 822 845 1667
Contingencies : 140 152 292
Working Capital Margin : 174 44 218
Total : 9700 10300 20000
Means of Finance:
(Rs. Lakh)
Financing Pattern Sugar Cogen Total
1. PSAPPL’s Equity : 3201 1774 4975
2. SDF Quasi Equity : 0 1625 1675
3. FI Loan : 6499 6901 13400
Total : 9700 10300 20000
Parameter First Year Fifth Year
Estimated W/C Requirements Rs. Lakh 4699 5772
Estimated Annual Turnover Rs. Lakh 25399 31162
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Profit Before Tax Rs. Lakh 4407 5109
Accumulated Cash Surplus Rs. Lakh 2812 14080
Employment Potential Nos. 370 370
Debt Service Coverage Ratio (DSCR)
Average
Maximum
Minimum
2.06
4.72
1.61
Payback Period, Years 4 to 5
Internal Rate of Return on total Investment,
%
21.38
Project Cost for Distillery
(Rs. Lakh)
Particulars Ethanol
Plant
Land and Site Development 150
Buildings 2346
Indigenous Plant and Machinery 9000
Miscellaneous Fixed Assets 80
Prelim. & Preoperative Expenses 590
Contingencies 244
Working capital margin 290
Total 12700
Means of Finance:
(Rs. lakh)
Particulars Ethanol Plant
PSAPPL Equity / Internal accruals (27%) 3429
SDF Quasi Equity (35%) 4445
Bank / F. I. Loan (38%) 4826
Total 12700
First year Fifth year
Estimated W/C Requirements Rs. Lakh 1157 1833
Estimated Annual Turnover Rs. Lakh 4925 8772
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Profit Before Tax Rs. Lakh 827 2837
Accumulated Cash Surplus Rs. Lakh 1521 5245
Employment potential Nos. 81 81
Debt Service Coverage Ratio (DSCR) Average 2.38
Maximum 3.82
Minimum 1.35
FACR 1.34
Payback period Years 5 to 6
Rate of Return on total project cost % 19.32 %
Strengths
The main strengths of this integrated project include:
Background and experience of the promoters
Proposed Sugar Factory & Infrastructure
Commitment & vision of promoters, with forward integration planned right from
beginning
Excellent irrigation facilities with ensured cane cultivation & availability on a long
term basis
Project location in potential sugarcane area
Experienced, willing and committed farmers
Ensured cane availability
Demand supply gap in fuel ethanol in India
Conducive policy / regulatory frame work
High order of socio-economic and environmental value to the local populace
Latest technology equipment with highest efficiency and
Sound techno commercial viability
3.5 Risks Factors
Risk Factors Remarks
Industry Risk
The Industry is cyclical and highly regulated. The price of
free sale sugar is directly/indirectly controlled by the govt.
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Therefore, the company has been making its operations
integrated, comprising of sugar, cogeneration and ethanol
plant to protect its margins and profitability and avert
cyclicality.
Implementation
Risk
PSAPPL has experienced people in its management team.
Keeping in view overall good track record, it is felt that
PSAPPL has the competence for timely implementation of
project as per the schedule. The ethanol project shall be
implemented on turnkey basis. The ethanol project being
implemented on turnkey basis, will reasonably assure
completion of the project within the envisaged cost.
However, any increase in cost of plant & machinery shall
be met by the internal accruals.
Operating Risk Though the company is new to the production and
marketing of ethanol, it is in the business of manufacturing
and marketing of sugar with proposed capacity of 5000
TCD & cogen 35 MW. Moreover, the ethanol project is
being implemented on a turnkey basis and will be backed
by suitable clauses in terms of warranty and guarantee. As
such it is felt that the operating risks would be mitigated to
a considerable extent.
Though the availability of adequate quantity of molasses is
also dependent on the supplies from neighboring units to
meet the shortfall, the company has identified nearby sugar
mills from where molasses can be sourced.
Credit Risk Average DSCR of the ethanol project is estimated to be
2.38, which is satisfactory. PSAPPL has been regular in
meeting its commitments to FIs/Banks and SDF.
Financial Risk The company is comfortably placed to infuse its equity
contribution in the project and is awaiting sanction of term
loan from banks. As such, no problem is envisaged
Raw Material Risk PSAPPL has announced a reasonable remunerative price in
line with the market trend and neighboring sugar mills.
