PRE-FEASIBILITY REPORT

Modernization cum Expansion of Sugar Unit from 5,000 to 8,000TCD Capacity and Cogeneration Project of 19.5 MW Installed Capacity

M/s. Karmayogi Shankarraoji Patil Sahakari Sakhar Karkhana Limited Mahatma Phule Nagar, Bijwadi, Taluka Indapur, District Pune, Maharashtra

Prepared By

VASANTDADA SUGAR INSTITUTE *

Manjari (Bk), Pune, Maharashtra 412 307 Telephone: (020) 26902100, 26902343/7/6, Fax (020) 26902244 Web Site: www.vsisugar.com
*Accredited by QCI/NABET (Provisional) for EIA consultancy services Recognized R & D Center by Department of Scientific and Industrial Research (DSIR), Ministry of Science and Technology, Government of India and P.G. and Doctoral Research Center by University of Pune

March 2012

PRE-FEASIBILITY REPORT
KARMAYOGI SHANKARRAOJI PATIL SAHAKARI SAKHAR KARKHANA LIMITED EXPANSION OF SUGAR UNIT FROM 5,000 TO 8,000TCD AND 19.5MW COGENERATION UNIT

1.0

INTRODUCTION

The Karmayogi Shankarraoji Patil Sahakari Sakhar Karkhana Limited (KSPSSKL), is located at Mahatma Phule Nagar, village Bijwadi Tal-Indapur, Dist-Pune. It is 1.5km off Pune-Hyderabad National Highway (NH 9). Initial crushing capacity of the KSPSSKL was 1750 TCD. On account of modernization of the plant from time to time and by effective utilizing of in-built capacity of the plant the KSPSSKL has achieved a crushing capacity of +5,000 TCD since 1999-2000. distillery of 30 KLPD capacities. The sugar factory also operates a molasses based

Geographical Location

18008N; 74057E 523 MSM

Nearest City/Town Road

Indapur is the nearest town 08 km from the site. The site is located off Pune-Solapur National highway No. 09. Distance- 1.5 km from factory site Baramati railway station 45 from the site. Pune is the nearest airport 135 km from the site. Village Rajwadi 2.5 Kaulthali 3.5 Km National Highway 9 - 1.5km Village Ramoshiwadi 1.5Km

Railway Station Air Port East West North South

2.0

HIGHLIGHTS OF THE PROJECT Karmayogi Shankarraoji Patil Sahakari Sakhar Karkhana Limited (KSPSSKL)

Project Proponent

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Location of the project

Mahatma Phule Nagar, village Bijwadi Tal-Indapur, Dist-Pune Maharashtra Email : indrasugar@yahoo.com Ph no: 02111-2886103/123/144/146 Fax : 02111 - 286105

Land

18 acres built up area after expansion, 6 acres provided for green belt development

Project

Modernization cum expansion of sugar unit from 5,000 TCD to 8,000 TCD along with cogeneration unit of 19.5 MW installed capacity

Product

i) ii) iii) iv) v)

White Sugar: 920 MT/Day Bagasse : 2240 MT/Day Molasses ; 320 MT/Day Press mud: 320 MT / Day Power: 18.585 MW electricity

Running Days Main Raw Material

210 Days i) ii) iii) iv) Sugar Cane: 8,000 MT/Day Lime : 9.76 MT/Day (0.15% Cane ) Sulfur: 4.64 MT/Day (0.05% Cane ) Bagasse : 1,690 MT/day

Water Requirement Fuel

2,835 m3/day Ujani dam (Permission available )

Bagasse 1690 MT/day

3.0 Need of Project and its importance to the country and region: India is the second largest producer of sugar over the globe. With more than 45 millions of sugar cane growers in the country, the bulk of the rural population in India depends on this industry. One of the agro-based industries in India, the sugar industry is the second largest agricultural industry followed after the textile industry. Maharashtra Sugar Industry is one of the most notable and large-scale sugar manufacturing sectors in the country. There are few major reasons for the expansion of the sugar factory and increasing availability of cane and pressing demand of the local share holder farmers to crush all the cane they grow is the foremost reason. Since, the Karkhana is located
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towards east of the Pune district, where an excellent network of canals exist. The command area of the KSPSSKL comprises 112 villages from Indapur and Daund talukas of Pune district and Karmala, Malshiras & Madha talukas of Solapur district. Out of total command area of the KSPSSKL, 70% area is irrigated by Ujani and 30% area is under well irrigation. Nira right bank canal project also covers some area under irrigation. Hence the availability of water is ample in the area; and thus the area under cultivation of sugar cane is going on increasing every year. Increase in the cane production can also trace though the figures of cane crushed by the KSPSSKL during previous 10 years. Table 1: Production of Sugar cane and cane crushing for last 10 Years

Sr. No.

