feasibility report of sugar mill cogen power plant

7/28/2019 Feasibility Report of sugar mill cogen power plant

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Prefeasibility Report: Proposed 19MW Cogeneration Project

Bhimashankar SSKL 1

PRE-FEASIBILITY REPORT

NEW 19.0 MW COGENERATION UNIT OF

BHIMASHANKAR SAHAKARI SAKHAR KARKHANA LTD

1.0 INTRODUCTION

M/s. Bhimashankar Sahakari Sakhar Karkhana Limited, at Dattatryanagar, P.O. Pargaon via

Awasari, Taluka: Ambegaon, Dist. Pune.410 406 is engaged in the manufacture of sugar and is

registered under the Co-operative Society Act, 1961 on 31.03.1994 vide registration

No.PAN/AGN/A/S-47/ 1994. In Nov. 1999, the first elected board of directors took charge of the

industry from government nominated director board under the chairmanship honorable

founder Shri Diliprao Walse Patil, speaker, legislative assembly, (Govt. of Maharashtra). The

initial installed crushing capacity of the factory was 2,500 TCD. Because of increasing

availability of sugarcane in the area of operation, the factory expanded its crushing capacity to

4,000 TCD. The management now plans to establish a 19.0 MW cogeneration plant to fulfill their

need of power and sell the surplus power to Maharashtra State Electricity Distribution

Corporation Limited (MSEDCL).

2.0 PROJECT SETTING

The sugar factory has a plan to set up a 19.0 MW co-generation project within its premises. The

plant is located off Pune-Nashik national highway No.50 just a 15.5 Km towards west. The

geographical coordinates of the site are 18058”N. and.74005’E.

During 2009-10 the crushing was 5,88,909 MT with average recovery of sugar of 12.0%. In

Season 2009-10 the bagasse production for these season 1, 55,471 MT. Bhimashankar SSK Ltd.,

is now planning to balance the sugar plant and increase the saving of bagasse by using biogas.

Further efforts will be made to procure surplus bagasse from the neighboring sugar units.

3.0 HIGHLIGHTS OF THE PROJECT

Name of the

Industry

Bhimashankar Sahakari Sakhar Karkhana Ltd.

Location of the

project

Dattatrayanagar, P.O. Pargaon via Awasari,

Taluka: Ambegaon, Dist. Pune 410 406State- Maharashtra

Email : [email protected]

Ph no: 02133-284231/32/41/46

Fax : 02133 - 284381

http://www.pdfcomplete.com/cms/hppl/tabid/108/Default.aspx?r=q8b3uige22






Bhimashankar SSKL 2

Land 18 acres built up area, 6 acres provided for green belt

development

Project 19.0 MW Cogeneration (Power) plant

Product Electricity Generation -18.0 MW

Running Days 236 Days

Main Raw Material Water as main raw material for steam generation.

Bagasse as a raw material for fuel.

Water Requirement 900 m3/day

Ghod River, Kathatpur KT Weir. (Permission available)

Fuel Bagasse – For season - 1074 MT/day

During Off season: 305 MT/day

Production

equipment and

machinery

Steam generators (Boilers), Condensate system, Turbo-generator

sets, Cooling tower, Fire protection system, Bagasse and Ash

handling system.

Boiler and Steam

Turbo Alternator

(STG Set)

Presently the factoryis having one boiler of 37 TPH capacity

working at 45 ata pressure and 445oC ± 50 C steam temperature.

For a new boiler is of 80 TPH capacities at 88 Ata pressure and

515OC± 50C steam temperature is planned to install. Operating load

of the new boiler is estimate to be about 71.50 TPH during normal

crushing season including the extraction of steam for process

requirement, HP heater and de-aerator heating steam

Manpower Total staff around 35

Project Cost Rs. 4461.25 Lakhs

EMP cost Rs.300.00 Lakhs

4.0 SITE SPECIFICATION

4.1 Connectivity

· The site is located off Pune-Nashik National highway No. 50, Distance- 15 km from

factory site.