Also, it is providing services to educate farmers about the
best practices in sugarcane cultivation for improvements in
the yield. Company is proposes operating a 5000 TCD
Sugar plant & 35 MW cogen power plant in the same
premises as proposed for the ethanol plant. The molasses
required for the ethanol plant shall be readily available
from the sugar plant. The Neighboring sugar mills has
already shown willingness to supply the molasses for
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meeting the shortfall.
Market Risk/ off
take risk/ payment
risk
The Govt. of India has allowed mixing 5% ethanol in
petrol and has increased of ethanol percentage to 10%,
recently. Since there is need for huge investment to set up
additional required capacity of 96 million litres of ethanol
by 2017, PSAPPL is not expected to face any problem in
selling the ethanol from proposed project.
3.6 Implementation Schedule
The entire project will be commissioned by October 2016 after the financial closure expected by
October 2015. Meticulous planning and strong project management proposed will ensure this
schedule.
4.0 Project Description
4.1 Type of Project
The proposed project mainly involve the Manufacturing of Sugar from Sugar cane,
Cogeneration of Electricity and Fuel ethanol of 80 KLPD capacity.
4.2 Location of Project
The proposed unit is located at village Selu, PO Jategaon, Taluka Gevrai, District Beed,
Maharashtra.
4.3 Products & By-products
S.No. Name of Products
1 Sugar
2 Power
3 Ethanol
4.4 Sugar Plant
The objectives of the sugar plant of the proposed integrated project are mainly to manufacture
quality sugar for national & international markets at optimum operating and energy efficiencies,
as well as provide raw materials for cogen power plant. The integrated project will push the
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product, which has highest realization in the market at any given time, either sugar or power. The
design of the sugar mill would match the latest and modern technologies, being employed for the
cogen power plant. At the same time, the flexibility of operation, expansion and diversification,
also will be available.
To meet the objectives indicated above, the sugar plant of the integrated agro energy project, will
have special emphasis on following:
Highest mill extraction efficiency (more than 96%), at low investment and
power consumption
Lowest steam consumption for the boiling house (less than 40 %), lowest
boiling house losses and reduction in capital cost
Lowest power consumption (less than 25 kWh/TCH for electrified fibrizor
and mill drives)
Lowest raw water consumption (practically nil)
Lowest effluent discharge (practically nil)
Lowest labour cost and chemical consumptions
Highest sugar recovery (more than 11.5% on cane) and sugar quality
The main parameters of cane crushed from 3rd
year onwards will be as follows:
Pol % cane, average 14%
Recovery, average 11.50 % on cane
Fibre, average 14% on cane
Bagasse generation, average 30% on cane
Bagasse moisture, average 50%
Molasses, 4% on cane
The design parameters of the proposed modern sugar plant have been indicated in the
following table:
Capacity / hr, TCH : 227.27
Capacity / day, on 22 hrs basis, TCD : 5000
Average season days, nos. : 160
Bagasse generation (30% on cane),
TPH, @ 50% moisture
: 68.18
Bagasse available as fuel (29.20% on
cane), TPH
: 66.36
Sugar produced (avg. 11.50% recovery),
MT
: 92000 (@ designed
capacity level)
Sugar quality
: ICUMSA color at 420 nm,
less than 40, moisture
max. 0.01 %
Cane preparatory index : 90 +
Imbibition water % fibre : 250 +
Maceration % cane : 30.00
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Mixed juice % cane : 100
Primary pol extraction, % : 75
Mill extraction, % : 96
Reduced mill extraction, % : 96.50+
Reduced boiling house extraction, % : 91.00+
Total sugar loss, % cane : Max 1.6
Downtime % available hours, including
cleaning
: Max 4
Downtime % available hours, excluding
cleaning
: Max 2.5
LP Sugar Process steam required at 2.5
kg/cm2 (40% on cane), TPH
: 90.91
Process power consumption at 25
kWh/TCH, MW (with electrified
fibrizor & mill drives)
: 5.68
Molasses production (4% on cane), MT : 32000 (@ designed
capacity level)
4.5 Cogen Power Plant
The cogen power plant will have installed capacity of 35 MW and will employ 110 kg/cm2 and
540 C configurations. Bagasse generated from cane crushing, excluding handling losses and
bagacillo requirements will be available for operation of the high- pressure boiler during season
of 160 days. Saved bagasse will be used during the off-season period of about 15 days.