Year

Total Cane crushed (MT)

Total Cane production in area (MT) 87,000 3,53,000 8,00,000 5,00,000 5,00,000 10,46,000 13,50,000 13,25,000 11,00,000 14,00,000

1 2 3 4 5 6 7 8 9 10

2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10

5,91,560 8,08,516 7,49,863 4,16,597 3,98,077 8,76,907 12,34,935 12,11,128 9,89,976 12,83,800

In season 2010-11 the expected crushing will 13, 59,500 where as the production or availability is about 16, 00,000 MT. The above table infers that there is ample sugarcane available in the command area of the KSPSSKL. However, the crushing capacity is a limiting factor to fulfill the demand of the local farmers. The sugar cane cultivation is anticipated to grow at least for next few seasons. Thus, the KSPSSKL has to develop its infrastructure to crush all available cane in the command area. Hence, the management has decided to modernize the existing 5,000 TCD sugar factory and install a 3,000 TCD unit so as to increase the cane crushing capacity of the KSPSSKL to 8,000 TCD. The present peak demand of power is more than 16,000 MW and only 13,000 MW is met thorugh various sources. Considering the immediate requirements of energy and till the end of the present period, about 5,737 MW shall be installed during the next four years, hence the government of Maharashtra permitted such an sugar factory to utilize the

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resource-able energy fuel and to make a power which will helps to decrease the energy deficit. While doing this, optimum utilization of the available resource is strived by the management, by using a renewable energy source of bagasse. Bagasse is a by-product of sugar factory, used as a fuel for boilers that produces process steam. Bagasse-based cogeneration project is an effort for efficient use of available bagasse and steam to generate the power for to fulfill the captive need and export the surplus to the state grid. Hence, the KSPSSKL is installing a new 15MW capacity steam turbine, in addition to existing 1.5 and 3MW. Thus, it will have an installed capacity of 19.5MW and it will produce an electricity of 18.585MW. 4.0 Demand- Supply Gap

The present peak demand of power is 15,988 MW and only 11,800 MW is met during the period 2009. Including the present deficit and projected growth rate, about 18,759 MW shall be added till the end of 12th plan period. Considering the immediate requirements of energy, another 5,600MW shall be added during 11th plan period ending 2012; hence the Government of Maharashtra permitted such an sugar factory to utilize the resourceable energy fuel and to made a power which will helps to decrease the energy deficit. Table 2: Data on Monthly Demand~ Supply gap in MW in the state for Year 2009

2009 Month
Jan-09 Feb-09 Mar-09 Apr-09 May-09 Jun-09 Jul-09 Aug-09 Sep-09 Oct-09 Nov-09 Dec-09

Demand
14,926 15,272 15,332 15,195 15,304 14,387 13,044 15,171 14,800 15,572 15,988 15,386

Availability
10,151 11,010 11,536 11,325 11,179 11,175 10,317 11,384 11,598 11,714 11,883 11,713

Short fall*
4,775 4,262 3,796 3,870 4,125 3,212 2,727 3,787 3,202 3,858 4,105 3,673

*Peak shortfall on a particular day of the month V. Import vs. Indigenous production
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The process is straight line and the technology even for the pollution control/disposal is available indigenously VI. Export Possibility The finished products viz. Sugar, have export possibility and the surplus power generated form cogeneration will be export to the local grid. VII. Domestic / export markets Local as well as international market is available for sugar and molasses. Electricity will be exported to the local grid of MSEDCL. VIII. Employment Generation: The KSPSSKL requires educated and skilled staff at expanded sugar factory as well as cogeneration unit. This requirement is furnished table 3. The indirect employment is anticipated to be plenty, since the project is going to produce surplus power. This power may be used to run various businesses and agricultural activities Table 3: Employment Potential of Sugar & Cogeneration Project

