pre- feasibility report -...

PRE- FEASIBILITY REPORT

For

Proposed expansion of

Sugar Plant from 3500 TCD to 7500 TCD,

Power plant from 4 MW to 24 MW

&

Distillery of 60 KLPD

Trident Sugars Limited Kothuru-B & Didgi Village,

Zaheerabad Mandal

Sangareddy District, Telangana

Trident Sugars Limited

Sugar, Co-gen & Distillery

Pre-Feasibility report

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1.0 EXECUTIVE SUMMARY

Trident Sugars Limited is an existing Sugar plant operating at Kothur – B & Didgi Villages,

Zaheerabad mandal, Sangareddy District, Telangana.

The following is the capacity of the existing Integrated Sugar Complex

Sr. No Unit Capacity

1. Sugar 3500 TCD

2. Captive power plant 4 MW

Total area already in possession of the management is 129.1 acres.

Now the company has proposed to enhance the capacity of the Sugar plant & Power plant

and new Distillery unit. The proposed expansion and new Distillery unit will be taken up in

the existing plant premises only.

The following will be the capacities after proposed expansion


Existing Expansion Total

1. Sugar 3500 TCD 4000TCD 7500 TCD

2. Power plant 4 MW

(captive)

20 MW

(co-gen)

24 MW

3 Distillery -- 60 KLPD 60 KLPD

The following is the summary of the proposed expansion project

S. No. Parameters Description

1. Existing Plant capacity Sugar – 3500 TCD

Co-gen power – 4 MW

2. Proposed expansion Sr.

No Unit

Capacity



2. Power

plant

4 MW

(captive)

20 MW

(co-gen)

24 MW

3. Distillery -- 60 KLPD 60 KLPD

3. Total area already in

possession

129.1 acres

4. Sy. No. of the land survey no. of Kothuru - B Village

12, 18, 19, 20, 21, 22, 23, 24, 25, 26/1, 48 & 173

Survey no. of Didgi village

13 & 13A

5. Project cost

(expansion)

Rs. 252 Crores




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6. Water requirement

a. Water requirement for

existing plant

108 KLD

b. Water requirement for

the proposed

expansion

1100 KLD

c. Total water

requirement

1208 KLD

d. Source of water Ground water

Permission for drawing water from ground will be

obtained from SGWB

7. Waste water

generation

a. Effluent generation

from the existing plant

360 KLD

b. Effluent generation

from the expansion

1640 KLD

8.

Existing Effluent

treatment

Sugar Plant

Effluent generated from the Sugar plant is being treated

in specially designed ETP and treated effluent is being

utilized for greenbelt development after ensuring quality

of treated effluent with standards stipulated for onland

for irrigation by CPCB / SPCB.

9. Effluent treatment

(proposed expansion)

Sugar Plant

Effluent generated from the Sugar plant will be treated in

specially designed ETP and treated effluent will be

utilized for greenbelt development after ensuring quality


irrigation by CPCB / SPCB.

Power Plant

Cooling tower blowdown, DM plant regeneration water

and Boiler blowdown will be treated in neutralization

tank and treated effluent will be utilized for greenbelt

development / ash conditioning / dust suppression in the

plant premises after ensuring quality of treated effluent

with standards stipulated for onland irrigation by CPCB /

SPCB

Distillery Plant

Spent wash will be concentrated through Multiple Effect

Evaporators and concentrated Spent wash thus

obtained will be bio-composted along with the

pressmud.




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The condensate generated during evaporation will be

treated in Sugar Plant ETP and will be utilized for

greenbelt development / ash conditioning / dust

suppression in the plant premises after ensuring quality


for irrigation by CPCB / SPCB

10. Steam requirement

(existing)

Steam requirement existing sugar plant is being met

from existing 20 and 32 TPH boilers

11. Steam requirement

(expansion)

Steam required will be met from proposed 100 TPH

12. Air emissions (existing) Emissions from Project are Particulate matter, SO2 and

NOx

Wet scrubbers has been provided to boiler to bring down

the particulate matter to below 100 mg/Nm3.

13. Air emissions

(expansion)

Emissions from Project will be Particulate matter, SO2

and NOx

ESP will be provided to 100 TPH Boiler to bring down

the particulate matter to below 50 mg/Nm3.

The exhaust gases from the boiler will be discharged

into the atmosphere through a stack of 80 m height for

effective dispersion of gases into the atmosphere.

14. Noise levels Ambient Noise levels are within the standards

prescribed by MoE&F Notification and its amendments

and after proposed expansion also similar practice will

be followed.

15. Solid waste generation

(existing)

Sugar Plant

press mud generated from the Sugar plant is being

given as manure to farmers

Bagasse generated from the Plant is being used as

fuel for boiler

ETP sludge generated is being utilized as manure

Boiler ash is being given as manure to farmers

16. Solid waste generation

(expansion)

Sugar Plant

press mud generated from the Sugar plant will be

used as filler material for Bio-composting

Bagasse generated from the Plant will be fuel for

power generation.

ETP sludge generated will be utilized as manure

Power Plant

Ash generated form the power plant will be given to

farmers as organic manure when bagasse / biomass is

used as fuel and will be disposed off to brick/cement

manufacturers when coal is used as fuel.




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Distillery

Yeast sludge generated will be bio-composted along

with concentrated spent wash

17. Noise levels Ambient Noise levels are within the standards

prescribed by MoE&F Notification and its amendments

and after proposed expansion also similar practice will

be followed.




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2.0 INTRODUCTION:

2.1 Identification of project and Project Proponent Trident Sugars Limited (subsidiary of Natems Sugars Pvt. Ltd.) is an existing Sugar plant

operating at Kothur – B & Didgi Village, Zaheerabad mandal, Sangareddy District,

Telangana.

The Promoters

The following is the list of promoters of the company

S.No Name Designation

1. Shri Nandakumar Ramanujalu Chairman

2. Shri Dr. R.N. Ramnath Vice Chairman

3. Shri Ramamurthy Director

4. Shri.Guruvayurappan Margabanthu Director

2.2 Brief Description of nature of Product:

2.2.1 Sugar

Sugar known as sucrose or saccharose is an anhydrous crystalline organic product of

comparatively 99.96% purity. The physical properties of sucrose are defined as follows

CRYSTALLINE NATURE:

Sucrose crystals are hard and belong to the mono-clinic system, characterized by three

axes of unequal length. Density of sucrose is equal to 1.606 gm/cu.cm. The presence of

impurities in sugar have a remarkable influence on the formation of the crystals.

SOLUBILITY:

Sucrose is very soluble in water and in dilute ordinary alcohol. The solubility in water

increases with the rise in temperature, such that for a 10% sucrose solution, the boiling point

is 100.04 Deg.C and for a 90% sucrose solution the boiling point is 130 Deg.C. It is insoluble

in chloroform, in cold absolute alcohol, either and glycerine.

SPECIFIC GRAVITY:

The specific gravity of sucrose varies from 1.033 to 1.106 according to the concentration of

the solution. The density of the sugar solution is determined in practice by brix and baume

spindles or balling saccharimeter.




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OPTICAL ROTATION:

Sucrose and glucose rotate the plane of the polarised light in a `clockwise‘ direction or to the

right and is called dextro-rotatory. Fructose, rotate in a `counter clock wise‘ direction or to the

left and is known as levo-rotatory. The specific rotation of sucrose is 66.5 Deg.

CHEMICAL PROPERTIES:

Dry sugar (sucrose) melts at 160 Deg.C into a thick transparent liquid which on cooling again

becomes crystalline. If heated for a long time at 160 Deg.C sucrose splits up into glucose

and levulosane. At higher temperatures between 190 to 220 Deg.C the decomposition is

more complete and caramel is produced. On further, heating, carbondioxide, carbon

monoxide, acetic acid and acetone are produced.

In the presence of moisture, sucrose decomposes at 100 Deg.C and becomes dark in colour

liberating water. On prolonged heating of sucrose at the boiling point and at ordinary

pressures, the dissolved sucrose combines with water and breaks up into glucose and

fructose in equal parts and the phenomenon is called Hydrolysis of Inversion.

APPLICATIONS:

The principal use of sugar as explained is as the sweetening agent in foods. The

consumption of sugar is distributed in the various sectors such as for daily human

consumption in household sector for food processing industries, beverages, baking industry,

confectioneries and miscellaneous users. Sucrose serves as raw materials for manufacture

of glucose, fructose, invert sugar syrups etc.

Non-food uses of sugar constitute a small amount of total sugar consumption. They include

use of sugar as a octacetate, a denaturant in ethyl alcohol, as sucrose diacetate, Hexa-

isobutyrate, octa benzoate, as mono and difatty acid esters for surfactants, as allyl sucrose,

in plasticisers and as raw materials for manufacture of various chemicals like glycerol,

mannitol etc.

Dextran is a polysaccharide produced from sucrose by the biological process and is a very

effective plasma volume expander. Sucrose when administered by intravenous infusion

relieves shock and prevents loss of body fluids after excessive burns, wounds or infectious

diseases. Other industries wherein sucrose is finding application towards drying oil esters

for surface coating industries and sugar derived detergents.




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PRODUCT SPECIFICATIONS:

The specifications required for white sugar complying with Indian sugar standards are

defined as follows:

Characteristics Requirements

Moisture (%) weight 0.05% Max.

Pol 99.5% Min.

Reducing sugars (%) by weight 0.10% max.

Conductivity x [106] 100 max.

Sulphur dioxide (ppm) 70 max.

Calcium oxide (CaO) (mg/100gm) 30 max.

Turbidity, (%) by weight 15 max.

2.2.2 Power

Power is generated by converting the thermal energy of steam into electrical energy through

Turbo-generator.

The power generated will be utilized for meeting the power requirements for sugar, Distillery

and other auxiliaries. Remaining power after meeting the power requirement for the project,

will be exported to nearest sub-station.

2.2.3 DISTILLERY PRODUCTS

Extra Neutral Alcohol

ENA IS 6613 – 1972 is an Extra Neutral Alcohol, Basic raw material for IMFL.

Produced from Molasses, Sweet Swargam, Cane Juice and Grain etc.

Rectified Spirit IS 323 – 1959 Quality is inferior to ENA.

ENA is nothing but refined Rectified Spirit.

ENA Process is a physical process in which Aldehydes, Esters and Fusel Oils impurities

are separated by virtue of their difference in Boiling Points by steam Distillation.

ENA RS ETHANOL

01 Ethanol content percent by Volume at 15 . 6O C,Min

94.68 94.68 99.50

02 Acidity gms/100 ml1 Max 0.002 0.002 0.006

03 Residue on Evaporation gms/100 ml1 Max

0.002 0.005 0.005

04 Ester content gms/100 ml Max 0.01 0.02 0.02

05 Aldehydes gms/100 ml1 Max 0.004 0.006 0.006

06 PP Times, Minutes 30 Nil Nil




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2.3 Demand – Supply Gap:

The sugar industry today is facing fierce competitive situation due to fluctuations in sugar

prices in the national & international markets, higher cane prices to be paid to the cane

growers, rising input costs, etc. The survival and growth of this industry depends on energy

efficiency, cost optimization and revenue generation from bi-products and down steam

products including power, ethanol, chemicals, etc.

The implementation of co-gen power plant concurrently with the sugar modernization cum

expansion project along with other by-products, right from the beginning goes a long way to

integrate the operations and improve sustainability.

Sugar Industry Overview

The origin of Indian sugar industry dates back to 1930, when the first sugar factory was set

up in the pre-independence era. Over the last 76 years, the sugar industry has steadily

grown and has become the backbone of the agricultural and rural economy in India. Today,

sugar is the second largest agro processing industry, next to the textile industry. India is one

of the largest producers of sugar in the world, with a production of over 15 million tones.

Sugar factories are located mostly in the rural India. They act as centers of development,

provide largest direct employment in the rural areas and contribute substantially to the

Central and State exchequers. The prospects of earning foreign exchange from export of

sugar are also quite high.