The auxiliary steam consumption for the power plant will be for soot blowing and other auxiliary
consumptions like Steam Jet Air Ejector (SJAE) & Gland Steam Condenser (GSC) at high
pressure, for twin HP heater at medium pressure and for de-aerator at low pressure. The auxiliary
power consumption for the power plant will be about 9% & 9.5% of generation during seasons
and off-season periods, respectively.
The colony power requirement will be met by the cogen power plant, both during season and off
season periods.
The brief design parameters for the cogen plant will be as follows:
Boiler capacity, TPH : 1 x 150
Pressure, kg/cm2 : 110.00
Temperature, C : 540
Turbine capacity, MW : 35
Turbine type : Double extraction - cum
condensing
Season operation, days : 160
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Off season operation, days : 15
Fuels used for season operation : Mill Bagasse
Fuels used in off season : Saved bagasse
Boiler efficiency, %
- On bagasse : 70.00, 2
Feed water temperature, C : 210
Captive power consumption, % of
generation in season & off-season
: 9 & 9.50
Turbo-generator efficiency, % : 90.00
Sr. No. Item Unit Value
Season Operation
1 Avg. cane crushing TCD 5000
2 Net season days nos. 160
3 Hrs. / day nos. 22
4 Normal cane crushing TCH 227.27
5 Cane crushed Lakh MT 8.00
6 Bagasse generation % cane 30
7 Bagasse generation TPH 68.18
8 Bagasse for bagacillo / handling loss % cane 0.80
TPH 1.82
9 Bagasse available for boiler TPH 66.36
10 Total equivalent bagasse available for
boiler
TPH 66.36
11 Bagasse saved for off season MT 19136
12 Bagasse used by new boiler Kg steam /
kg
2.65
13 Bagasse used by new boiler TPH 55.85
MT 214464
14 Steam generation TPH 148.00
15 Steam consumption TPH
15.1 HP steam @ for SJAE & GSC 0.50 0.74
HP heater I 9.00 13.32
Sub-total 14.06
15.2 MP steam @ 8 kg/cm2
HP heater II 9.00 13.32
Sub-total 13.32
15.3 LP steam @ 2.5 kg/cm2
Sugar process % cane 40.00 90.91
De-aerator 5.00 7.40
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D/s water addition 2.00 1.97
Sub-total 96.34
15.4 Condensing steam 24.28
15.5 Total 148.00
16 Power generation MW 4.8 31.00
17 Power consumption MW
- Sugar process kWh/TCH 25.00 5.68
- Colony 0.15
- Cogen auxiliaries 9.00 2.79
- Total 8.62
18 Power export
MW 22.38
MUs 85.93
19 Total no. of days / year nos. 175
Off Season Operation
20 Off-season fuel requirement TPH 52.83
No. of days on saved bagasse nos. 15
22 No. of hrs / day nos. 24
23 Steam generation TPH 140.00
24 Steam consumption TPH
24.1 HP steam @ for SJAE & GSC 0.50 0.70
HP heater I 10.00 14.00
Sub-total 14.70
24.2 MP steam @ 8 kg/cm2
HP heater II 10.00 14.00
- Total 14.00
24.3 LP steam @ 3 kg/cm2
- De-aerator 7.00 9.80
- D/s water 2.00 0.20
- Total 9.60
24.4 Condensing steam 101.70
24.5 Total 140.00
25 Power generation MW 4 35.00
26 Power consumption MW
- Cogen auxiliaries 9.50 3.33
- Sugar process 0.10
- Colony 0.15
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- Total 3.58
27 Power export
- MW 31.43
- MUs 11.38
28 Boiler size (110 kg/cm2 & 540 deg C) TPH 1 150
29 TG size (105 kg/cm2 & 538 deg C) MW 1 35
Water & Condensate Balances
While steam, power and bagasse balances both for season and off season operations of the cogen
power plant have been indicated in section 2.2.5, the water and condensate balances are given in
the following table:
Item Value, TPH
Season Off season
Condensate return from sugar process 86.00 0
Condensate from Steam to de-aerator 7.40 9.80
Blow down flash recovery 0.50 0.40
Condensate from condenser 25.02 102.40
Make up water from DM plant 5.91 1.00
Condensate from HP heater 26.64 28.00
Flow from de-aerator 151.47 141.60
Bagasse / Fuel Balance
The bagasse and fuel balances are indicated in the following table:
Sr. Item Value
No. Season
Off season
1. Crushing rate, TCH 227.27 -
2. Bagasse generation at 30 % on cane,
TPH
68.18 -
3. Bagacillo / handling loss at 0.80 % on
cane, TPH
1.82 -
4. Bagasse available as fuel at 29.20 % on
cane, TPH
66.36 -
5. Total equivalent bagasse available, MT 233600 -
6. Bagasse consumed by new boiler, TPH
(MT)
55.85
(214464)
52.83
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7. Bagasse saved / available for off
season operation, TPH (MT)
19136
Power Balance
Following table gives the power balance for the season and off-season
Sr. Item Value, MW
No. Season Off
season
1. Power generation, MW 31.00 35.00
2. Power consumption, MW
- Sugar process (@ 25 kW / TCH after mill /
fibrizor drives electrification)
5.68 0.10
- Colony 0.15 0.15
- Cogeneration auxiliaries 2.79 3.33
- Total 8.62 3.58
3. Power export, MW 22.38 31.43
4. Power export at design capacity level, MU 85.93 11.38
5. Total, season + off season MU at design levels 97.31
Based on the qualification criteria of the topping cycle under the MERC tariff order, the
eligibility of the proposed project in season has been worked out as under:
Sr.