· Pune is the nearest railway station 55 from the site.

· Pune is the nearest airport -55 km from the site

4.2 Land use pattern

Since the project is going to be commissioned within the existing sugar factory premises and no

additional land is required, hence the project is not causing any land use change in the area.

4.3 Ecologically sensitive attributes: There is no tropical forest/ biosphere reserve/ national

park /wildlife sanctuary /wetland/Tiger reserve/area with threatened/reserved forest etc








Bhimashankar SSKL 3

under wildlife protection act (1972)within radius 10 km study area. The nearest sanctuary to

the site is ‘Bhimashankar Wildlife Sanctuary’ located at a distance of 60km.

4.4 Social and Existing Infrastructure in the study area

As explained earlier this area is covered in Ambegaon taluka. The study area is decided as an

area within 10 km radius from the proposed unit. Altogether there are 36 villages in the study

area. The infrastructure such as school, college, medical centers, roads, electricity and supply of

drinking water is available to the local people. The factory is actively involved in several socio-

economic developmental activities of the region, finance for cane development, housing facility

to its workers, helping the member farmers for various purposes such as educational, social,

health, and cultural.

Education Facilities: 24 primary schools, 4 middle schools, within study area.

Health Services: The overall health facilities such as public health center, private clinics,

dispensaries and nursing homes, etc. availability in the study area are adequate to serve the

localities’ .

Veterinary Center: The study area contains sizable cattle population consisting of cows,

buffaloes, bullocks, goats, sheep, poultry etc. The bullocks are used for ploughing, harrowing,

sowing and intercultural operations whereas buffalo, cows, sheep, goats and hens are kept as

subsidiary source of income.

Drinking Water: Drinking water supply for most of the villages is made available by

Maharashtra Jivan Pradhikaran

Communication: There are 19 Post offices and Telegraph within study zone

Electricity: All villages have power supply from Maharashtra State Electricity Board.Road and transport: Asphalted roads are present throughout the study area, those connects to

each of the village. There is a regular service of State Road Transport Corporation (MSRTC) bus

available in the region.

5.0 CLIMATIC INFORMATION INCLUDING BASE LINE ENVIRONMENTAL CONDITION

Climate Ambegaon taluka falling in the moderate rainfall intensity zone. Average

rainfall is around 800.44mm. The annual average temperature is varies from

19-33oC

Relative humidity - Early summer (January to March)42-55% o In monsoon it

ranges 75-81%

Wind The predominant wind direction observed during the study period was west

direction; with 22 % of the 0-7 kmph Calm conditions constituted about 27.78









Bhimashankar SSKL 4

% of the total time observed.

Geology The district forms part of Western Ghat and Deccan Plateau. This Taluka falls

to the foothill of Sahyadri Mountain range. The study area largely falls in the

Basin of Bhima- Ghod River.

Hydrology The district has three major drainage system namely, Bhima–

Ghod. River

system in the northern, north eastern and eastern part, of which Bhima River

has a total length of about 355 km. and Ghod River has a drainage of about 196

km. River Ghod approx 2 km away from the factory site in North direction.

Soil The type of soil in the area is black to calcarious soil. Deep black soils have

good water holding capacity due to rich humus content. Excepts certain

packers, the soil have good drainage. These soils contain less 'Humus' Organic

Matter. The pH of the soil is 8.0 to 8.9.

Land-use

Pattern

It is observed from the available data that, the project surrounding land is

mainly used for agricultural purposes, followed by residential purpose

agricultural activities, partly for the pasture and other uses.

Ecology The wild vegetation in the study area consists of semi-aired with significant

thorny species. Mainly agricultural (cultivated) vegetation is dominant in the

study zone. There is no wildlife sanctuary or national park or biosphere

reserve exists in the 10 km radius area. Also, there are no rare or endangered

floral or faunal species recorded in the 10 km radius zone.