Sugar factories in India have capacities ranging from 1250 TCD to 20,000 TCD. The Indian

sugar industry has developed indigenous capabilities for design, manufacture, supply,

operation and maintenance, R&D and cane development. The major stakeholders of this

industry in India are Ministry of Agriculture, Govt. of India, Ministry of Consumer Affairs,

Food and Public Distribution, federations of co-operative and private sector sugar factories

at the national and the State levels, sugarcane growing farmers, equipment and technology

suppliers, research institutions, consultants and service providers, financial institutions and

Central / State Governments.

A total of 727 sugar factories are in operation today, with additional few new sugar factories

under implementation in different parts of the nation. The area under sugar cane cultivation,

sugar cane production, sugar cane crushing in sugar factories, average season days, sugar

recovery and sugar production has increased steadily over the years. The crop yield per

hectare and recovery has improved, particularly in the last decade.




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Following Table shows the distribution of sugar factories all over India.

Status of Sugar Factories in India

State Private Public Co-op Total

Assam 1 2 3

Orissa 4 4 8

Bihar 13 15 28

Uttar Pradesh 116 14 28 158

Uttarakhand 4 2 4 10

Punjab 8 16 24

Haryana 3 13 16

Andhra Pradesh 20 1 12 33

Telangana 10 1 11

Tamilnadu 27 3 16 46

Maharashtra 80 169 249

Gujarat 5 22 27

Madhya Pradesh 16 2 5 23

Kerala 1 1 2

Rajasthan 1 1 1 3

Karnataka 48 3 25 76

Pondicherry 1 1 2

Goa

1 1

Chattisgarh

1 1

Dadra Nagar & Haveli

1 1

West Bengal 2 1 3

All India Total 360 42 325 727

Source: Sugar India Year book, 2016

The Ministry of Consumer Affairs, Food & Public Distribution, and Government of India

revised the standard specifications for sugar plant & equipment, in the year 1987. The

special committee finalized specifications for economical capacity of 2500 TCD, expandable

to 3500 TCD, employing higher-pressure boiler and turbine configuration and efficient

equipment, with a potential to export incidental surplus power to the grid.

The Indian sugar industry was de licensed in the year 1998 vide press note No. 12 issued by

the Government of India, Ministry of Industry, Department of Industrial Policy and Promotion,

on August 31, 1998. The salient features of de licensing are as follows:

The sugar industry stands deleted from the list of industries requiring compulsory

licensing under the provisions of Industries Development and Regulation Act, 1951.

However, in order to avoid unhealthy competition among sugar factories to procure

sugarcane, a minimum distance of 15 km would continue to be observed between




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and existing sugar factory and a new factory, by exercise of powers under the Sugar

Control Order, 1966.

The entrepreneurs, who wish to de-license their sugar factory, would require filing an

Industrial Entrepreneur Memoranda (IEM) with the secretariat of industrial assistance

in the Ministry of Industry, as laid down for all de-licensed industries, in terms of the

press note dated August 2, 1991, as amended from time to time.

Entrepreneurs who have been issued Letter of Intent (LoI) for manufacture of sugar

need not file an initial IEM. In such cases, the LoI holder shall only file Part B of the

IEM at the time of commencement of commercial production against the LoI issued

to them. It is however open to entrepreneurs to file an initial IEM (in lieu of LoI /

industrial license held by them) if they so desire, whenever any variation from the

conditions and parameters stipulated in the LoI / industrial license is contemplated.

The statistics on economic and commercial performance for the industry is quite fluctuating.

The changes in the agro climatic conditions and sugarcane crop production, as well as the

sugar markets have been mainly responsible for these fluctuations. Efficiency, quality, and

integration have become order of the day for this industry. The industry has grown till today

over the last seven decades. The strength and capacity built so far will surely help meet

these challenges. The following are major options to meet these challenges:

a. Effecting substantial improvement in cane development and management,

including cultivation practices, varietals and water management, so as to improve

yield and recovery, without affecting the average fibre content.

b. Effecting visible improvement in the operational efficiencies and reduction of sugar

losses.

c. Effecting and sustaining improvement in energy efficiency, both in steam and

power, for saving of additional bagasse, for both sugar and by-products

manufacture.

d. Effecting adequate capacity building within and without.

e. Maximizing sugar exports for value addition.

f. Effective marketing in the national and international markets.

g. Product quality and diversification.

h. Commercializing the excess power capacity by exporting to utilities or to other bulk

power consumers.

Ministry of Consumer Affairs, Food & Public Distribution Department of Food & Public

Distribution Government of India has issued a revised order dated November 10, 2006,




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amending Sugarcane (Control) Order, 1966. The key provisions of this order are outlined

below:

a. No new sugar factory shall be set up within a radius of 15 km of any existing sugar

factory or another new sugar factory in a State or two or more States.

b. Before filing the Industrial Entrepreneur Memorandum (IEM) with a Central Govt., a

certificate from the Cane Commissioner or Director Sugar or specified authority of the

concerned State Govt. shall be obtained regarding the distance criteria re-defined as

above.

c. Submission of performance guarantee of Rs. 1 crore to Chief Director, Sugar, Dept.

of Food & Public Distribution, within 30 days of filing the IEM, as a surety for

implementation of the IEM within the stipulated or extended time.

d. The stipulated time for taking effective steps shall be 2 years and commercial

production shall commence within 4 years from the date of filing of the IEM, failing

which the IEM shall stand de-recognized and performance guarantee shall be

forfeited.

e. If an IEM remains un-implemented within the stipulated or extended time limits, the

performance guarantee shall be forfeited after giving a reasonable opportunity of

being heard.

f. The above clauses will be applicable for IEM already acknowledged as on the date of

this notification, but who have not taken effective steps for its implementation, duly

defined, shall furnish a performance guarantee of Rs. 1 crore to the Chief Director,

Sugar.

Ethanol Sector Overview

The use of alcohol as a drink is an age-old story. It appears that in India the technique for

fermentation and distillation was available even in the Vedic times. Alcohol is an integral part

of the Ayurvedic system of medicine also.

Carew & Co. Ltd. set up the first distillery in the country at Cownpore (Kanpur) in 1805 for

manufacture of Rum for the British army. The technique of fermentation, distillation and

blending of alcoholic beverages was developed in India on the lines of practices adopted

overseas, particularly in Europe.

The original use of alcoholic fermentation was of course for preserving fruit juices. Now the

fermentation is adapted for the preparation of fermented grain beverages and then distilled

beverages. The utilization of Ethanol, for industrial use is a recent phenomenon. It became

important towards the end of the Second World War.




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When large-scale production of alcoholic beverages was taken up, various Governments

found that alcohol was a good source for increasing government revenue through collection

of tax. When synthetic organic chemistry advanced rapidly, about a century ago, alcohol

became an indispensable chemical for this industry. However extensive manufacturing of

alcohol for industrial use was hampered due to excessive taxes. The problem was to device

a means for conserving government‘s interest in tax collection on potable alcohol and at the

same time making alcohol for industrial use relatively free of tax. Thus different governments

introduced the process of denaturation of alcohol for industrial use.

During the Second World War, the demand for the industrial alcohol increased 4-5 times,

above the prewar period, due to the production of smokeless powder for weapons. The

imports of molasses were hampered due to war conditions. This leads to evolving the

process of grain fermentation for meeting the requirement of Ethanol.

In India, after the protection granted to the sugar Industry in 1932, a large number of sugar

factories were established in the country, particularly in Maharashtra and Uttar Pradesh

where irrigation facilities existed for cultivation of sugarcane. Increase in sugar production

resulted in accumulation of molasses, which resultantly, caused unmanageable

environmental problems. At that time the demand for molasses was almost insignificant and

the sugar mills had to incur considerable expenditure for disposal of molasses. For resolving

these problems a joint committee of U.P. and Bihar was constituted in 1938 to explore the

possibilities of using molasses for developing alcohol-based industries. The Committee

recommended establishment of distilleries for production of alcohol, utilizing molasses as a

substrate.

The committee also recommended that alcohol produced by the distilleries should be

admixed with petrol, to supplement motor fuel. This helped in solving the problems of

disposal of molasses. It also filled up the gap in the demand and supply of motor spirit.

As a result, after meeting alcohol requirement for manufacture of gasohol, substantial

quantity of alcohol was diverted for production of alcohol based chemicals.

Present Status

Fossil fuels are declining. Transportation sector consumes more than 50% of the fuels.

Environmental degradation from these fuels is a major problem all over the world. World oil

production is expected to last till 2125 A.D., if consumption at the present level is




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maintained. On this background the use of Ethanol for fuel blending should be given a top

priority.

India requires ethanol for the following three major purposes:-

For potable liquor

For industrial use

For fuel blending

Today, the distillery industry of India uses only molasses for manufacturing alcohol. There

are handful of grain distillery units (e.g. Seagram Manufacturing Ltd.) and the alcohol

produced by them is used for captive use to make value added liquors.

All other liquor (IMFL) manufacturers use alcohol produced from molasses. In advanced

countries, liquor for human consumption is made only from grain alcohol. It is known that

alcohol produced from molasses can have residues such as sulphates, sulphites, higher

aldehydes, higher alcohols, higher acids and ketones etc., which are not present in alcohol

from, grains.

However, no such above-mentioned distinction is made in India. Thus alcohol produced only

from one source i.e. molasses is used for all 3 purposes (liquor, industrial use, fuel

blending). There is an urgent need to bring in above quality consciousness in the IMFL

industry and appropriate policy measures by the Govt.

Today, Indian distillery industry broadly consists of two parts:

One is alcohol production from molasses for industrial alcohol and two alcohol production

from molasses for liquor purposes.

Ethanol demand for fuel blending is a recent phenomenon. For this purpose, alcohol from

molasses is used.

The potable distillery producing Indian Made Foreign Liquor (IMFL) has a steady but limited

demand. The alcohol produced is now being utilized in the ratio of approximately 52 per cent

for potable purpose and the balance 48 percent for industrial purpose.




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Ethanol blending

Ethanol blending is the practice of blending petrol with ethanol. Many countries, including

India, have adopted ethanol blending in petrol in order to reduce vehicle exhaust emissions

and also to reduce the import burden on account of crude petroleum from which petrol is

produced. It is estimated that a 5% blending (105 crore litres) can result in replacement of

around 1.8 million Barrels of crude oil . The renewable ethanol content, which is a byproduct

of the sugar industry, is expected to result in a net reduction in the emission of carbon

dioxide, carbon monoxide (CO) and hydrocarbons (HC). Ethanol itself burns cleaner and

burns more completely than petrol it is blended into. In India, ethanol is mainly derived by

sugarcane molasses, which is a by-product in the conversion of sugar cane juice to sugar.

The practice of blending ethanol started in India in 2001. Government of India mandated

blending of 5% ethanol with petrol in 9 States and 4 Union Territories in the year 2003 and

subsequently mandated 5% blending of ethanol with petrol on an all-India basis in November

2006 (in 20 States and 8 Union Territories except a few North East states and Jammu &

Kashmir). This was also an attempt to reduce the Under-recovery of Public Sector Oil

Marketing Companies (OMCs). Ministry of Petroleum and Natural Gas, on 1 September,

2015, inter-alia has asked OMCs to target ten percent blending of ethanol in Petrol in as

many States as possible. In countries like US, blending is allowed upto 10%. Subsequent to

Brazil's bio-fuel programme, which began in 1976, close to 94% of cars sold in Brazil are

flexible fuel cars that can handle ethanol blends from 18 per cent upward .

Ethanol blending first found mention in the Auto fuel policy of 2003. It suggested developing

technologies for producing ethanol/ bio fuels from renewable energy sources and introducing

vehicles to utilise these bio fuels. Later, as per National Policy on Bio-fuels, announced in

December 2009, oil companies were required to sell petrol blended with at least 5% of

ethanol. It proposed that the blending level be increased to 20% by 2017.

Ethanol, being a by product of the sugar industry, was expected to be freely available.