Engineer Department Designation Assistance Engineer Electrical engineer Electrical supervisor Mill & Boiling House Fitter (A grade) Mill & Boiling house Fitter (B grade) Turbine attendant Electrician Wireman Total Staff

Manufacturing Additional Manpower department Number Designation Number Designation Number 04 01 04 08 04 04 04 07 40 Manufacturing Chemist Juice Supervisor Pan In charge Pan man Quadruple met Centrifugal Met Sugar house Clerk -------Total 04 04 04 04 04 04 04 -----28 Instrument engineer 01 Mechanical Engineer 01 Electrical Engineer Instruments Technician Electrical Supervisor Mechanical Supervisor Switch board attendant -----Total 80 Plenty 01 04 01 01 03 ----12

Total man power for sugar expansion along with Cogeneration (Engineer + Manufacturing + Additional ) Expected indirect man power

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2.0 Project Description I. Type of project The project is modernization cum expansion of sugar unit from 5,000 TCD to 8,000 TCD along with cogeneration unit of 19.500MW installed capacity. Bagasse is a byproduct of sugar unit has tremendous potential as a renewable source of energy. Hence, cogeneration unit is interlinked with sugar unit. II. Location with coordinate Project coordinate : 18008N; 74057E 523 MSM

project boundary :

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Proposed Sugar Unit

Proposed mill house

Proposed Cogeneration house

III.

Details of alternative site consider and basis of selecting the proposed site:

The proposed project is actually modernization cum expansion of sugar factory and installation of 15MW turbine. KSPSSKL already possess adequate land i.e. more than 200 acres, for the new set up as well as its ancillary units such as pollution control system, greenbelt, etc. Considering these facts, the point of alternative site search becomes irrelevant. IV. Size or magnitude of operation

Modernization cum expansion of sugar unit from 5,000 TCD to 8,000 TCD along with cogeneration unit of 19.500 MW installed capacity V. Project description with process details

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a) The Process Sugar

SUGAR MANUFACTURING PROCESS Cane Supply Boiler

Steam

Milling

Bagasse

Juice Lime & Sulphur House Rotary vacuum filter Press mud

Sulphitation

Clarification Evaporation

Pan boiling Crystallizer

Centrifugals

Sugar

Packing

Figure1: Flowchart of sugar manufacturing process

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Extraction of Juice

The sugarcane is passed through preparatory devices like knives for cutting the stalks into fine chips before being subjected to crushing in a milling tandem comprising 4 to 6 roller mills. In the best milling practice, more than 95% of the sugar in the cane goes into the juice Clarification

The treated juice on boiling fed to continuous clarifier from which the clear juice is decanted while the settled impurities known as mud is sent to rotary drum vacuum filter for removal of unwanted stuff called filter cake is discarded or returned to the field as fertilizer. Evaporation

The syrup is again treated with sulphur dioxide before being sent to the pan station for crystalization of sugar. Crystalization takes place in single-effect vacuum pans, where the syrup is evaporated until saturated with sugar. At this point seed grain is added to serve as a nucleus for the sugar crystals, and more syrup is added as water evaporates. Centrifugation

The massecuite from crystallizer is drawn into revolving machines called centrifuges. The perforated lining retains the sugar crystals, which may be washed with water, if desired. The mother liquor molasses passes through the lining because of the centrifugal force exerted and after the sugar is purged it is cut down leaving the centrifuge ready for another charge of massecuite. Gradation & Packing

The final product in the form of sugar crystal is dropped through pan section and this sugar is graded and picked in 50 kg bags. The grade of the sugar depends on the size of the crystal viz. Small (S) and Medium (M) b) Process of Cogeneration The proposed cogeneration, aims at improving the energy efficiency of the sugar factory significantly and enabling the plant t o generate surplus power from its cane crushing operation. This surplus power will be exported to the state electricity grid. Energy efficiency and the export of power to the grid are made feasible due to the availability of high pressure and high temperature steam and by the utilization of the available bagasse. The flow chart for generation of the power in cogeneration as shown in following figure

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Surplus to Electricity grid Power Captive Power