No.
Item Value
1. Net Energy Input (A), M Kcal/hr 125.66
(55.85 TPH x 2250 kcal/kg)
2. Electrical power output (B), M
Kcal/hr
26.66
(31 MW x 860 kcal/kWh)
3. Useful thermal output (C) (energy in
the process), M Kcal/hr
59.91
(90.91TPH x 659 kcal/kg)
4. Total energy output (B+ C), M
kcal/hr
86.57
5. 20% of total energy output (D), M
kcal/hr
17.31
6. Evaluation condition (CD) Yes
7. Efficiency, % (B+C/2 / A) 45.05
Note: Hence, the proposed project is eligible under the MERC tariff order and
qualifies under the same.
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Key performance parameters
The key performance parameters for the cogen power plant are given below:
Sr.
No.
Description Value
1 Steam Generator efficiency, % : 702 on bagasse
2 Steam to Fuel Ratio, kg bagasse / kg : 2.58
3 DEC Turbine efficiency, % : +90%
4 Average Steam to Power Ratio, kg / kW
Season
Off-Season
:
:
4.80
4.00
5 Auxiliary Power consumption, MW (%)
Season
Off-Season
:
:
2.79 (9.00)
3.33 (9.50)
6 Power Generation / Export :
Season–MW/MU’s Generation : 31.00/ 119.04
Export : 22.38 / 85.93
Off-season–MW/MU’s Generation : 35.00 / 12.68
Export : 31.43 / 11.38
Annual Total - MU’s Generation : 131.72
Export : 97.31
7 Exportable Surplus power
(% Generation)
Season : 72.19
Off-season : 89.75
Total : 73.88
4.6 Distillery Unit
4.6.1 Process
The brief manufacturing processes for project component are given below:
The process envisages use of own & B-heavy as well as procured molasses from nearby sugar
factories for manufacture of ethanol during sugar mill season and during off-season days.
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Cane crushing system
Fermentation system
Distillation & Fuel Ethanol
Effluent treatment system
Following is a brief description of the process:
4.6.2 Cane crushing system
The crushing capacity of sugar mill is 5000 TCD. All the molasses generated in the boiling
house will be stored / utilized for the ethanol plant. The molasses recovered during manufacture
of sugar will be 4.5% of cane. The net generation of the molasses at optimum level of operation
will be 36000 MT. To balance the requirement of molasses, the other nearby sugar mills will be
utilized by PSAPPL.
4.6.3 Fermentation system
The molasses stored in the storage tanks will be supplied to the fermentor, where it will be
diluted partly by water and partly by the effluent produced by the ethanol plant and then
fermented in a continuous fermentation reaction.
4.6.4 Distillation
The fermented wash will be then fed to the distillation column. Here the wash will be distilled to
generate the rectified spirit, which will be sent to the molecular sieve section where rectified
spirit will be converted to ethanol.
The ethanol plant will produce 80000 liters of total spirit per day & 76,000 litres per day ethanol
that will be sold to the oil companies for blending with petroleum products.
4.6.5 Effluent treatment system
The spent wash of a distillery process is a serious problem by way of threat to the environment.
Its volume from continuous fermentation plant is as large as 7.56 TPH for a distillery of 80
KL/day capacity based on multi pressure distillation with integrated evaporator system.