However, Oil marketing companies (OMCs) were not even able to get bids for more than

50% of the amount offered for purchase . Further, the Government decided on 22.11.2012

that procurement price of ethanol will henceforth be decided between Oil Marketing

Companies (OMCs) and suppliers of ethanol. In addition, on 03.07.2013, it was decided that

ethanol would be procured only from domestic sources. This led to a rise in ethanol prices,

which to a great extent reportedly eroded the economy of the blend. At present, government

has permitted OMCs to implement the ethanol blending programme in notified 20 States and

4 Union Territories as per the availability of ethanol.

http://www.arthapedia.in/index.php?title=Under-recovery




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There are reportedly significant transaction barriers which impede smooth supplies of

ethanol for blending. In several States, State not only imposes levy on molasses but also

regulates the movement of non-levy molasses. Inter-state movement of ethanol requires No-

Objection-Certificates (NOCs) from the State Excise Authorities along with permits from

dispatching and receiving States. Most States impose ―Export/Import‖ duties on ethanol

leaving and entering their boundaries. There are some instances where Octroi is levied on

ethanol for entry into municipal limits. Hence States were requested by the Central

Government to liberalise restrictions on the supply of ethanol so that its blending with petrol

can be encouraged while improving the financial health of sugar sector and also liquidation

of cane dues of farmers.

As per the estimates given in Auto Fuel Vision and Policy 2025 issued in May 2014, blended

petrol is available only in 13 states and the average blend is 2%. During the sugar year

2014-15, OMCs have achieved a blending percentage of 2.3% as per the press release

dated 25 April 2016.

Hence, in order to improve the availability of ethanol, the Government, on December 10,

2014, fixed the price of Ethanol in the Range of Rs. 48.50 to Rs. 49.50, depending upon the

distance of distillery from the depot/installation of the OMCs. (The rates are inclusive of all

central and statutory levies, transportation cost etc, which would be borne by the Ethanol

suppliers). Fixation of ethanol price based on distance, has encouraged movement of

ethanol to longer distances, including States having lack of distilleries. Further, ethanol

produced from other non-food feedstocks besides molasses, like cellulosic and ligno

cellulosic materials including petrochemical route, has also been allowed to be procured

subject to meeting the relevant Bureau of Indian Standards (BIS) specifications.

2.4 Employment generation (Direct & Indirect):

The man power required for the proposed expansion will be 120 Nos. which is inclusive of

30 nos. on permanent basis and rest all will be on Temporary or contract basis.

S.No. Particulars No. Employees

1. Technical & Administrative Staff 20

2. Skilled & Semi Skilled 60

3. Unskilled & Helpers 40

Total 120




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3.0 PROJECT DESCRIPTION:

3.1 Type of the Project:

The proposed Project mainly involves

Production of Sugar from Sugarcane

Power generation using Bagasse / Coal as fuel

Production of Rectified Spirit / ENA / Ethanol using Molasses as raw material

3.2 Location:

Trident Sugars Limited is an existing Sugar plant operating at Kothur – B & Didgi Village,

Zaheerabad mandal, Sangareddy District, Telangana.

Now the company has proposed to enhance the capacity of the Sugar plant, Power plant

and install new Distillery unit. The proposed expansion will be taken up in the existing plant

premises only.

3.3 Details of the Alternate sites:

No Alternate sites have been examined as existing premises has been given permission to

set up Sugar plant.

3.4 Size or Magnitude of Operation:

The following will be the capacities after proposed expansion




2. Power plant 4 MW (Captive)

20 MW (Co-gen)

24 MW

4. Distillery -- 60 KLPD 60 KLPD

3.5 Process details:

3.5.1 Sugar Process Description

Sugar is nothing but sucrose in its purest crystal from. While sugar is produced from

sugarcane in India, it is produced from sugar beet in the European countries, which requires

cold climatic conditions for its growth. Basically, sugarcane contains 14% to 17% Fiber, 16

to 24% Dissolved solids and the rest is all water. About 80% to 87% of the dissolved solids

in sugarcane are sucrose solids. Hot day and cold night climate (maximum difference of

temperature between day and night) is the favorable weather condition for sugarcane




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growth. The task of the sugar factory is to extract maximum sugar from sugarcane with

minimum losses and at minimum expenditure by adding value of its bye-products.

We can divide the process operations of sugar manufacture into 6 steps namely,

1. Juice Extraction

2. Juice clarification

3. Evaporation

4. Crystallization

5. Centrifugation

6. Drying, Bagging & storing

JUICE EXTRACTION:

Juice is stored in the fibrous cells of the sugarcane stalk. We have to break open these cells

and squeeze the juice out for processing. For this, sugarcane is made into small pieces by

the preparatory devices, which cut the sugarcane using knives. These pieces are further

processed at the fibrizer of shredder where they are pealed into fibrous shape. This finely

prepared sugarcane is subjected to compressions at mills where juice is extracted. The

residue from mills called bagasse has the character of re-absorption. Hence, it absorbs juice

back into it when it is released from mills. To extract this juice also, water is sprayed into the

bagasse mat at the point where it comes out from mills. This water will penetrate in to the

cells and dilute the juice remaining in them. This diluted juice is again extracted in next

compression. Like this, the prepared cane is subjected to 4 to 5 compressions to extracts

maximum juice from sugarcane. Juice from all compressions is collected, weighed and sent

to processing house for reaping out the sugar.

Bagasse leaving the last mill is sent to boilers for generating steam. This steam is used for

producing power by the turbo-generator, which is used for operating the machinery in

factory. The exhaust steam leaving the turbine is used in the boiling house for various

process operations.

JUICE CLARIFICATION:

Weighed juice from milling plant is pumped to boiling house for clarification. The juice is first

subjected to heating in a tubular heater, where juice is passed inside the tubes and steam is

applied externally, to heat it to 700C. This hot juice is sent to reaction vessel where Milk of

Lime {Ca (oH)2} and sulfur-Di-oxide gas (SO2) are mixed. These chemicals will react with

Phosphates present in juice in the form of P2O5 and produce precipitates of Ca3 (PO4)2 and

CaSO3. These precipitates (called Mud) will absorb all the impurities in juice such as




18

suspended matter, waxes, gums, pectines, coloring matter, etc. This treated juice is

subjected to heating again to its boiling temperature, i.e. around 1030C. This juice is sent to

settling tank called clarifier for settling the mud through a flash tank where excess heat and

dissolved gases like Ammonia present in the juice are vented to atmosphere, which if

permitted to enter the clarifier will disturb the settling process.

Mud is settled t the bottom in the clarifier and clear juice is taken out from the top. The mud

is mixed with bagacillo, fine powder of bagasse, and subjected to filtration at vacuum filters

for recovering the juice in it. This juice called filtrate juice is mixed to the weighed juice

received from mills for subjecting it to clarification.

EVAPORATION:

Clear juice from clarifier contains around 14% solids only and the rest is all water. This juice

is sent to multiple effect evaporator station for concentrating to 60 to 65% solids. Vapor

produced in one body of the evaporator set is used as heating medium for the next body by

maintaining differential pressures in each body; thereby lot of steam economy is ached. This

thick juice called syrup is subjected to sulphitation for removing coloring matter from it.

CRYSTALIZATION:

Thick, sulphited syrup from evaporator set is boiled again in vacuum pans for further

concentration. When the syrup is continued to boil above its saturation point, sucrose in

dissolved from in the syrup will come out as crystal. This liquid –crystal state of the material

is called Massecuite. We can control the crystal growth by maintaining saturation level in

pan by feeding sulphited syrup and continuing boiling. Since the saturation state is

maintained, sucrose in syrup will keep depositing on the already formed crystal, and hence

the crystal size increase. Once the sugar crystal attains required size, the Massecuite is

forwarded into a storage vessel called crystallizer, before it is sent for liquid-crystal

separation. This first grade Massecuite is called A-Massecuite. The liquid portion of this

mass is called molasses and it still contains some sugar. The reap out that sugar also, this

molasses is taken into masse is called B-Molasses. Sugar is melted and taken to first stage

boiling. The second stage masse is called B-Massecuite. This is subjected to centrifugation

separately for separating B-sugar and B-Molasses. Sugar is melted and taken to first stage

boiling. The second molasses called B-Molasses also contains some sugar. Hence this is

again taken to pans for boiling third grade Massecuite called C-Massecuite. This

Massecuite contain more non sugar solids and recoverable sugar is less compared to first




19

two stages. This Massecuite is centrifuged in continuous centrifugals to separate sugar and

molasses.

Molasses from this third grade Massecuite contain some more sugar, but cannot be

extracted due to presence of heavily concentrated non sugars. Hence this molasses called

Final molasses will be used as raw material for production of Alcohol & Motor spirit or

Ethanol.

CENTRIFUGATION:

Centrifugation is the stage where liquid and crystal portion of the Massecuite are separated.

The separation is achieved by subjecting the Massecuite to centrifugal force in a cylindrical

or conical shaped basked to which screens of micro openings (0.4 mm for cylindrical baskets

and 0.05 mm to 0.09 mm for conical shaped baskets) are fixed through which liquid portion

is separated. First grade Massecuite is less viscous and can be separated freely from a

thick cake. Hence, this is centrifuged in batch type centrifugal. This cycle contain series of

operations such as charging of Massecuite into the machine, spinning to purge out the

molasses, washing the sugar cake for removing the molasses film on crystals, drying by

spinning at high speed and automatic discharge of sugar on to hoppers for further drying to

first grade Massecuite. Hence these Massecuite are centrifuged in machines with conical

shaped basket, called continuous centrifugal machines.

DRYING, BAGGING & STORING:

Sugar, as it is discharged from centrifugal on to the hoppers contain moisture and cannot be

bagged directly. While the sugar travel forward on the hopper, hot air at around 600C is

blown through the sugar crystals to evaporate excess water on the surface. The time the

excess water is evaporated, sugar gets heated up because of the hot air. Hence cold air is

blown again through the dried sugar crystals to bring down the temperature to around 400C.

Dried and cooled sugar is passed through grader to separate lumps, powder and for size

separation. Larger size crystals are called ‗M‘ sugar and smaller size crystals are called ‗S‘

sugar. These two sugars are stored in separate bins for bagging.

Sugar is packed in 50 Kgs PP bags or 100 Kgs jute bags, depending on the market demand,

and stored in warehouse in stacks.




20

PROCESS DESCRIPTION OF PRODUCING WHITE SUGAR FROM IMPORTED RAW

SUGAR.

Imported raw sugar from 2 tons jumbo bags is dumped into the 4 tons capacity storage bin

located inside the sugar godown with the help of crane. Raw sugar from this bin is fed to a

horizontal sugar melter through a feeding device called rotary valve for continuous and

uniform feeding. Hot water is added in the melter to maintain melt liquor consistency. The

sugar melt liquor is then passed on to a vibratory mesh to remove any foreign material in it.

It is then let into the pump receiving tank from where it is pumped through pipe line to

processing house.

The sugar melt liquor from here is mixed in the regular process scheme that is adopted for

making sugar from sugar cane.

At first, the sugar melt liquor is clarified to remove dissolved colour and other impurities

using chemicals such as colour precipitant, phosphoric acid and lime. Clear melt is pumped

to storage tanks at vacuum pan station from where it is taken into vacuum pans for

evaporation for re-crystallization.




21




22

3.5.2 Co-generation Power Plant

Sugar plant will be expanded to 3500 TCD from 7500 TCD. The cogeneration capacity is so

designed that the plant will be able to feed steam and power requirements entire Sugar

Complex. The capacity of the boiler will be 100 TPH at 110 ata and 540+/- 5 deg C. The

turbine capacity would be 20 MW at 110 ata and 545 ºC steam parameters. The new turbine

will be of Extraction-cum-condensing type.

For off-season operation, we will utilize the purchased biomass fuel, saved bagasse and

imported coal. The season period will be 5 to 6 months and off-season will be 3 to 4 months

depending on the availability of fuels at economical price.

3.5.3 Manufacturing Process (Rectified Spirit/Ethanol/ENA)

Yeast propagation:

Yeast seed material is prepared in water-cooled yeast vessels by inoculating molasses with

yeast. The contents of the yeast vessel are then transferred to the Yeast activation vessel.

The purpose of aerated yeast activation in the yeast activation vessel is to allow time for the

yeast cell multiplication.