Scio-

Economic

Environme

nt

The infrastructure such as school, college, medical centers, roads, electricity

and supply of drinking water is available to the local people. The Karkhana is

actively involved in several socio-economic developmental activities of the

region, finance for cane development, housing facility to its workers, helping

the member farmers for various purposes such as educational, social, health,

and cultural.

Historical

Sites

No historically important sites are present in the study zone of the proposed

site

6.0 BENEFITS OF BAGASSE BASED COGENERATION

Cogeneration offers energy, environmental, and economic benefits, including:

· Saving money








Bhimashankar SSKL 5

· By improving efficiency, cogeneration systems can reduce fuel costs associated with

providing heat and electricity to a facility.

· It saves the fossil fuel consumption by using the as well as and related foreign exchange.

· It does not increase the foreign exchange cut flow, as the plant and machinery are

indigenously available

· It has lower installation and operating cost compared to the thermal power plant.

· The profit made by incomes through exportable power improve financial position of the

sugar factory

· Improving power reliability

In cogeneration systems, it is located at the point of energy use. It provide high-quality and

reliable power and heat locally to the energy user. It helps by reducing congestion on the

electric grid by removing load. In this way, cogeneration systems effectively assist or support

the electric grid, providing enhanced reliability in electricity transmission and distribution.

· Reducing environmental impact

Cogeneration reduces the amount of fuel burned for a given energy output and reduces the

corresponding emissions of pollutants and greenhouse gases.

· Conserving limited resources of fossil fuels

Cogeneration requires less fuel for a given energy output, the use of cogeneration reduces the

demand on our limited natural resources—

including coal, natural gas, and oil—

and improvesour nation's energy security.

7.0 RAW MATERIALS

Bagasse and water will be main raw material. The total requirement for the unit (including

domestic and other.) 900m3/day .The bagasse is fuel material for this plant will be made

available from the attached sugar factory. Bagasse requirement for cogeneration plant will be

1074.0 MT/day during season and 305 MT /day during non-crushing season.

8.0 WATER REQUIREMENT

The water for sugar/cogeneration plants will be drawn from existing overhead service water

tanks and will be recycled after cooling separately. Water from the reservoirs will be used for all

plant and fire-fighting purposes. To achieve better efficiency and to maintain the plant and

machinery in good condition, it is necessary to have proper water treatment system. Process

water will be treated in a water treatment unit as well as a water-softening unit. By having









Bhimashankar SSKL 6

proper water supply system such as clear water pumps etc, the distillery can have good water

supply arrangement.

Table 1: Water Consumption Details Cogeneration

Water Consumed for Consumption M3 /day

Domestic Use (Drinking, Toilet, etc.) 5.0

Gardening Nil

Industrial purpose

1. Process* Nil

2. Washings* Nil

3. Boiler feed** 80.0

4. Cooling tower make -up water ** 810.0

5. Others (Pump gland sealing) 5.0

Total 900 m3/day

* Treated water from ETP will be utilized for gardening purpose

**One time – startup - requirement for boilers and cooling towers = 20,808 m3

Table 2: Water budget for 19 MW proposed cogeneration plant

Sr.

No Station

Input

m3/day

Loss

m3/day

Effluent

m3/day Sent to

Recycle

m3/day

1. Boiler 85 35 50 Sugar ETP 50

2.

Cooling

Tower/

Spray Pond

810 810 00 Sugar ETP 00

3. Domestics 5 2 3Septic Tank

Soak pit Nil

Total 900 847 53 50

9.0 STEAMDuring cane crushing season, the steam will be generated from two boilers, one is of 80TPH

capacity, 88 Ata pressure and 515oC ± 50 C temperature; second is of 37 TPH capacity with 46

ata Pressure and Temperature 445 ± 50C. Produced steam will be supplied to a new TG set of 13







Bhimashankar SSKL 7

MW and existing 6 MW. The exhaust steam from cogeneration unit will be utilized in sugar

factory, distillery, and other subunits.