The spent wash evaporation technology is a multiple effect evaporator system in which heat
recovered from one effect is used to concentrate spent wash in second effect evaporator with
continuous recirculation of concentrated spent wash with in the system until desired
concentration is obtained. This entire concentration process is carried out under vacuum leading
to less consumption of steam and maximum concentration of spent wash with in less period of
time.
The concentrated spent wash generated after entire process of evaporation is then sprayed in a
furnace with support fuel bagasse and is then burnt in a boiler.
4.6.6 Choice of Spent wash Treatment System
In order to fulfill the Pollution Norms and to achieve zero Discharge and at the same time to
operate ethanol plant for the period more than 270 days per annum, PSAPPL proposes to go for
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spent wash Concentration and Incineration Technology simultaneously generating Steam and
Power for the process and Ethanol plant.
With effective utilization of such a technology big hurdle of spent wash disposal will be solved
and distilleries will become zero effluent discharging unit.
4.6.7 Condensate Polishing Unit
The condensate polishing unit is also envisaged to take care of spentlees, cooling tower blow
down, washing and process condensate from evaporation plant. After treatment all the stream at
CPU, water can be recycled to process and as cooling tower make up.
4.6.8 Requirement of Molasses:
The requirement of in –house molasses to run the ethanol plant for at least 160 days as per SDF
norm is 54,468 MT. PSAPPL will utilize 36,000 MT of own molasses and 22.14% or 12,400 MT
of B-heavy molasses required to be diverted, for meeting the shortfall quantity of 18,468 MT of
final molasses.
4.6.9 Use of B-heavy molasses:
The entire process & advantages of Ethanol production by B-heavy molasses route for meeting
the shortfall in the molasses quantity, is explained as below.
There is practically no change in the manufacturing process for Ethanol
production, only the source of molasses is both from low purity molasses
available from C curing of the sugar process and from diversion of
required quantity of B-heavy molasses after B curing.
No need of any additional investment and machinery for this diversion and
meeting the molasses shortfall, except minor piping and accessories
Flexibility for starting & stopping within no time gap, as per the market
position for Sugar or Ethanol
Improvement in sugar quality thereby increasing revenue
Increase in the boiling house capacity to the extent of diversion of B-
heavy molasses, due to increase in consequent pan capacity and reduction
in massecuite % cane
Reduction in steam consumption, resulting in additional bagasse saving
Possibility of storage of B-heavy molasses, in the same final molasses
storage tanks
The calculation of requirement of B-heavy molasses diversion, to meet the molasses shortfall is
given below:
Requirement of Molasses & B Heavy molasses for 160 days
1 Final Molasses required for proposed 80 KLPD Ethanol
plant for 160 days ( 80000/235 x 160), MT
54468
DPR on Integrated Sugar & Cogen Power Plant at Selu, Tal-Gevarai, Dist-Beed
19
2 Present availability of molasses @ 4.5 % on cane for 5000
TCD sugar plant for 160 days ( 5000 x 160 x 4.5 %), MT
36000
3 Shortage of own molasses for proposed 80 KLPD Ethanol
plant ( 1-2), MT
18468
4 B-heavy molasses production from 5000 TCD sugar plant
@ 7% on cane for 160 days. i.e. (5000 x 160 x 7 %), MT
56000
5 Recovery of ethanol from Final molasses, Lits/MT as per
SDF norms
235
6 Recovery of ethanol from B-heavy molasses, Lits/MT
Ethanol Recovery =
(Fermentable Sugar x Ethanol Conversion Factor x
Fermentation efficiency x Distillation efficiency x
Dehydration efficiency ) / Alcohol Strength
Fermentable Sugar = 61 % ,
(based on latest RT 8 ( c ) records giving B heavy molasses
purity and reasonable assumptions thereof, as special
analysis for B heavy molasses is unavailable with the sugar
factory, as no diversion is made till date )
Ethanol Conversion Factor
= Sucrose to Alcohol Factor x 1000 / Alcohol Specific
Gravity
= (0.5111 x 1000 /0.794) = 644
Fermentation efficiency = 90%
Distillation efficiency = 98.5%
Dehydration efficiency = 99.6%
Alcohol Strength = 99.8%
350
7 The quantity of B-heavy molasses (of 65 to 70 TRS)