Fermentation:

The fermentation technology adopted in the industry is of continuous fermentation with yeast

recycle with this technology the total spent wash generation will be restricted to a max. of 10

kl/kl of R.S. (As per latest CPCB recommendation).

The purpose of fermentation is to convert the fermentable sugars into alcohol. During

fermentation, sugars are broken down into alcohol and carbon-di-oxide. Significant heat

release takes place during fermentation. However the fermentation temperature is

maintained at 32 – 35 0C by forced recirculation heat exchangers.

At the end of fermentation, the wash is fed through a yeast separator where the yeast cream

is separated, acidified in the yeast treatment tank and returned to the yeast activation vessel

for activation. Sludge is separated in a sludge decanter. The clear wash from both the yeast

separator and sludge separator flows to the clarified wash tank. The wash is then pumped to

distillation.

EXISTING PROCESS FLOW

DIAGRAM (SUGAR)




23

Distillation:

Fermented Wash about 8% v/v alcohol is preheated in two stages i.e. in the beer heater

using the Rectifier vapours and then in the Fermented wash PHE using the effluent. The

preheated wash is then fed the Degasifying Column to remove residual CO2 and volatiles.

The wash then flows down to Analyser Column, which acts as a total stripper. The alcohol

water vapour mixture which rises upward in this column is fed to the Rectifier Column. The

spent wash, which is devoid of alcohol, flows down the Analyser Column for suitable

treatment.

The lower boiling impurities are concentrated in the Aldehyde Column where about 5% spirit

is drawn off as impure spirit with a minimum strength of 660 OP.

The alcohol vapours are concentrated in the Rectifier Column to produce Rectified Spirit of

95% v/v strength. Higher boiling impurities, which are formed during fermentation, are

removed by taking side draw purges to a decanter from the Rectifier Column. A trace stream

of spirit is drawn off as impure spirit (about 2% of plant capacity) to remove the concentrated

volatile compounds. The high grade Rectified Spirit is taken as a draw from the upper trays

of the Rectifier Column.

The Rectified spirit is fed to the purification column. Dilution water is fed on the top most tray

of the column with a dilution ratio of 1: 9. This column serves to remove the impurities based

on the principle of HYDROEXTRACTION. The water is fed to the column in such a way that

it selects the higher alcohols and other impurities to move upwards and extracts ethanol

down. The purifier bottom alcohol composition is maintained at 12 % v/v. At this

composition there is an inversion in relative volatiles of higher alcohols as compared to

ethanol and these alcohols get separated in the top distillate. Top draw for volatiles is fed to

the Fusel oil concentration column.

The purified dilute ethanol is removed from the bottom of the purification column and fed to

the rectification column, which concentrates the ethanol to 96% v/v. The high grade spirit is

drawn from one of the upper trays of the rectification column. A small heads cut is removed

from the overhead stream as technical alcohol (T.A.) cut to with draw impurities and is fed to

the heads concentration column. The lees from the exhaust column is recycled as dilution

water after a part of it is purged. The purged spentlees is used to preheat the make-up

dilution water.




24

Lower side draw streams are taken from rectification column to avoid fusel oil build up in the

column. These streams are then taken to the fusel oil column. This column concentrates

the dilute streams of ethanol containing esters and fusel oils to approximately 95% v/v of

ethanol. The concentrated ethanol is removed as T.A. cut from the top of the column. T.A.

cut is removed out of the system in order to remove propanol and remaining is fed to the

heads concentration column where the heads from the purification column and rectification

are fed to the static mixer. Soft water, which has been preheated, is used for diluting the

high proof ethanol. An impure spirit cut of about 5% of the rectified spirit feed is drawn from

the top of the column. The dilute ethanol solution at the bottom of this column is pumped

back to the purification column for repurification.

Carbon Dioxide Recovery System (By Product):

Carbon dioxide produced during fermentation will be recovered by means of scrubbing

arrangement, chemical treatment drying process and finally liquefaction. The water utilized

for scrubbing will be recycled back into the fermentor.

CO2 gas will pass through scrubbing tower, where the gas is scrubbed with water. From the

scrubber after washing the gas will pass through air compressor and then the gas will pass

through a tower containing sodium dichromate to eliminate the impurities, if any and then to

drying arrangement with sulphuric acid. Subsequently it passes through a tower containing

coke coated with washing soda to eliminate odour. Finally it goes to the chilling unit to cool

the gas before passing through different cylinders, where the cooled gas will be filled into the

cylinders under pressure. The scrubber blowdown will be recycled into the fermenters.

Total CO2 production : 45.6 T/day

This carbon dioxide in cylinders will be sold to industries like soft drink manufacturing units,

etc.

Ethanol Production:

This plant is filled with imported 3A grade Molecular Sieve. It is operated with vaporized

Alcohol and removes water completely. Then Molecular sieves are regenerated under

vacuum of 710 mm Hg. Feed Alcohol comes to this Plant in a Day Tank continuously from

bulk storage tank. From this tank alcohol is pumped to a steam vaporizer at 4 Kg/cm2

pressure. This is vaporized in a steam heater and then vapor is super heated to 160oC in a

super heater and taken to Molecular Sieve Unit. This super heated vapor now pressure

through one Molecular Sieve column for moisture removal. There are 2 Molecular Sieve

columns. At a time one column remain in drying cycle while other columns under goes

vacuum regeneration. Each column remains in cycle for 6 minutes. Here drying process




25

takes place at 3.0 Kg/cm2 pressure and dry alcohol vapor of 99.8% purity comes out as final

product. This alcohol vapor is condensed in a water cooler and then collected in another day

tank. From this tank dry alcohol is continuously pumped to bulk day storage tank through a

level controller and a control valve. In the regeneration process some left over alcohol also

comes out which is condensed in regeneration condenser. This alcohol is around 95%

strength and is re-cycled in to rectifier column continuously.

The other Molecular Sieves column under goes regeneration by a vacuum pump. In this

column vacuum pumps pulls and creates vacuum of 710 mm Hg. At this vacuum the

moisture from Molecular Sieve pores comes out and along with 30% pure alcohol from on

line Mole Sieve bed is sprayed. Thereafter during vacuum process, some left over alcohol

and water from Molecular Sieves comes out and is condensed. Concentration of this lean

alcohol is around 70% alcohol, which can be recycled to the Rectifying Column. From

Rectifier the pure water will be sent out automatically.




19

3.6 Raw Materials

The following will be the raw material requirement for the for the existing and proposed expansion project

S.NO RAW MATERIAL SOURCE QUANTITY ( TPD) METHOD OF TRANSPORT


Sugar plant :

1 Sugar Cane Local area 3500 4000 7500 By trucks, tractors& bullock carts

2 Lime Local area 5.50 6.29 11.79 Through covered trucks by Road

3 Sulphur Local area 1.75 2.00 3.75 Through covered trucks by Road

Co-gen power plant :

1 Fuel

Bagasse From Sugar plant 200 1000 1200 Conveyor

(or)

Coal Imported 96 480 576 By Sea/ Rail/Road Covered trucks

Distillery:

Molasses From Sugar plant &

External

--- 230 230 Through Pipeline/Tanker




20

3.7 Resource Optimization / recycling and reuse: Sugar Plant

Condensate from the Sugar Plant will be utilized for Cooling tower make up

Power Plant

The effluent generated from the Plant will be treated in Neutralization pits and will be utilized

for dust suppression, ash conditioning and Greenbelt development after ensuring compliance

with stipulation for on land irrigation by MoEF / CPCB

3.8 Availability of Water:

Water requirement for the existing plant is being met from Ground water resources. Water

required for the proposed expansion also will be met from the Ground water resources.

Required permissions will be obtained from SGWB before drawing water from Ground

Water required for existing plant 108 KLD

Water required for proposed expansion of Sugar,

Co-gen and Distillery unit

1100 KLD

Total 1208 KLD

3.9 Power Requirement:

The power required for the existing project and expansion project will be met from the Captive

& Co-generation Power plant.

3.10 Quantity of wastes generated:

3.10.1 Waste water generation

Waste water generation from the existing Sugar plant is 360 KLD. Waste water generation

from the proposed expansion project will be 1640 KLD.

3.10.2 Waste water Treatment: Sugar Plant & Distillery

Total wastewater generation will be 400 cum/day from sugar plant expansion. The condensate

generated from Distillery during concentration of spent wash will be 400 KLD. Effluent




21

generation per ton of cane crushed will be as per CREP recommendations. The following is

the ETP description.

Design Data & Performance Projections

This Wastewater Treatment plant ( sugar + distillery) is designed for following parameters &

shall perform as under upon reaching steady state of its operation:

PARAMETER RAW WASTE WATER TREATED WASTEWATER

Flow (m3/Day) 800 810

pH 5.0 – 6.5 6.5 – 8.0

BOD (mg/l) 3000 < 100

COD (mg/l) 6000 < 250

TDS mg/L 2000 < 2100

TSS mg/L 500 < 100

Oil & Grease mg/L 100 < 10

PROCESS DESCRIPTION

The proposed wastewater treatment plant shall consist of following treatment units.

PRIMARY TREATMENT

Screen

Oil & Grease trap

pH adjustment

Equalization Tank

SECONDARY TREATMENT

UASB Anaerobic reactor

Aeration Tank

Secondary Clarifier

Sludge Drying Beds

Screen Chamber:

Screen chamber constructed in RCC shall be provided with SS 304 fabricated bar screen for

removal of free and floating material. The screen shall be inclined at 45 Deg with horizontal.

Oil & Grease Trap:

Oil and grease trap constructed in RCC shall be provided for removal of free and floating oil

from the Wastewater. The oil trap shall of gravity type and shall be provided with Belt type oil

Skimmer.




22

Lime Preparation Tank:

A lime preparation tank constructed in RCC. In this tank is used for lime solution preparation

and continuous mixing of lime. Lime solution is then feed to equalization tank for pH correction

in a required proportion. 1 HP agitator shall be provided for mixing in the tank content.

Equalization:

Wastewater emanating from sugar has fluctuations in wastewater quality and quantity.

Equalization tank shall be provided for dampening these fluctuations. In equalization tank the

raw effluent is collected and equalized for adequate time. An equalization tank shall be

provided with an agitator to mix the tank content thoroughly. The equalized effluent from

equalization tank shall then be pumped to buffer tank. A stand by floating mixer shall also be

provided for equalization tank

Buffer Tank:

Buffer tank constructed in RCC shall be provided for preconditioning / pre-acidification of the

raw effluent. In buffer tank the Raw Effluent is mixed with treated effluent form UASB Reactor.

The nutrient required for the process will also be added to the effluent in Buffer tank. The

content of buffer tank shall be mixed hydraulically using UASB Reactor feed pumps. The tank

content will then be pumped to UASB Reactor for first stage biological treatment.

UASB Reactor:

Upflow Anaerobic Sludge Blanket reactor is provided for anaerobic treatment of Sugar plant

effluent. The UASB reactor shall be constructed in RCC M-25. The reactor consists of three

zones viz. Influent distribution zone, Reaction zone, Gas solid liquid separation zone.

Influent Distribution zone: The raw wastewater enters into the at the bottom through influent

distribution zone. A sophisticatedly designed piping network is provided for uniform distribution

of the effluent in the tank. The effluent then travels upward in the reactor.

Reaction Zone: In the reaction zone the anaerobic bacteria are maintained in the form of

sludge blanket. The organic matter in the wastewater comes in contact with the bacterial

population and is degraded anaerobically to methane rich biogas, the end product of

anaerobic digestion. The process of conversion of organic matter in to the biogas is a two-

stage process. In the first stage the organic matter in the raw effluent is converted in to the

volatile acids by acid forming bacteria. In the second stage the acid produced in the first stage

are converted in to methane by another group of bacteria i.e. methane formers. In UASB

process both the stages are completed in single reactor. The biogas so produced is bubbled

through the effluent and is separated out in the third section i.e. Gas-Solid-Liquid separation

zone. The suspended solids are also separated to prevent escape of solids from the reactor.