Table 3: Steam Balance

10.0 BOILER

The factoryis having one boiler of 37 TPH capacities working at 45 ata pressure and 445oC ± 50 C

steam temperature. For new boiler 80 TPH capacities at 88 Ata pressure and 515oC± 50C steam

temperature is planned. Operating load of the new boiler is estimate to be about 71.50 TPH

during normal crushing season including the extraction of steam for process requirement, HP

heater and de-aerator heating steam.

Table 4: The boiler details

Sr.no.

Boiler Pollution ControlEquipment

Steamgeneration

1New 80 TPH @ 88 ATA Pressure and

temperature 515 ± 50C

Electrostatic

precipitator71.1 TPH

2.Existing 37 TPH @ 46 ATA Pressure

and temperature 445 ± 50C

Multi cyclone dust

collector35.4 TPH

Total Steam generation during crushing season 106.5 TPH

Table 5: Steam Turbine Generator (STG)

Sr.

No.Steam Turbine Generator Power generation (MW)

1. 13 MW (New) 12.100

For season Off season

Total steam generation 106.53 TPH 28.25TPH

Steam required for Sugar process @2.5ata 72.73TPH --

Steam for distillery and ENA units @ 2.5 ata 6 TPH 6TPH

Steam to De-aerator 7.0 TPH 3.0 TPH

Steam to H.P .Heater @7ata 7.8TPH --

Condensing flow steam 13TPH 19.25TPH

Total steam consumption 106.53 TPH 28.25 TPH







Bhimashankar SSKL 8

2. 6 MW (Old) 5.900

Total power generation 18.000

11.0 BAGASSE HANDLING SYSTEM

There will be provision for handling excess bagasse which will not be used in the boiler (during

season) to a storage area. The Bagasse will be supplied to boiler from elevated carriers and belt

conveyors.

For the non-crushing season the fuel handling system will also used to handle alternative fuels

such as cane trash.

12.0 ASH HANDLING SYSTEM

Ash generated in the Boiler consists of bottom ash and fly ash. Fly ash handling system shall

consist of dense phase handling system. Fly ash collected at various generation points will be

collected and conveyed to a fly ash silo.

13.0 PROCESS

The proposed cogeneration, aims at significantly improving the energy efficiency of the sugar

factory, enabling the plant to generate surplus power from its cane cursing operation. This

surplus power could be exported to the state electricity grid.

The proposed co-generation system is designed to utilize the present boilers & T.G. sets for

steam generation and surplus electrical power generation.

Figure 1: Schematic of Cogeneration Project

Exhaust

Boiler Bagass

Power

Sugar Process

Surplus to Electricity grid

De-aerator

HP Heater

Captive Power

SteamTurbo

Generator







Bhimashankar SSKL 9

14.0 COGENERATION SCHEME

The co-generation schemes operations during crushing season (160 days) are designed to use

bagasse as a biomass fuel, which is as per the guidelines and qualifying norms stipulated by

MERC.