Bagasse

Boiler

Steam Turbo Generator

PRDS

Exhaust Steam

HP Heater

Sugar factory and allied units

Figure 2: Process flow diagram of Cogeneration power plant VI. Raw materials required along with estimated quantity, like source market area final product, mode of transport of raw materials and finished good products Table 4: Availability raw materials & finish product and transport mode Raw Estimated source market final product Estimated source quantity MT/day local Plantation 920 White Sugar Lime 9.76 Pune Mumbai Solapur Sulfur 4.64 Pune Mumbai Solapur
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Transport mode

materials quantity MT/day Sugar Cane 8,000

market

Maharashtra India

Truck Tractor Bullock card

Bagasse

2,240

Pune

Truck Tractor

Molasses

320

Maharashtra

Tankers

Bagasse

2466

Own sugar factory

Burnt boiler

in

1690

Local

Conveyor

Power MW

18.585

Local grid

By cable

VII.

Resource optimization / recycle and reuse envisaged in the project

Modernize of the existing 5,000 TCD sugar factory and install a 3,000 TCD unit so as to increase the cane crushing capacity of the KSPSSKL to 8,000 TCD. While doing this, optimum utilization of the available resource is strived by the management, by using a renewable energy source of bagasse. Bagasse is a by-product of sugar factory, it will be used as a fuel for boilers that produces process steam. Bagasse-based cogeneration project is an effort for efficient use of available bagasse and steam to generate the power for to fulfill the captive need and export the surplus to the state grid. Hence, the KSPSSKL is installing a new 15MW capacity steam turbine, in addition to existing 1.5 and 3MW. Thus, it will have an installed capacity of 19.5MW and it will produce an electricity of 18.585MW. Water and its source Table 5: Water requirement and availability Particular Water Domestic Use (Drinking, Toilet, etc.) Gardening* Industrial purpose Process Washings Boiler feed** Spray pond ** Others (Pump gland sealing) Total Bagasse Power 1800.00 300.00 200.00 500.00 5.00 2835.00 1690 MT/day 10.50 MW Own factory Own factory 10.00 Nil Ujani dam Permission available is Estimated quantity Source

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IX) Quantity of waste to be generates & scheme for their disposal

Bagasse - Generation 2466MT/D And utilization as fuel 1690MT/D

Sugar Cane Sugar unit

Molasses 320MT/day

Boiler feed water

Cogeneration unit
Boiler/furnace Boiler blow down 200m3/d Steam

Filter cake 320MT/day Fly and bottom ash (Max. 33.80 MT/Day) Exhaust Steam

STGs
18.585 MW Electricity

Bio-compost unit
Effluent from sugar unit 800m3/day Sent to own 30KLPD distillery unit

Cooling treatment

Other wastewater ~50m3/day Sludge drying bed

Sugar factory ETP capacity 1700m3 Effluent 850m3 Recycled to sugar factory OR spray pond make-up

Sludge

Treated water for greenbelt/irrigation

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Figure 3: Quantity of waste to be generates & scheme Table 6: Waste Management Waste Material Bagasse Solid 2466MT/day Used as a Fuel at sugar/Cogeneration and distillery project Molasses Pressmud Liquid solid 320MT/day 320MT/day Used as a raw material for distillery Used as a raw material for making biocompost, final disposal system for the spentwash i.e. distillery effluent Ash Solid 33.80MT/day Used as a filler material for bio-compost, final disposal system for the spentwash i.e. distillery effluent Type Quantity Upshot

X) Schematic representation of the feasibility drawing which give information of EIA purpose Sugar factory modernization and expansion capacity from 5,000 to 8,000TCD

Sugar industry 5 (i) Categorization as per EIA notification 2006 (SO 1533), as amended on Dec. 2009 (SO 3067)

Bagasse based Cogeneration Project i.e. Thermal power plant based on biomass energy Capacity: 19.500MW

Power plant 1(d)

Screening category B1

Scoping: State Expert Appraisal Committee And State EIA Authority

4. Site Analysis I) Connectivity Table 7: Connectivity of the project Nearest City/Town Indapur is the nearest town 09 km away from the site.

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Road

The site is located off Pune-Solapur National highway No. 09. Distance- 1.5 km from factory site Also a network of State highways and Zilla Parishad roads exist in the vicinity

Railway Station Air Port

Baramati the nearest railway station 45 from the site. Pune is the nearest airport 135 km from the site.