23

Gas-Solid – Liquid Separation: In gas solid liquid separation a hood fabricated in M S and

duly painted with corrosion resistant paint is provided. The hood separates the solid from the

overflowing reactor content. Gas collectors are provided for collection and conveyance of gas.

The treated effluent overflows through a launder and will take to a secondary treatment.

Aeration tank:

The partially treated effluent from UASB shall then be subject to activated sludge process for

further reduction of organic matter. Aeration tanks are provided for degradation of organic

matter through biological process. Microorganism in the controlled environment carries out the

biodegradation process. The container i.e aeration tank of requisite capacity is provided for

this purpose. The tank shall be provided with an aeration mechanism to transfer the oxygen

from air to tank content for survival for microorganisms. Slow speed fixed type surface

aerators shall be provided for this purpose. The content in the aeration tank is kept under

constant aeration and mixing. The aeration thank shall be constructed in RCC.

Secondary Clarifier:

A secondary Clarifier in the form of circular tank shall be provided for settlement of fully

aerated Effluent from the aeration tank. The tank shall be provided with centrally driven fixed

bridge type clarifier mechanism. Part of the settled sludge at the bottom of the settling tank will

be pumped to the aeration tank and part of it will be discharged on sludge drying beds as per

operational requirement. This sludge being fully mineralized is suitable for sun drying on sand

drying beds.

Sludge Drying Beds: In aeration system the sludge is sufficiently mineralized and does not

need any further treatment before dewatering and disposal. Sand filtration drying beds will be

provided, where sludge will be dewatered by filtration through sand bed and sun drying of the

dewatered sludge is scraped & may be used as manure after composting.




24

PROPOSED EFFLUENT TREATMENT PLANT FLOW CHART

(1000 KLD)

Pump

Recycling Pump

Bar Screen Chamber

Equalization tank

Lime Dosing Tank

Sludge Drying Bed

Raw Effluent

Oil Removal tank

Buffer Tank

Chlorine Contact Tank

Anaerobic

Reactor

Aeration Tank

Treated Tank

Primary Clarifier

Aeration Tank-II

Secondary Clarifier




25

Cogeneration Power Plant

Total wastewater generation from power plant will be 500 Cum/day. The effluent generated

from the power plant will be treated and utilized as following.

Cooling tower blow down, DM plant regeneration and Boiler blow down will be neutralized and

after treatment it will be utilized for ash quenching, dust suppression and greenbelt

development.

Sanitary waste water will be treated in septic tank followed by soak pit. Hence there will not be

any adverse impact on environment due to the proposed activities.

Non Process Effluent Treatment & Disposal:

The boiler blow down and DM plant regeneration waste water will be treated in a neutralization

tank and after treatment it will be mixed with CT Blow down. All these treated effluent streams

will be stored in a Central Monitoring Basin (CMB). The treated effluent will be used for dust

suppression / ash conditioning and onland for irrigation within the premises after ensuring

compliance with CPCB / SPCB standards. The scrubbed water from CO2 Scrubber will be

consumed in the Fermentation section. The effluent will be used for greenbelt development

within the plant premises after ensuring the compliance with CPCB/SPCB standards.

Distillery

As per CPCB recommendations the spent wash quantity will be restricted to a maximum of 8

kl/kl of R.S. for Molasses by adopting continuous fermentation technology with yeast recycle.

The Maximum Spent wash input to Bio-methanation will be 480 KL/day

TREATMENT SCHEME

Spent wash generated will be treated in three stages

1. Bio-methanation

2. Evaporation

3. Bio-composting

BIO-METHANATION

"CSTR" continuous flow stirred-tank reactor process will be adopted for Bio-methanation,

which is based on the concept of conversion of organic matter into biogas. The process of

conversion of organic matter into biogas occurs through a group of bacteria.

Figure – 10.1




26

In 'CSTR' process, which is a high rate process, anaerobic digestion takes place in the

Mesophillic range of temperature, the pH inside the reactor is usually kept around 7.2 while

proper ratio of volatile acid and alkalinity is maintained.

The following three stages are involved in the process of anaerobic digestion

1. Hydrolysis: In the process of hydrolysis the complex molecular compounds i.e. polymers

are converted into the simple molecular form i.e. monomers.

2. Acidogenesis: The monomers so formed at the end of hydrolysis process are converted

into volatile fatty acids. Acetic acid forms the major portion of volatile fatty acids. The

process of conversion of monomers into acids is carried out by a group of anaerobic

bacteria known acid formers.

3. Methanogenesis: Acids produced at the end of Acidogenesis process are converted into

carbon dioxide and methane gases. The process of conversion of acid into gases is

carried out by group of anaerobic bacteria known as methane formers.

In CSTR process the bacteria responsible for digestion process are kept in suspension with

the help of Lateral as well as central mixers.

Sr. No Design Basis Input Output

I. Spent wash Volume 480 TPD @ 12 %w/w solids 480 TPD @5 %w/w solids

II. BOD (mg/lit) 65000 85-90% reduction

III. COD (mg/lit) 120000 60-65% reduction

IV. pH 3 to 4 6 to 7

SR. NO TREATMENT UNIT SPECIFICATION/VOLUME MOC

1. Buffer Tank Capacity : 100 m3 RCC Lined Lagoon

2. Bio digester feed Pump +

motor

Type-Open impeller; Horizontal,

Centrifugal, Self Priming Cap-16

m3/hr Qty-1+1 3 Phase squirrel

cage induction type Motor

SINGLE MECHANICAL SEAL

SS316

3. CSTR Digester Capacity-10700 m3

Qty -1 nos

Mild Steel, with

epoxy coating

inside

4. Flare Stack Overall Ht: 10.0 m

Dia: 1.0 m

MS with epoxy

coating

5. Degasser Dia: 1.6 m

Overall Ht: 10 m

Mild Steel, with

epoxy coating




27


inside

6. Lamella Clarifier Surface Area: suitable Mild Steel, epoxy

coated inside

Provided with

FRP Packs

7. Gas Holder Suitable capacity MS Dome + RCC

Wet well

8. Bio-Methanated Spent

wash tank

Capacity : 50 m3 RCC

9. Lamella Sludge

recirculation pump

Horizontal Centrifugal Pump

having 15 m3/Hr Discharge and 25

mtrs Head. Qty-1+1 SINGLE

MECHANICAL SEAL

SS316

10. Agitators for Mixing in

Bio-digester

Quantity :4 Nos Wetted

partSS304

11. Bio Gas Blower Rotary Twin Lobe type

compressor of 600 m3/hr capacity

with pressure rating of 2500

mmHg. Provided with safety

Valve, Non Return Valve, Coupled

with flame proof motor

12. Lamella Clarifier Packs Lamella Packs in FRP Molded

sheets shall be provided. The

Lamella packs shall be inclined at

60 Deg with horizontal. Each Plate

shall have area of 2 sqm. Each

Lamella Pack Shall has Plates of

1 m x 2 m size each. Thickness of

FRP/PVC plates shall be of 3 mm

13. Liquid Flow Meter for SW

feed

Electro-magnetic flow meter

having flow range of 0-18 m3/Hr,

SS 316 material

SS316

14. Gas Flow Meter Vortex type gas Flow meter to

measure instantaneous and




28


integrated flow meter, bio gas flow

0-800 m3/Hr

15. Pressure gauges for liquid

pressure measurement

Bourdon type pressure gauges

with Vi" NPT connection, pressure

ratings 0-5.0 kg/cm2, 4" Dial Size

16. Pressure gauges for Gas

pressure measurement:

Diaphragm type pressure gauges

with V-i" NPT connection,

pressure ratings 0-700 mmwc g,

4" Dial Size.

17. Temperature Gauges for

Panel Indication:

Dia Type temperature Indicator

with 0-100 deg C range. Qty-2 nos

—

18. Pressure switches for

flare stake

Pressure switches for High & Low

Pressure Indication and Blower

operation. Qty-2 nos

—

19. Flame Arrestor: Suitable Dia. SS Flame arrestor

suitable for biogas flow of 800

m3/Hr, Flanged connection.

—

20. Breather Valve 200 / 100 mm Dia Dead weight

type breather valve, pressure

setting 500 mm WCG and

vacuum setting 70 mmhg Qty-1 no

—

21. Level Indicator: Glass Tube level indicator with a

range of 0-1000 mmhg to

measure the water seal in flare

stack. Qty-1 no

—

EVAPORATION PROCESS

Evaporation is an operation used to remove a liquid from a solution, suspension, or emulsion

by boiling off some of the liquid. It is thus a thermal separation, or thermal concentration,

process. Evaporation process can be defined as one that starts with a liquid product and ends

up with a more concentrated liquid as the main product from the process.

In first evaporation stage,

Bio-methanated Spent wash will be subjected to heat through steam

Spent wash vaporized in first stage will give energy to second stage.




29

There will be total four falling film evaporator and one forced circulation evaporator.

These Evaporators will be in forward feed arrangement.

Vapours of Second evaporator will be fed to third effect Evaporator. Vapours of Third

evaporator will be fed to fourth effect Evaporator. Then, Vapours of fourth evaporator will

be fed to fifth effect Evaporator.

Falling film evaporators will be operated at very low temperature differences between the

heating media and the boiling liquid, and they also have very short product contact times,

typically just a few seconds per pass.

These characteristics make the falling film evaporator particularly suitable for spent wash

evaporation.

This is specifically designed Spent wash distributors for the proper distribution of Spent

wash in tubes. Specific design of the liquid distribution system achieve full and even

product wetting of the tubes. Because of the low liquid holding volume in this type of unit,

the falling film Evaporator can be started up quickly and changed to cleaning mode

easily.

Falling film evaporators are highly responsive to alterations of parameters such as

energy supply, vacuum, feed rate, concentrations, etc. it will be equipped with a well-

designed automatic control system therefore it can produce a very consistent

concentrated product.

BIO METHANATED SPENT WASH EVAPORATION SECTION

Spent wash feed : 480 TPD

Feed Solid Concentration : 5%

Process Condensate Qty : 400 TPD

Final Spent Wash after evaporation : 80 TPD

Final Spent wash Solids concentration : 30%

Sr. No. DESCRIPTION SPECIFICATIONS MOC

1. Flash tank Type: Vertical/ Cylindrical-

conical bottom Capacity: 4 m3

SS304

2. Biomethanated spent

wash Pre heater

Type - Shell & tube.

Quantity- 3 No.

SS304

3. Spent wash feed tank Type: Vertical/ Cylindrical-

conical bottom Capacity : 15

m3

SS304

4. Vacuum Blower for

flash tank

Type : Water Ring Blower

Capacity: 200 Nm3/Hr. Qty:

1+1 no.

Cl/ SS 304

Internals

5. Flash vessel condenser Type - Shell & tube, SS304




30

Quantity-1 No. HTA-51 M2

6. Feed Pump motor Capacity: 18 m3/hr Type -

Centrifugal Type, Quantity-1

+ 1 Nos. Single Mechanical

Seal

Wetted Parts

SS 316

7. Falling Film

Evaporators

Type : Shell and Tube Qty: 4

FF Evaporator HTA FF1: 100

m2 FF2: 150 m2 FF1: 150 m2

FF1: 150 m2

SS 304 Shell

with SS 316

tubes

8. Forced Circulation

Evaporator

Type : Shell and Tube Qty: 1

FC Evaporator HTA : 170

SS 304 Shell

with SS 316

tubes

BIO-COMPOSTING

FEATURES OF BIO COMPOSTING TECHNOLOGY

Zero discharge concept

Complete Destruction of BOD in effluent

Flies & odour free

High quality product

Dry baggable product, easy to handle and transport.

PROCESS OF BIO COMPOSTING

A Composting cycle takes 8 weeks to complete and involves the following activities.

1st week

1. Collection of raw material:

First week Filter Cake, Boiler Ash and organic residues compose one compost batch. They

are hauled from storage yard to the bioearth compost area, a level and well-drained land that

permit heavy equipment operations.

2. Formation of Windrows & Trimming

Using a pay loader the press mud is spread in piled windrows and trim to allow passage of

Aero tiller. Each windrow consists of 100-150 metric tons of press mud. Each windrow is of

1.5m width at bottom and 100m length.