required to be diverted for meeting balance molasses
requirement ( 18468 x 235 / 350), MT
12400
8 The percentage of diversion of B-heavy molasses, %
(12400 MT/ 56000 MT)
22.14%
4.6.10 Molasses balance:
The total requirement of molasses for the 270 days operation of the proposed ethanol plant at
optimum level of operation will be around 91,915 MT. PSAPPL will utilize 54,468 MT of
own/B-heavy molasses & the balance 37,447 MT of molasses will be procured from nearby
sugar mills.The installed capacity and capacity utilization levels for ethanol plant and respective
annual requirement of molasses have been shown in the following table:
Sr. Particulars Projected
DPR on Integrated Sugar & Cogen Power Plant at Selu, Tal-Gevarai, Dist-Beed
20
No. 2016-
17
2017-
18
2018-
19
2019-
20
100%
capacity
Utilizatio
n
1 Estimated annual crushing in LMT 8.00 8.00 8.00 8.00 8.00
2 Molasses recovery, % cane 4.50 4.50 4.50 4.50 4.50
3 Production of own molasses, MT 36000 36000 36000 36000 36000
4
Installed Capacity of Ethanol
Plant, KLPD 80 80 80 80 80
5
Ethanol yield from cane molasses
as per SDF Norm, lit/MT 235 235 235 235 235
6
Requirement of Molasses for 80
KLPD Ethanol Plant for 160 days,
MT 54468 54468 54468 54468 54468
7 Capacity Utilization, % 80% 85% 90% 95% 100%
8
Requirement of Molasses for 80
KLPD Ethanol Plant for 160 days,
MT 43574 46298 49021 51745 54468
9
Deficit of molasses for 160 days,
MT -7574 -10298 -13021 -15745 -18468
10
Recovery of ethanol from B-heavy
molasses, Lits/MT 350 350 350 350 350
11
Requirement of B-heavy molasses,
MT 5086 6914 8743 10571 12400
12
Requirement of Molasses for 80
KLPD Ethanol Plant for 270 days,
MT 73532 78128 82723 87319 91915
13
Molasses procured from nearby
sugar mills for 270 days, MT 29957 31830 33702 35574 37447
DPR on Integrated Sugar & Cogen Power Plant at Selu, Tal-Gevarai, Dist-Beed
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SITE DETAILS AND INFRASTRUCTURE
5.0 Project Site, Key Features
5.1 Site Location
Village Selu
Taluka Gevarai
District Beed
Nearest Taluka Gevarai, 25 Km
Nearest Water Source Godavari River, 10 Km
Nearest Electrical Substation 132 kV, located at Gevarai at 20 Km
Required land is available at the project site and is owned by PSAPPL
The site is easily accessible by road,The site is located at Village Village Selu, PO
Jategaon, Taluka Gevarai, Dist. Beed, Maharashtra, which has very good ground water
availability and is near to the perennial source of water
The cane availability and potential in the command area is excellent and will ensure
sustained cane availability.
The off season non-fossil fuel requirements for the cogen power plant can be easily met
by saved bagasse. The evacuation of exportable surplus power from the cogen plant will
have to be made through the Gevarai substation 132 kV of MSEDCL, which is 20 km
away from the site.
The plant will operate on own & procured molasses
5.2 Infrastructure
The site has easy access to latest communication and other social infrastructure facilities,
including telecommunication, schools and colleges, medical & health facilities, commercial
infrastructure, etc. at Gevarai, which is a Taluka Headquarter.
There are no major mountains in the command area. The rest of the command area is by and
large plane, with good fertile soil.
The Climate of the district is characterized by a hot summer and general dryness throughout the
year except during the south-west monsoon season, i.e., June to September. The temperature
rises rapidly after February till May, which is the hottest month of the year. The mean daily
maximum temperature during May is 42.0°C and the mean daily minimum temperature during
December is 12.0°C.The normal annual rainfall (1901-1996) varies from about 600 to 800 mm.
It is minimum in the western part around Ashti and gradually increases towards east and reaches
maximum around Majalgaon.
These climatic conditions and the nature of the soil make the area ideally suitable for cotton,
jowar, soyabean, bajra, gram, tur, sugarcane and wheat.
DPR on Integrated Sugar & Cogen Power Plant at Selu, Tal-Gevarai, Dist-Beed
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The construction power can be easily made available from MSEDCL. The surplus power
generated during crushing season as well as off-season will be evacuated to Gevarai substation of
MSEDCL located at about 20 km from site.