II) Land form land use and ownership Within 10km Area There is no tropical forest There is no biosphere reserve There is no national park There is no wildlife sanctuary There is no coral formation Any sensitive stations are safe away Pune-Solapur National Highway (NH 9) 1.5 km Ujani back water at a distance of 8.00 km Nearest Railway station Baramati 45km and Bhigwan 40km from the site Nearest airport Pune 150 km from the site

The project is proposed within existing sugar factory premises, the land is already used for industrial purpose. It is owned by the KSPSSKL. The terrain is almost flat and requires hardly any leveling. III) Topography The terrain is almost flat, no hills in the surroundings. The geographical coordinates of the area are 18008N and 74057E. The proposed site is 523 meter above the mean sea level.

IV) Existing land use pattern (Agriculture, non agriculture, forest, water bodies including CRZ), shortest distance from the periphery of the project forest, national park, wild life sanctuary, eco- sensitivity area, water bodies Distance from HFL line, CRZ notification for notified industrial area.

Table 8: Information of reserve and notified land in area

The project is proposed within existing sugar factory premises, the land is already used for industrial purpose. The project surrounding land is either fallow land or used for agricultural purpose. Followed by agriculture, the land is used for residential purpose. There are 23villages in the study area 10 km radius. The canals of river Nira is flowing in west to East direction at a radial distance of 1.0 Km from the plant site. The Ujjani dam is
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at an aerial distance of about 8 km from the site towards north and north-east. The nearest residential area to the factory is at a distance of 1.5 km towards south. Towards east west and north the settlement areas are beyond 3km distance. There is an agricultural and fallow land in the surrounding area of the site. A small artificial pond is present towards west of the site at a distance of 2.5km. There is no sanctuary, bio-sphere reserve or national park in the 10km radius area. The nearest sanctuary to the site is Great Indian Bustard bird sanctuary at Nanaj, district Solapur approximately 140km from the site. VI) Existing Infrastructure Raw Material: Sugar Cane:

The viability of the proposed expansion of sugar unit as well as cogeneration unit depends on the availability of sugar cane. Table 8, describes the cane production of the operational area of the KSPSSKL and the cane crushing performance of the KSPSSKL for last ten years. Table 8: Production & crushing performance for last ten years Sr. No. Year Total Cane production in area (MT) 1 2 3 4 5 6 7 8 9 10 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 87,000 3,53,000 8,00,000 5,00,000 5,00,000 10,46,000 13,50,000 13,25,000 11,00,000 14,00,000 5,91,560 8,08,516 7,49,863 4,16,597 3,98,077 8,76,907 12,34,935 12,11,128 9,89,976 12,83,800 Total Cane crushed (MT)

Above table shows the raw materials potential in the command area Irrigation and transportation Facilities:

The KSPSSKL is located in the vicinity of back water of Ujani reservoir (approx. 8Km towards north). Thus more than 70% of the area of agricultural land is under irrigation, where as remaining area found very good ground water level. Hence, farmers prefer a cash crop such as sugar cane. Another important factor is proximity of National Highway (NH 9) and also network of state and Zilla Parishad roads in the operating area of the KSPSSKL
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Fuel

The availability of bagasse is mainly dependent upon the crushing of cane at sugar factory. The cane crushing data of the factory for five seasons i.e. 2005-06 up to 2009-10 has been tabulated as follows.
Table 9: Bagasse production for last five seasons (i.e. 2005-06 to 2009-10) Year 2005-06 2006-07 2007-08 2008-09 2009-10 Sugarcane Crushed (MT) 3,98,077.00 8,76,907.00 12,34,935.00 12,11,128.00 9,89,976.00 Bagasse produced (29%) 1,15,442.00 2,55,173.00 3,58,131.00 3,51,227.00 2,87,093.00

Thus, from the above data it can be inferred that the sugar factory is having adequate source of fuel i.e. bagasse. Water:

At present sugar factory draw water from Ujani dam the permission letter attached at the end of report as an annexure. The water requirement for proposed project will be around 2835m3/day. Water conservation will be achieved by recycling of water. Water from the reservoirs will be used for all plant and fire-fighting purposes diesel driven pump (capacity as per TAC recommendation) along with one electrical pump will be installed for supply to all fire hydrants and sprinklers

Table 11: Water consumption details

Activity 1. 2. 3 4. 5. 6. 7. 8. Domestic Use (Drinking, Toilet, etc.) Gardening* Industrial purpose Process Mill Washings Boiler feed** Spray pond ** Others (Pump gland sealing) Total
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Consumption (M3 /day) 10.00 Nil 1800 320 200 500 5 2835

Power

Power generation and consumption of the proposed project will be as follows.