Table 6: Power balance for crushing season is as follows

Total Generation of power

from T,G set of 13 MW and 6 MW

18.000 MW

Sugar Factory power consumption 5.100 MW

Distillery, cogeneration unit and administration, colony load. 0.900 MW

Total Captive consumption 6.000 MW

Surplus power to be exported to state grid 12.000 MW

Table 7: Power balance for off- season

Captive consumption

Distillery, Sugar factory administration, Cogeneration Plant

auxiliaries

1.250 MW

Exportable Power 4.700 MW

Total Power generation 5.950 MW






Prefeasibility Report: Proposed 19MW Cogeneration Project Bhimashankar SSKL

11

Figure 2: Process flow chart for season

Bagasse as Fuel 29.95 T/hr

Boiler

80TPH

Total Steam 71.1TPH

45 k /cm2 a 485oC

84 Ata pressure at - 505 o C

13 MW T.G. Set

12100KW

Captive consumption 6000 KW

Boiler 37 TPH

~5900 KW

18000 KW

Bagasse as Fuel 14.80 T/Hr

Export Power 12000 KW

Total Steam 35.4 TPH

45 k /cm2 a 485oC

6MW T.G. Set

43Ata pressure at – 440 o C





Bhimashankar SSKL 13

Figure 3: Process flow chart for off-season

15.0 ENVIRONMENT PROTECTION AND WASTE MANAGEMENT

Environment protection and the control of solid, liquid, and gaseous effluent or emissions

are key element in the design of all steam and power generating system. At present the

most significant of these emissions are sulfur dioxide (SO2), Oxides of nitrogen (NOx) and

fine airborne particulate matter (SPM) and gases.

Bagasse being a biomass, a renewable fuel does not add any net CO 2 to the atmosphere,

because of the carbon recycling during the growth of cane. The same is applicable even for

the other biomass fuel propos to be used in the plant during the off-season operation.

15.1 Air Environment

Atmospheric emission arises primarily from the by-product of the combustion process SO2,

NOx, particulate fly ash are exhausted from the stack. A second source of particulate matter

and gases is fugitive dust from bagasse/Biomass/Ash handling equipment. A final source of

air emission is the cooling tower and associated thermal rise plume, which contains heat

and some trace materials along with the water vapor.

Boiler 37TPH

Power 5.95 MW

~

Total Steam 28.7 TPH

Captiveconsumption

Surplus power 4.7 MWexported

Bagasse 12.7 TPH

6 MW T.G. Set







The element polluting the air that are discharged from the proposed unit are,

q Dust particulate from fly ash in flue gas

q Sulfur-di-oxide in the flue gas (Very minor)

15.1.1 Control Measure

1. Electro Static Precipitator(ESP) for effective control of fly ash

2. The existing stack height is 60 m which is as per norms, considering the particulate

matter emission. There is very little sulfur in biogas (1.5% of total volume). hence

the criteria for fixing stack height based on SO2 emission is applicable. The

temperature encountered in the steam generator while burning high moisture

bagasse and biomass is low enough to minimize the NO2 production.

3. Moreover, the tender specification for stem generation will stipulate over fire air

system with staged combustion, which will also ensure reduction in Nitrogen –oxide

emission. Hence, no separate measures are taken to nitrogen oxide pollutants.

4. Fly ash collected from the dust hoppers and the air heater hopper and the ash

collected from the furnace bottom hoppers can be used for two purposes.

1) The high potash content in the bagasse ash makes the ash good manure.

2) It could be sold to brick manufacturing units as per their requirements.

15.2 Water Environment

Aqueous discharge arises from a number of sources. Theses include cooling tower blow-

down, sluice water from the bottom ash handling system, boiler chemical cleaning solution,

and gas side water washing waste solution.

15.2.1 Effluents and Sewage Disposal

Effluent: Wastewater from power plant does not have any significant BOD/COD level. All

wastewater will be neutralized prior to discharging .An effluent treatment plant for sugar

mill is already in operation for the wastewater and provided with aerators, to meet the

norms prescribed by MPCB. The total waste water generated from various units is

estimated to be about 50-55m3/day. The existing ETP of sugar factory (1000m3capacity) is

adequate to treat the effluents from cogeneration unit.

Sewage: Existing sewage system, which is connected to common septic tank and it

discharges as per the normal accepted local practices. (Refer Figure 4)

15.3 Solid Waste Generation and Management

The solid waste will be mainly, the ash generated in the boiler, which collected by

electrostatic precipitator. Total ash generation during crushing season will be 21.48 MT per

day. It will be 6.091MT per day during off season. The boiler ash is usually rich in Potash;










hence it could be directly applied int o agriculture field or sold to the brick manufacturers as

per their demand. Figure 4

15.4 Thermal Pollution

The hot effluents are the spray pond overflow. The hot water will of about 42 0C

temperature and the quantity will be in minor quantity around 4-5 m3/day. This hot water

will be cooled down to normal temperature in cooling pond and then recycled. Hence, there

will be no thermal pollution of any surface water body around the project site.