2nd week

1. Aerating and mixing:

Make the first pans of the mixovator on windrows.




31

2. Inoculation of bioearth:

After the first aeration pass, the material will have achieved moderate mixing and ready

for application of acitobactor and Phosphorous soluble reagent at ½ kg per ton of

waste. This will accelerate composting stabilize temperature 65-750C and enhance

beneficial microbes.

3. Aerate the pile after inoculation and retrim.

3rd to 6th week

1. Maintenance of Moisture:

The Moisture of the pile is maintained to 50% to 60% heat is evolved during process,

this built up together with solar heat and other factor increases. Temperature resulting

to evaporation. Moisture drops to a level of about 30%to35%.

2. Application of Distillery effluent after Digesters:

Excessive/ inadequate moisture slows down composting exhibited by drop in

temperature from the trend established. Windrows are watered back to desired

moisture level using distillery effluent as moisturizing agent. The total volume

applicable each week is sprayed three times during the week.

3. Aeration:

Make one to two pass of the Mixovator after each effluent application and then retrim.

Mixovator grinds, blends, spreads, aerate and disperse the growing fungi for a uniform

and thorough decomposition of the windrow.

4. Inoculation with culture

During the 5th week, culture is again applied at 0.5 kg/ton in order to restimulate

microbial activity and to stop the development of odour.

5. Curing, Aging and Drying

7th week:

Effluent application is stopped at the end of the 6th week and the compost is allowed to cure

and age. Water is applied during the 7th week while mixing is continued twice in a week until

moisture stabilizes at 20%to 30%.

8th week:

Disposal of Bio earth to End –user Farms:

Transport the bio earth to end-user farm or a suitable storage in order to vacate the area

occupied by the compost and accommodate another batch Otherwise, a large bio-earth

composting area may be needed to process the annual production of waste.




32

LAND REQUIREMENT FOR BIOCOMPOSTING

Quantity of Bio-methanated evaporated spent wash 80 KLD

No. of operating days 270 days

Annual Quantity of Bio-methanated evaporated spent wash 21,600 KL

Off seasonal run-off from compost yard 400 KL

Total effluent to be sent to compost yard 22,000 KL

Pressmud to effluent ratio 1:1.5

Filler material requirement per Annum 14,667

Composting cycle 60 days

No. of cycles 4

Filler material required per cycle 3667 T

Filler material that can be processed in 1 Acre: 1000 Tons/cycle

Land required for composting 3.7 acres

Total land requirement

Land required for composting 3.7 acres

Land required for storage of filler material 1.1 acre

Land required for storage of finished product 0.8 acre

Total land required for composting 5.7 acres

Quantity of organic compost 7,920 T

Availability of Pressmud

Total Pressmud generation from sugar plant 45,000 TPA against the requirement 14,667 TPA.

The above Bio-compost will be given to farmers to be used as manure in the agricultural fields.

Hence availability of pressmud will not be a problem.

Leachate collection system

A leachate collection system will be provided will be constructed with RCC M20 grade

concrete along with 250 micron HDPE lining to make it leak proof as per CPCB/BIS

specifications.




33

Specifications for compost plant

Specification of floor of compost yard will be as under (with arrangement of leachate collection

& surface runoff and its pumping to holding lagoon and laying of pipe network for automatic

spraying of spent wash)

I. Compaction of soil

II. 5 cm local sand cushion (bottom)

III. 250 micron HDPE sheet (as per BIS specification)

IV. 5 cm sand cushion (top)

V. Brick / stone soling (not less than 6 cm in case of brick & 3 cm in case of stone

soling)

In case the coefficient of permeability is less than 10-8 cm/sec (as in black cotton soil), 30 cm

depth of impervious soil, compacted with 30 cm depth of murum at the top may also be used.

The bio-compost yard will be kept dry before starting of the monsoon period. The compost

yard is surrounded by garland canal to divert storm water from outside entering inside and

bund to prevent the surface run off from going outside the compost yard during rainy days.

Outside the garland canal greenbelt will be prepared for aesthetic reason and for avoiding

erosion. 10 acres of land will be prepared for Bio composting as per CPCB guidelines.

Specification for storage of filler material

Press mud will be transferred to compost yard before on set of monsoon and covered with

HDPE / PVC sheet / tarpaulin.

Specification for storage of finished product (compost)

Land area is raised by about 30 cm above ground level. The maximum height of storage is

restricted to 4m. Finished compost will be kept. Covered with PVC / HDPE sheet / Tarpaulin to

prevent soaking from rain water.

Compost quality

Moisture content : < 35%

Organic carbon : 20 -25%

Phosphorous : 1.5 - 2.0%

Nitrogen : 1.5 - 2.0%

Potassium : 2.0 - 3.5%

C: N ratio : <17




34

Equipment & Machinery available for composting in the plant (as per CPCB protocol)

1. Tractor for transportation of press mud from storage site to compost area - 1 No.

2. Homogenising machine along with auto spraying system with 70 HP tractor

(for churning up to the bottom) - 1 No.

3. Front end loader with tractor or JCB of bucket capacity of 600 -1000 kg -1 No.

4. Automatic windrow forming mechanism – 1 No

5. Sieving Machine - 1 No.

6. Sewing machine for bagging of compost (finished product) - 1 No.

Organic compost produced in the treatment of spent wash with pressmud will be supplied to

the farmers at subsidized prices. With this the usage of compost chemical fertilizers

consumption will come down. With compost the sugar cane yield will increase by about 25%.

Storage of Pressmud

Pressmud will be transferred to compost yard before on set of rainy season and shall be

covered with tarpaulin.

Biomethanated Evaporated Spent wash storage lagoon

During the monsoon period bio-composting cannot be carried out. Hence distillery will be not

be operated during monsoon season and will be operated for only 270 days in a year.

Biomethanated Evaporated Spent wash storage lagoon size will be restricted to 5 days instead

of 30 days.

The storage lagoon will be made impervious constructed with RCC M20 grade concrete along

with 250 micron HDPE lining. The storage capacity of the lagoon will be for 5 days. The

capacity of the Bio-methanated Evaporated Spent wash storage tank will be 12.5 m x 8 m x

4.3 m.

Leachate collection Tank

Leachate Collection tank will be made impervious with 250 micron HDPE lining as per CPCB

specifications.

Spent wash storage lagoon

Spent wash storage lagoon having storage capacity for 3 days, which is far below the CPCB

norm of 30 days. This storage lagoon will be made impervious by providing 500 micron HDPE

lining as per CPCB specifications. The size of the lagoon will be 21.5 m x 17 m x 4.3 m

(including a freeboard of 0.3m).




35

Treatment of Non-process effluent

Total Non-process effluent from project (excluding sanitary wastewater) : 236 KLD.

Back wash from DM plant and Softener, Boiler blowdown will be neutralized in a neutralization

tank and will be mixed with Cooling tower blowdown in the CMB and will be utilized for

greenbelt development, dust suppression and ash conditioning after ensuring compliance with

treated effluent quality as per MoEF / SPCB Standards.

3.11 Solid Waste:

The following are the solid waste generation & disposal.

S.No Solid waste Quantity (TPD)

Disposal Existing Expansion Total

Sugar Plant

1. 1. Bagasse (27%)

945 1080 2025 Will be used as fuel in boilers

2. 2. Molasses (4.5%)

158 180 338 Will be used in the Distillery

3. 2.

Filter cake

140 160 300

As mud is recycled to diffusor, No Filter cake generation presently, for expansion , it will be given to farmers as manure

4. ETP Sludge 0.14 0.16 0.3 Will be used as manure Cogeneration Power plant

5.

Ash generated when Bagasse used as fuel in Boiler

3.5 17.45 20.95

Ash generated Will be disposed to farmers to use as manure in Agricultural lands

Ash generated when Coal used as fuel in Boiler

7.6 38 45.6 Will be given to cement plants/brick manufactures




36

4.0 SITE ANALYSIS

4.1 Connectivity:

Component Description

Road The site can be well approached by a SH # 4 (Zaheerabad – Bidar)

Rail Nearest Railway station located at 5.8 Km (Mettalkunta)

Air port Nearest Airport located at Hyderabad which is at distance of 100 Kms

from the Plant site

Sea Port Krishnapatnam port is at a distance of 450 Kms from the Plant site

4.2 Land form, Land use and Land ownership:

The present use of the land is Industrial as existing sugar & power plant is under operation.

Now the proposed expansion integrated sugar complex activities will be taken in the existing

plant premises only.

4.3 Topography:

The topography of the land is more or less flat without undulations.

4.4 Existing land use pattern:

The present use of the land is Industrial

4.5 Existing Infrastructure:

The infrastructure required for operating the integrated sugar complex exists at the site

4.6 Soil classification:

The soil at the site is Sandy loam

4.7 Climatologically data:

District climate is classified as tropical. The summers here have a good deal of rainfall, while

the winters have very little. The climate here is classified as AW by the Köppen-Geiger

system. The average temperature in Sangareddy is 26.3 °C. The average annual rainfall is

861 mm.




37

4.8 Social Infrastructure Available:

Education

An IIT was established in 2008 near to Sangareddy at Kandi. And also JNTUH College of

Engineering Sultanpur at Sultanpur which is near by the city has been established recently.

Road:

Since Sangareddy is near Hyderabad, it is well connected to other areas like Hitech city, DLF

Gachibowli (appx 35 km away), Panjagutta and Secunderabad. The NH-9 passes through the

city. Sangareddy has two Bus Stations, the Old for Ordinary service and the new for luxury

and other services.

About 15 km Away from Sangareddy there is an outer ring road which connects to

Shamshabad airport- Rajiv Gandhi International Airport Hyderabad and to Gachibowli and

Medchal.

Rail

The nearest railway stations are Lingampally which is about 30 km, Secunderabad about 50

km and Nampally Station around 55 km. In coming years it is expected that there will be Metro

rail/ MMTS track to connect the city to Lingampally.

Air

Nearest Airport is Hyderabad International Airport which is 70 km from Sangareddy.

5.0 PLANNING BRIEF

5.1 Planning Concept:

The integrated complex will be of Sugar, Co-gen. & Distillery Project at Trident will integrate

sugar mill operations with enhanced energy efficiency measures and optimum usage of

Molasses and Bagasse. During season, the Co-gen Plant will be operated on bagasse

generated in the Plant and coal when necessary.

All excess available power will be exported to the grid. During off-season based on the

availability of Bagasse / biomass from nearby sugar mills power will be generated.

Further, the integrated Sugar & Co-gen projects will improve the overall profitability of TSL,

through its additional revenue generation. This will enable TSL to give higher dividend to

promoters & higher price per ton of cane to its cane growers. Also the project will help to

improve Telangana State‘s power situation.




38

5.2 Population Projection:

Unskilled Man Power required for the proposed expansion Project will be met from the local

villages completely. Qualified semi-skilled man power required will be met from local villages if

available. Hence there will not be much population increase in the area.

5.3 Land use Planning:

The following is the Land use Planning of the area

ITEM EXTENT OF LAND (ACRES)

Existing Expansion After expansion

Built up area of Sugar plant 10 5 15

Built up area of Co-Gen Power

plant

4 6 10

Built up area of Distillery plant -- 4 4

Internal roads 4.00 2.50 6.50

Green belt area 45 45

Bio-composting 10 10

Vacant area 38.6 38.6

Total 129.1 129.1

5.4 Amenities / Facilities:

Facilities like canteen, rest rooms and recreation facilities will be provided in the proposed

expansion project.

6.0 PROPOSED INFRASTRUCTURE:

6.1 Industrial area

The following Plant and machinery will be installed in the Industrial processing area

List of Plant and Machinery for proposed expansion

Sugar Plant

Item Description Nos. Type/Capacity

Cane Weighment

Cane weighbridges 2 1 # 60 T capacity

1 # 10 T capacity

Cane Unloading

Cane unloader 2

Sling Type cane unloaders 7.5T SWL

Capacity,

Gantry and structure 1

Feeder table 2 1 # 7 m X 7 m




39


Cane handling & Preparation

Feed Cane Carrier 1

Head end shall be suitable to 2200 mm

swing dia. Fibrazor.