Table 12: Power generation & consumption

Power Generation From 15 MW BP type TG set From De-aerated 1.5MW BP type TG Set From 3MW BP type TG set TOTAL Power Consumption Sugar Factory ETP Office, Colony, Workshop, Other Total Surplus exportable power (During season only) 10.500MW 0.075MW 0.350MW 10.925 7.660 MW 14.085 MW 1.500 MW 3.000MW 18.585 MW

VI) Soil classification These soils have less depth and course texture thereby making them less fertile than black soils. On the other hand deep black and medium deep soils VIII) Social Infrastructure available Schools (Primary as well as secondary) Colleges (Science, commerce, Arts, engineering, medical, pharmacy, education) Health centers, dispensaries, hospitals ST bus Electricity Drinking water supply Banks (Cooperative as well as nationalized) and credit societies Veterinary centers

The present project is proposed by one of the leading and progressive cooperative sugar industry from western Maharashtra. During the period of establishment, the industry received a strong leadership in the form of Late shri. Shankarraoji Patil. Presently Honorable Minister Shri Harshavardhanji Patil is leading the KSPSSKL. The sugar factory has already initiated several activities for the development of the region. Some of the prime activities are as follows.

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 It is providing good quality seed (Cane) material and fertilizers to member farmers. It has established an educational facility through which academic as well as technical education has been made available to the nearby students It is running a cooperative consumer society. It is operating soil testing facility and provides bio-fertilizers at very nominal price

It helps farmer to obtain loan from local credit societies and banks
5. Planning I) Planning concept Type of industry : Modernization cum expansion of sugar unit from 5,000 TCD to 8,000 TCD along with cogeneration unit of 18.585 MW total power generation capacity Facilities for transport: KSPSSKL is situated just 1.5 Km off the National

highway 9. All the villages from the command area of KSPSSKL are accessible by asphalted (pucca) road, operational year around. Hence, public transportation is available. State transport (ST) buses ply on schedule and connect almost all the villages of the command area. Town and country planning / Development authority classification: is the local authority. The

The project is located at village Bijawadi Grampanchyat

Bijawadi panchyat has issued No Objection Certificates (NOC)for this proposed project. This industry was established since 1984-85. Since, then the land is used for industrial purpose and will be used for the same purpose only. II) Population projection: No population flux is anticipated due to the project III) Land use Planning: 18 acres for sugar and cogeneration (including expansion and new turbine set), 6 acres provided for green belt development IV) Assessment of infrastructure Demand (Physical & Social) The basic infrastructure such as roads, electricity, transportation, drinking water supply, health centers and hospitals, school, colleges, sanitation facilities are available in the vicinity. The proposed project is not going to exert any unbearable load on any of these resources. In fact, the project could reduce the electricity load by generating 18.585MW of power. V) Amenities/ Facilities KSPSSKL is already having following facilities. Canteen, Laboratory, Guest house, rest room, petrol pump, Hotels, medical facilities, drinking water plant, soil & water testing laboratory etc.

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6. Proposed Infrastructure I) Industrial Area : (Processing Area) : 18 Acres II) Residential Area (Non processing Area): 25 Acres already exist III) Green belt IV) Social Infrastructures : 06 Acres (in addition to existing) : All type of infrastructure is already available in the vicinity. V) Connectivity : National highway 9 and state highway as well as zilla parishad road infrastructure exist

Road Railway Air Port VI)

Pune-Solapur National highway No. 09. - 1.5 km from factory site Baramati the nearest railway station 45 from the site. Pune is the nearest airport 135 km from the site.