The process steam required at 8 kg/cm2 for cogen plant and 2.5 kg/cm2 for the sugar plant during
season will be supplied by the cogen power plant. The high pressure, medium pressure and low-
pressure steam required for cogen auxiliaries will also be met. The power requirement for sugar
process during season, for cogen auxiliaries and colony will have to be met from the cogen plant.
The steam and power cycle has been designed accordingly.
The cogeneration plant requires compressed air, both for instrumentation and for servicing,
which is generated by installing the air compressors of the required capacity, as part of the cogen
power plant.
The process steam & power required at 3.5 kg/cm2 for the proposed ethanol plant which will be
met through 32 TPH, 45 kg/cm2 slop fired boiler and matching 4 MW turbine.
5.3 Manpower
The skilled manpower required for operation of sugar and cogen power plants will be easily
available from Gevarai & Beed city. PSAPPL will require about 455people for operation of
proposed integrated project. PSAPPL is in a process of appointing required manpower and has
already appointed key top management positions for the purpose.
5.4 Effluent Disposal
Due care will be taken in design, implementation and operation of the captioned integrated
project for satisfactory disposal and effective utilization of plant effluents, waste water and
colony waste water. Scientific treatment will be given to ensure that waste water from all sources
needs the norms stipulated by the Maharashtra State Pollution Control Board (MPCB).
5.5 Raw Materials
5.5.1 Sugarcane availability
Proposed sugar plant of 5000 TCD installed capacity requires about 8.00 lakh MT of
sugarcane. Considering the capacity utilization, 6.40 lakh MT of sugarcane in the first
year of operation, 6.80 lakh MT in the 2nd
year, and 7.20 lakh MT from the 3rd
year
onwards shall be required.
Presently, after meeting the cane requirement of existing sugar factories, 12.10 lakh MT
surplus cane will be available for PSAPPL. The irrigation & climatic conditions are quite
conducive. Considering this situation & long term cane development program being
adopted by PSAPPL, the proposed project will not have any difficulty for making the
DPR on Integrated Sugar & Cogen Power Plant at Selu, Tal-Gevarai, Dist-Beed
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required sugar cane available for crushing for the proposed capacity. (Refer Cane Survey
Report for availability of sugarcane in the command area)
5.5.2 Raw Materials for Cogen Power Plant
As indicated in the steam / power cycle design, the total bagasse available from the sugar
mill, from cane crushing of 8.00 lakh MT, as fuel, will be 2,40,000 MT ( TPH for 24
hrs/day and 160 days / season after deducting bagacillo & handling losses), out of this
2,33,600 MT (66.36TPH) will be utilized by the cogen plant boiler, leaving saved
bagasse of about 19,136 MT for the off season operation.
For off season operation of 15 days, saved bagasse of 19,136 will be used.
Therefore no difficulty envisaged in getting fuel for cogen plant for 175 days of
operation.
5.5.3 Raw Materials for Fuel Ethanol Plant
The total requirement of molasses for the 270 days operation of the proposed ethanol
plant at optimum level of operation will be around 91,915 MT. PSAPPL will utilize
54,468 MT of own/B-heavy molasses & the balance 37,447 MT of molasses will be
procured from nearby sugar mills.
It is concluded that PSAPPL can easily generate the required quantity of molasses and
procured molasses from nearby sugar mills to operate plant for 270 days.
5.6 Utilities & Consumables
Water and power are the main utilities required for operating the integrated project.
Water will be drawn from Godavari River, perennial source of water at a distance of
about 10km from the site. Therefore no difficulty envisaged in terms of availability of
water required for the proposed sugar complex. Power required for construction and in
case of shut down of plant will be drawn from the MSEDCL grid.
The consumables required for operation of sugar plant include sugar bags, laboratory and
ETP chemicals, oils / lubricants and other chemicals for the machinery and processing,
etc.
The consumables required for operation of ethanol plant include, laboratory and
chemicals, oils / lubricants and other, etc.
The consumables indicated above will be available in substantial quantities from nearby
Gevarai town, and no difficulty will be envisaged.
Conclusions
Over all, the project is well conceived and conceptualized, with sound commercial viability. The
expected financial returns are quite satisfactory. The project is being implemented by promoters
DPR on Integrated Sugar & Cogen Power Plant at Selu, Tal-Gevarai, Dist-Beed
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having requisite background and experience and with proposed employment of experienced
professionals, experts and consultants. All perceived risks have adequate safe guards. The project
is recommended for equity participation and lending by financial institutions.