Chain strength should be 60 T breaking

load. Head end

Sprocket is 16 teeth.

Prepared cane carrier 1

Chopper 1

2 #250 HP HP motor will run in reverse

direction at 300 rpm

through gear box having 1.95:1 ratio

Leveler 1

2 #350 HP HP motor will run in forward

direction at 585 rpm

Fibrazor 1

2200 mm swing dia, 144 nos. hammers of

23kg with new

Pocketed type anvil.

Cane pusher 1

1400 mm dia pusher driven by 30

HP/1440 rpm through

speed reducer and open spur gear

Auto cane feed control Lot

Juice Extraction Plant

Donnelly chute 2

Mills 2

2 # Mills 42" x 84" with pressure feeding

system.

First and last mill s to be provided with

GRPF

Under feed roller 2 UFR of 1100 mm PCD

Mill drive 2

2# 1250 HP AC /Planetary drives

Inter carrier 2

Rake carrier with 50 HP drive carrier

speed shall be

25m/min

JUICE HANDLING EQUIPMENT

Juice Screen 1 Rotary screen with 0.35 slit opening.

Cush - Cush conveyor 1

Double scroll type 410 mm dia x 7000.

The screw

conveyor is driven by 10 HP / 1440 rpm

Mass flow meter for imbibition water 1 150 cu.m/hr capacity, 50 m head

JUICE PUMPS

Unscreened juice pump 2 350 cu.m/hr, 12 m head 960 rpm

Screened Juice pump 3 400 cu.m/hr, 12 m head 960 rpm

Imbibition juice pump 2

350 cu.m/hr, 12 m head, 30 HP/960 rpm -

2 nos.

Imbibition water pump 2 200 cu.m/hr, 50 m head, 50 HP/1440 rpm

Mill house crane 1 Install 1# 40 t EOT crane

Mill house gantry Lot

Millhouse lathe 1 Install 1# lathe to be procured to suit




40


1200 x 5000 mm rollers grooving

JUICE TREATMENT

Water flow meter 1 0-200 t/h, volumetric flow meter

Water weighing scale 1

Juice flow meter 1

Install 1 # volumetric flow meter with

density compensation

in parallel with the flow meter. Capacity

200 t/h

Juice weighing scale 1

Driver trough 1

Check weighing scale

Weighed juice receiving tank

Weighed juice pumps

Phosphate addition system

Preparation tank

Install 1 # phosphoric acid preparation

tank.

Capacity 1 cu.m

Storage tank

Dosing pump

Install 1 # dosing pump of capacity 100

lph

Juice flow stabilization system 1

Install common control system suitable for

400 t/h

for both the flow meters.

Juice sulphitor 1 250 HL capacity

Prelimer 1

pH control system for juice sulphitor 1 pH control system

Sulphured juice receiving tank 1 Cylindrical tank, Cap : 12.5 cu.m

Sulphured juice pumps 3 Install 2 # 400 cu.m/h, 60 m head pumps.

CLARIFIER & FILTERATION

Flash tank 1 Install 1# flash tank suitable for clarifier

Install 1# volumetric flow meter & control

valve to control flow to the clarifier

Clarifier 1

Install 1 # clarifier of 36' dia or Install 1#

short retention time

Clarifier suitable for 2750 TCD.

Polyelectrolyte preparation tank 1 Install along SRT clarifier

Polyelectrolyte storage / dosing tank 1 Install along SRT clarifier

Polyelectrolyte dosing tank 1 Install along SRT clarifier

Rotary vacuum filters 2 2 # Dia 3600 x Long 7200 mm (12' x 24')

Vacuum filtrate Pick-up receivers 3 2 # Dia 600 x Long 1200 mm MS

1 # Dia 900 x Long 1500 mm MS

Vacuum filtrate wash receivers 3 2 # Dia 600 x Long 1200 mm MS


Filtrate collection tank 1 SS make dia 1100 x 2490 long

Filtrate pumps 2 Cap : 70 cu.m/h, 21.5 m head




41


Filter condenser 3 2 # Dia 600 x Long 2400 mm MS


Entrainment separator 3 2 # Dia 450 x Long 900 mm MS


Vacuum pump 2

2# 1200 cu.m/hr with 30 hp motor, motor

rpm 1460

pump rpm 1250

1# 300 mm size water jet air extractor for

both filters

Mud overflow circulation tank 1 Dia 2235 x 1500 long

Mud recirculation pump 3 Cap : 70 cum/hr, 21.5 m head

Cake wash water pump 1 Install 1# pump Cap : 10 cum/h, 55.6m

head.

Feed mixer 1

1 # Dia 1000 x 3500 mm long for both

filters, U shaped.

Bagacillo blower and chute 2 Connected with 20 hp motor

Bagacillo piping 2 1 # pipe of 500 mm dia

1 # pipe of 350 mm dia

Cyclone separator 2 1 # MS make dia 1500 x 3150

1 # MS make dia 1340 x 2700

Mud belt conveyor 1 650 mm width troughed, 36000 mm long

Cake collection bin 1 MS make 2500 x 2500 x 1100

Vibratory screen or filtrate

1

80 mesh screen vibratory type with

rectangular

screen of 1075 x 1000 x 30

Filtrate Clarification System

Filtrate buffer tank 1

Cap : 20 cu.m, dia 2.5 m x 4.0 m height,

steam coil

is installed inside to maintain temperature

of filtrate

Untreated filtrate pumps 2 Cap : 45 cu.m/h, 15 m head

Flow meter 1 Cap : 0-50 cum/h, Magnetic type

Lime sucrate preparation tank 1 Cap : 4 cu.m, dia 1.5 m x 2.25 m Ht

Lime sucrate dosing tank 1 Cap : 4 cu.m, dia 1.5 m x 2.25 m Ht

Lime sucrate dosing pump 2 Cap : 800 lph, 1.5 bar discharge pressure

Phosphoric acid storage tank 1 Cap : 1 cum

Phosphoric acid dosage pumps 2 Cap : 100 lph, 1.5 bar discharge pressure

Flocculent preparation tank 1 Cap : 4 cum, dia 1.5 m x 2.25 m Ht

Flocculent dosing tank 1 Cap : 4 cu.m, dia 1.5 m x 2.25 m Ht

Flocculent dosing pumps 2 Cap : 800 lph, 1.5 bar discharge pressure

Reaction tank 1

Cap : 2 cum, Dia 1.1 m x 2.25 m Ht.,

Impeller

speed 48 rpm

Aeration pumps 2 Cap : 20 cu.m/h, 15 m head

Filtrate floatation clarifier 1 Cap : 13 cu.m, Dia 3.0 m x 1.8 m Ht.

Automation Set Total system is automated




42


Milk of Lime and SO2 Preparation

Quick lime elevators 1

Electric hoist for bag lifting with 0.5 hp

motor

Lime slaker 1 Cap : 1200 Kg/h, 5.5 KW, 12 final rpm

Lime clarifier 1 Koran, 3.7 KW, perforation dia 0.5 mm

Vibratory screen 1 Circular, 60 mesh size, 3.7 KW, 1.5 m dia

Milk of lime storage tanks 2

Dia 3000 x 3150 mm height, 20 cum

each, 5 KW

Milk of lime pumps 2

Install 1 # new pump cap: 10 cu.m/h, 20

M head.

Sulphur burners for juice,

Continuous type 2 200 kg./h. Film Type Burners

Sulphur burner for syrup, continuous 2 Cap. 70 kg/h one working

Air compressor 4 Install 1# 1000 cum/h air compressor

Air receiver 1

air receiver for compressor suitable for

two compressors

Juice heating and Evaporation

Raw Juice Heater (Tubular type) 2 300 sq. m heating surface

Condensate Receiver for JH 2

Collect juice condensate to common

receiver for both

juice heaters

Condensate pump 2

Use both pumps for common receiver.

One working and

one stand by

Sulphured Juice heater (Tubular

type) 3 300 sq. m heating surfaces.

Condensate Receiver for JH 3

Use only 2# condensate receivers one

each for each effect bleeding

Condensate Pump 3

20 cum/h capacity, 30 m head

condensate

pumps for SJ1 & SJ2

Clear juice Heater 2 2 # Direct contact Heaters

Condensate Receiver for JH

Condensate pump

Clear juice column 1 Dia 3000 x 5000 height

Clear juice filters

Install 2 # leaf filter for clear juice filtering

suitable for 4000

TCD with all accessories

Clear juice pump 2

Capacity 250 cum/h and 60 m head to

CJ pumping

Intermediate juice receiving tank

Evaporator Set Quintuple

Quint I 1 2500 sq. m body as Quintuple 1st effect.

Quint II 1 2700 sq. m body as Quintuple 2nd effect.




43


Quint III 1 1250 sq. m body as Quintuple 3rd effect

Quint IV 1 600 sq. m body as quintuple 4th effect.

Quint V 1 600 sq. m body as quintuple 4th effect.

Condensate receiver for Quint -1st

effect 1

Install 1# 1.2 mtr dia and 2.0 mtr height

mound

Condensate pump for Quint-1st

effect 2

Install 1# 130 cu.m/hr, 30 m head

condensing pump as

common standby for quintuple 1 & 2

bodies

Condensate receiver for Quint-2nd

effect 1

Install 1# 1.2 mtr dia and 2.0 mtr height

mound

Condensate pump for Quint -2nd

effet 1

100 cum/h, 30 M head pump for this duty

pump

Condensate receiver for Quint -3rd

effect 1 Quintuple 3rd effect condensate receiver

Condensate pump for Quint -3rd

effect 1 Cap : 50 cum/h, 30 m head

Condensate receiver for Quint -4th

effect 1 Quintuple 5th effect condensate receiver

Condensate pump for Quint -4th


Condensate receiver for Quint -5th

effect 1 Quintuple 5th effect condensate receiver

Condensate pump for Quint -5th


Common condensate flash tank for

2nd Condensate 1

2.5 meter dia and 5.0 meter length

receiver

Common condensate flash tank for

pan and JH Condensate 1

2.5 meter dia and 5.0 meter length

receiver

Syrup receiving tank 1 Dia 1000 x 1500 mm height

Syrup Extraction Pump 2 Cap : 70 cu.m/hr, 30 m head

Syrup Clarification System

Buffer tank 1 Cap : 32 cum, Dia 3.89 m x 2.5 m Ht

Untreated syrup pumps 2 Cap : 70 cum/h, 30 m head

Syrup heaters 2

HAS 77.5 sq. m, 144 tubes, 45 OD/18

SWG/4 m length, 9

tubes / pass, 16 passes

Color precipitant preparation tank 1 Cap : 1 cum

Color precipitant dosing tank 1 Cap : 1 cum

Color precipitant dosing pumps 2 Cap : 100 lph, 1.5 bar discharge pressure

Phosphoric acid storage tank 1 Cap : 1 cum

Phosphoric acid dosage pumps 2 Cap : 100 lph, 1.5 bar discharge pressure

Flocculent preparation tank 1 Cap : 4 cum, dia 1.5 m x 2.25 m Ht

Flocculent dosing tank 1 Cap : 4 cum, dia 1.5 m x 2.25 m Ht

Flocculent dosing pumps 2 Cap : 800 lph, 1.5 bar discharge pressure




44


Reaction tank 1 Cap : 32 cum, Dia 1.465 m x 1.72 m

Aeration tank 1 Dia 0.45 m x 2.0 m Ht.