Drinking water management

KSPSSKL draws water from Ujani reservoir. It operates a special water treatment plant to supply the drinking water to factory as well as the staff colony VII) Industrial waste management The sugar factory has been upgraded in previous year and installed the additional bio-tower for reduce the organic load and enhance the treatment capacity up to 1,700m3/day to treat the effluent coming from sugar unit along and cogeneration unit. Wastewater from other sources such as spray pond, excess condensate, etc will be collected cooled in the cooling pond. This effluent dont have any significance COD or BOD or any polluting content, except high temperature, hence all collected effluent will be cool and directly used for the irrigation purpose. The treated water shall be mainly reused for gardening/irrigation activity. The sanitary wastewater shall be disposed

by using septic tank and soak pit system. Thus, due to proper treatment of effluent and disposal of treated water within the factory premises, overall impact of wastewater from the unit on the surrounding water bodies or land is envisaged to be minor negative impact.

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Table 13: The ETP scheme Preliminary Treatment Oil and grease removal machine screen chamber Equalization, Neutralization chamber primary clarifier Secondary treatment Bio-tower Activated Sludge Process Disposal for irrigation

Figure 3: schematic structure of ETP Table 14: Solid waste generation, treatment & Disposal Waste Material Bagasse Solid 2466MT/day Used as a Fuel at sugar/Cogeneration and distillery project Molasses Liquid 320MT/day Used as a raw material for distillery Type Quantity Upshot

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Pressmud

solid

320MT/day

Used as a raw material for making bio-compost, final disposal system for the spentwash i.e. distillery effluent

Ash

Solid

33.80MT/day

Used as a filler material for bio-compost, final disposal system for the spentwash i.e. distillery effluent

VIII)

Power Requirement and source

Proposed cogeneration will generates the power which is the source for all industrials utilization as well as all subunits and needful uses the generation and consumption of power is as follows Table 15: Power balance Total Generation of power from T,G sets of 15 MW and 1.5 & 3.0 MW Sugar Factory power cogeneration unit consumption administration, colony load. Workshop and ETP Total Captive consumption, Surplus power to be exported to state grid 10.500 MW 0.425 MW 10.925 MW 07.660 MW 18.585 MW

The total energy exported by the cogeneration power plant during the crushing season would be 26.473 MU (7.66 MW X 160 days X 24 hrs/day X 0.9) @90 % factor.
7. Rehabilitation and Resettlement (R & R) Plan Proposed expansion of sugar unit along with additional 15MW turbine to make cogeneration of 19.5MW installed capacity, will be located within the existing sugar industry, hence there is no need of rehabilitation and resettlement (R & R) Plan. 8. Project Scheduled & Cost Estimates Table 16: Project scheduled & cost estimate 1. 2. 3. Date of start of constriction (Anticipatory) Date of completion (Anticipatory) Project cost Aug. 2012 Oct.2013 Rs. 121.00 crores

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4.

EMP cost

Rs. 4. 50 crores

9. Analysis of proposal (Final Recommendations) a) Improvement in the social infrastructure: Some prime benefits of the project are highlighted below The sugar factory expansion will fulfill the pressing demand of farmers to crush all the available cane, so local farmer will get benefitted It will save the money indirectly for reduce in the transportation of cane to nearby other factory, and reduce the environmental consequences due to it Shareholders are likely to get good rates for the cane Captive power demand of the factory is going to be fulfilled Cogeneration is of back pressure route, which requires lesser fresh water and wastewater generation is also minimal and mild polluted The process is straight line and the technology even for the pollution control/disposal are available indigenously Waste products generated in the sugar factory are useful as a raw material and fuel at sugar factory and its own distillery Direct employment opportunities for 80 local youths Indirect employment to many since, the project will be exporting electricity to local grid The aggregate effect of the project is likely to boost the local economy The employment opportunity will be for local people Factory will be go for take a CDM benefits in the form of money after this project b) Improving power reliability Proposed cogeneration system is focused on effective utilization of energy. It will provide high-quality and reliable power and heat energy to the industry. It also helps to reduce the electricity load of local grid. In this way, cogeneration project effectively assist or support the electric grid, by providing enhanced reliability in electricity transmission and distribution.

Prefeasibility Report Sugar and Cogeneration Project Karmayogi Shankarraoji Patil SSKL, Indapur
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