15.5 Noise Pollution

The principal source of noise generation is the boiler and DG. However the noise generated

in the boiler section will be localized and will not dissipate because of the enclosures

provided. Additionally, transportation and handling of bagasse also could raise the levels of

noise. The noise generated will be only temporary and during the period of operations.

Considering these facts, the project will have minor negative impact on noise environment.

Figure 4: Schematic of waste management

Bagasse feeding

Boiler/Furnac

Ash is rich in potash,

mixed with press mud

and sell to farmer as

manure Or Brick

manufacturers

Fly Ash and bottom ash(21.48 MT/day

Steam Turbine

19MW

ElectricityBoiler feed water

Boiler blowdown from

power plant

Neutralized

Reuse for cooling

tower make up OR Mixed in sugar ETP

Sluice water from the

bottom ash handling

system, boiler

chemical cleaningwater

Sent to ETP of sugar factory








15.6 Hazardous Waste

Spent oil from the gear boxes and automobile batteries will be disposed to the authorized

vender as per the Hazardous waste (Management and handling) Amended Rules, 2003.

15.7 Rain Water Harvesting SchemeRain water is one of the purest sources of water for improving the water table in the sub soil

and also the quality of water. Rain water which is otherwise wasted has to be recharged in

to the soil. This can be adopted either using traditional way or by modern technologies. The

various types of rain harvesting schemes are, diverting rain water collection through proper

channels to the nearest pond or open wells and run off from built in areas mainly roofs are

diverted to storm water drains, which is again taken to the nearest lake / pond.

Building up of recharge structures should be in scientific way. Recharge structures of size

approx. 2x2 m and 3m depth can be dug and filled with pebbles/rubbles of sizes more than

2”. At the center of this structure 6” or 8” pipe is driven to the depth of approx.10m, with

perforation of 1or2.” Such structures can be built at pre-defined places (minimum 4 or 5

places, depending up on the site situation) so that maximum quantity of rain water within

the premises of sugar factory can be collected. The water diverted through channels, from

roof tops and other means can be collected in this recharge structure, which will definitely

improve the water table as well as quality of the water and feed water to the plant during

drought season.

The industry has planned to implement the rainwater-harvesting project. It will appoint a

special consultant, under his guidance the project will be designed and implemented.

15.8 Fire protection system

Fire protection system shall be provided in accordance to the LPA regulations.

· It consists of a network of hydrants

· One electric driven pump, one diesel engine driven pump, one jockey pump.

· Portable fire extinguishers shall be provided at strategic locations

· Fire alarms

· All safety devices such as lightening arresters, trippers, etc

15.9 Rehabilitation and Resettlement

Proposed Cogeneration power plant located in existing sugar factory premises; therefore

there is no rehabilitation and resettlement problem.






16.0. Cost Estimates

Financial Projection1 Net Sales to MSEDCL 32995.8

2 Total cash cost of production

without depreciation and interest:

Variable Cost

9765.18

3 Profit before depreciation and

interest

23230.63

4 Less:

(Rs. lac)

Depreciation : 3904.37

Interest on term loan:1385.41Interest on SDF loan : 418.18

5707.95

5 Profit after depreciation and interest 17522.67

6 Add back depreciation 3904.37

Total Cash Accruals 21427.04

Estimated Environment

management cost

Rs. 300.00lakhs

Sr.

No.

Category Investment(Rupees in

lakhs)

1 Bagasse and Ash

handling

250.00

2 Fire protection 20.003 FD/ID fans 25.00

4 Greenbelt 05.00

Total 300.00




feasibility report of sugar mill cogen power plant

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