Syrup floatation clarifier 1 Cap : 32 cum, Dia 4.5 x 1.8 m Ht

Clear syrup tank 1 Cap : 14 cum, Dia 2.1 x 4.0 m Ht

Clear syrup pumps 2 Cap : 50 cum/hr, 35 m head

Automation Set Total system is automated

Leaf filters for syrup filtration

Install 2 # leaf filters to filter syrup before

going to pan floor

Syrup sulphitor 1 Sulphitor of 15 cum working capacity

Caustic Soda Tank 1

Cap : 19.4 cum, Rectangular type, 2900 x

2200 x 3000 mm

Caustic Soda pumps 1 Cap : 100 cum/h, 20 m head

Pressure reducing valve no.1 (PRV-

1) P1 to P2 1

kg/sq.cm (g)


2) P2 to P3 1

Cap : NA, 150 mm size from 7 kg/sq.cm

to 1.5 kg/sq.cm

kg/sq.cm (g)


3) P2 to P3 1

kg/sq.cm (g)


3) P4 to P2 1

Cap : 5 t/h, from 13 kg/sq.cm to 7

kg/sq.cm

kg/sq.cm (g)

Overflow surplus valve for exhaust

(OSV-1)

One exhaust over flow surplus valve of

capacity 30t/hr

Overflow surplus valve (OSV-2)

2# OSV's on two Quntiple two bodies,

Cap : 1# 20 t/h

and 1# 40 t/h

Overflow surplus valve (OSV-3) 1#OSV as relief valve. Cap : 20 t/h

Desuperheater No.1 Dia 1500 x 3000 mm height

Desuperheater No.2 Install desuperheater for PRV

Graining and Crystallization

Syrup & Molasses storage tanks 17 Each capacity 20 cum

5 # syrup, 2 # Melt, 1 # AL, 4 # AH, 3 #

BH & 2 # CL

Molasses conditioner 3

Continuous type, between runoff storage

tank and pan

supply tank

1 # Cap : 2.58 cum for AH

1 # Cap : 2.0 cum for BH

1 # Cap : 1.3 cum for CL

A Vacuum Pan - Batch 4

80 t with mechanical circulator. With Pan

automation.




45


Graining vacuum pans - Batch 1

60 Ton with Mechanical circulator with

automation

B' Vacuum Pan - Continuous 1

Install 1 # 30 t/h continuous pan for B

massecuite

C' Vacuum Pan - Continuous 1

Install 25 T /hr continuous pan for C

Boiling

Pan Condensate Receiver 2

Dia 2600 x 3800 mm for 2nd vapor, Dia

2000 x 2700 for 1st

Vapor

Pan condensate pump 3 2 # Cap : 50 cum/h, 30 m head

1 # Cap : 70 cum/h, 30 m head

Dry seed crystallizer 1 U Shaped Net Cap : 40 t

B Seed crystallizer 1 U Shaped Net Cap : 40 t

Grain Seed Crystallizer 2 U Shaped Net Cap : 90 t

A Vacuum crystallizer 1 U Shaped Net cap: 40 t

B Vacuum crystallizer 1 U Shaped Net cap: 40 t

C Vacuum crystallizer 1 U Shaped Net cap: 40 t

Crystallizer for `A' massecuite 5 U Shaped, Net Cap : 90 t

Strike receiver for `B' Massecuite 1 U Shaped, Net Cap : 90 t

B' Massecuite transfer pump 1 9 ‗‘ x 9 ― PSP pump, 30 m Head

Strike receiver for B Massecuite 1 U Shaped, Net Cap. 90 t

Vertical crystallizer for B'

Massecuite 1

Install 1 # 300 t mono vertical crystallizer

for B massecuite

Liquidation pump for Vert. Cry. 1 Rota type, 8" x 8", Cap : 35 t/h, 30 m head

Strike Receiver for `C' Massecuite 1 U Shaped, Net Cap.90 t

C' Massecuite transfer pump 1

Strike Receiver for `C' Massecuite 1 U shaped, Net Cap. 90T

Vertical crystallizer for C'

Massecuite 1 set

Install 1 # 300 t mono vertical crystallizer

for C massecuite

Liquidation pump for vert.Cry 1 Roto type, 8" x 8", Cap : 35 t/h, 30 m head

Cooler for hot water 1 Install 1# parallel heater

Cold water surge tank

Cold water circulation pumps 2 Cap : 36 cum/hr, 55 m head

Hot water surge tank by gravity

Hot water circulation pumps by gravity

Hot & Cold water overhead tank 3 1 # 7500 x 3750 x 2500 for hot water

2 # 7500 x 4500 x 2500 for cold water

Service water tank 1

Concrete 40000 x 20000 x 2500, net

capacity 2000 cum

Service water pump 3 1 # Cap : 450 cum/h, 22 m lead

2 # Cap : 300 cum/h, 40 m head

Centrifugals

A Massecuite centrifugal pug mill 2

U shaped 5600 long x 1000 wide. Each

catering to 3




46


Machines

A Massecutie Centrifugals 4

Install 4 # 1750 kg/charge fully automatic

DC drive

Centrifugal machines.

AH molasses receiving tank 1 Dia 1900 x 1250 height

AH molasses pump 2

Screw type pump of 30 t/h capacity, 25 m

WC

AL Molasses receiving tank 1 Dia 1900 x 1250 height

AL Molasses pump 1 Screw type, Cap : 30 t/h, 25mWC

Superheated wash water system Set Suitable for 7 batch machines

Superheated wash water pump 2 Cap : 20 cum/h, 55m head

Air Compressor 2 Discharge pressure 6 kg/sq.cm(g)

B Centrifugal pug mill 2

1 # U Shaped, 4600 long x 1000 wide, for

batch machine

1 # U shaped, 6100 long x 1000 wide, for

continuous m/c

B Centrifugals 3 1 # Batch machines of 1250 kg/charge

2 # WK 1500, Cap : 15-18 t/h continuous

machines

B-Magma mixer 2

1 # U shaped, 6000 long x 1000 wide for

batch machine

1 # U shaped, 4900 long x 1000 wide for

continuous m/c

B Magma pump 2 1# Rota type, Cap : 20 t/h, 30 m head

1 # Rota type, Cap : 20 t/h, 30 m head

B Molasses receiving tank 2 Dia 1500 x 1200 height, 1 # BL & 1 # BH

B Molasses pump 2

Screw type pump of 20 cum /h capacity,

25 mWC

CAW centrifugal pug mill 1 U shaped, 4600 long x 1000 wide

C after Centrifugals 2

WK 1500, Cap : 10-12 t/h. 1 # B curing

machine is common

standby for CAW

C After Magma mixer 1

U Shaped, 4900 long x 1000 wide for B &

CAW continuous

Machine

C-After magma pump 1 Common for B & CAW

CL Molasses receiving tank 1 Dia 1500 x 1200 height

CL Molasses pump 2


25 mWC

CF centrifugal pug mill 1 6800+1000 long x 800 dia

C Fore worker Centrifugals 3

wk - 1500 or equivalent machine for C

Fore curing

C-Fore magma mixer 1 U Shaped

1 # 6000 long x 1000 wide, with planetary

C-Fore magma pump 3 Rota type, Cap : 20 t/h, 30 m head

FM receiving tank (below machines) 1 Dia 1500 x 1200 height




47


FM Pump below machines 2


25 mWC

Final Molasses weighing scale 1

Weighed FM Receiving tank 1 Rectangular type

FM Pump below weighing scale 2


25 mWC

Final molasses storage tank 2 Cap : 7500 T each, 28 m dia x 9.50 m Ht

Final molasses transfer pump 2


25 mWC

Sugar Melter 2 Cap :: 35 t/h vertical

Melt pump 3

2 # Centrifugal, Cap 40 cum/hr, 30 m

head

1 # screw type, Cap : 30 t/h, 25mWC

Sugar Handling & Bagging

Gross Hopper Conveyor 1 Single tray type, 2.0 m width, 12 m long

Fluidized bed dryer 1

1 # 40 t/h fluidized bed dryer along with all

accessories

Sugar elevator from FBD to grader 2 Cap : 40 t/h

Sugar grader

2

1 # Cap : 35 t/h

1 # Cap : 35 t/h

Sugar elevator from grader to bin 2 Cap : 25 t/h

Sugar Bins 3 125 t sugar bin

Slat Conveyor 2 Width 400 mm, 1.5 KW

Bag stitching machine 3 Cap : 300 bags/h

Dry seed magma mixer 1 U Shape, Cap : 5 t

Dry seed transfer pump 1

Rota type, 8" x 8", Cap : 300 t/h, 30 m

head

Dust collector system Set

Dust collector tank 2 1 # Dia 3.0m x 3.7m Ht

1 # Rectangular wet scrubber, 2.5 x 1.5 x

2.0m

Dust melt pump 2 Cap : 35 cum/h, 25 m head

Sugar bag belt conveyor 6 Width 600 mm

Sugar bags mobile belt conveyor 10 Width 600 mm

Sugar Godowns 4

2 # 100m x 40m x 10m, Cap : 400000

bags

Condensing Plant

Evaporator condenser 1

1 #Single entry Vapor inlet dia : 1100 mm

with automation

Batch Pan condensers 5


with automation





48


with automation

Continuous Pan condensers 2


with automation

Ejector for pans & vacuum

crystallizer 1

Same system is to be followed for new

condensers also

Automation Set

Injection pump 4 1600 cum/h, 22 m head pumps

Priming pump 1 Cap : 25 cum/h, 3.75 KW

Cooling tower 3 Cap : 1600 cum/h, each cell

Cooling tower water pump

Priming pump 1 Cap : 25 cum/h, 3.75 KW

Electricals

Distribution transformers 3 2.5 MVA distribution transformer

Bus ducts 4 4000 Amps,

Power control centre (PCC) 3 4000 Amps,

Motor Control Center (MCC) 12

Distribution boards Lot

Push button stations Lot

Lighting Lot

Earthing LOt

APFC panel 2

LT power and control cables Lot

Miscellaneous work (cable tray,

danger baords, Lot

rail for transformer, gravel spreading

etc.)

Co-generation Plant:

Machinery Details:

Equipment name Qty. Capacity

Boiler Capacity 1 100 T

Turbine Capacity 1 20 MW

Electro Static Precipitator 3 Fields

FD Fans 2

ID Fans 2

Air heaters 1

Feed water system 2 HP heater-1 with 16 ata extraction steam

HP heater-2 with 8 ata extraction steam

Feed water pumps 3 80tph capacity,110kg discharge pressure

HP LP dosing system 2 HP dosing pumps for steam drum dosing

2 LP dosing pumps for derator dosing

Dearator 1

Bagasse Handling system 1 100 TPH




49

Coal Handling System 1 45 TPH

Biomass preparatory system 1

Feed regulation station 1 Control valve station with manual by pass

station

Atemperation system 1 Spray between primary super heater and

secondary super heater

D M plants 2 each 400 OBR at 30TPH

Water clarifier 1 200 TPH

Cooling tower system

No. of cells 4 1600 Cum.Mtr/Hr

Cooling tower pumps 4 1600 Cum.Mtr/Hr, Discharge pressure -

3.25 KSC

Two pass surface condenser with

cooling water flow 4200 Cum.mtr/Hr

Condensate extraction system

Pumps 3 50TPH each at 6kg pressure

Gland steam condenser 1 100 TPH

Steam ejectors 2 Main

1 Hogging

Turbine lub oil system/control oil

system

1

package

ST switch gear- 11kv

Generator transformer - 36MVA-

11/110kv

Distribution transformers 3 2.50mva each, 11kv/415volt

1 3.15mva, 11kv/415v

Diesel generator set 1 1500 kva

PRDS system 1 75 tph,87/8 ata

1 80tph,8/2.5ata

Pumping station at Kali river & Piping

Pumps 3 100 tph each, Pressure-4kg

Priming pump 2 20 tph

Infiltration pump 3 100 tph

Electrical substation at Kali pump

hose with 11kv/415 v transformer,

MCC and 250 kva diesel set

Switch Yard

110kva breaker 2

11kv breaker 1

100kv Isolators 3

CTs and PTs as per the requirement

Double circuit 110kv line to Haliyal

substation

Fire fighting system for complete

complex

Fire water pump motor driven 1 100 TPH at 10 KSC




50

Fire water pump diesel set driven 1 100 TPH at 10 KSC

Jacky pump 2 30 TPH at 10KSC

Distillery Plant:

SECTION I : FERMENTATION HOUSE :

MOLASSES WEIGHING SECTION :

1] Weighscale / Loadcell for Check : 1 No.

weighment. Capacity : 3 MT

2] Molasses feed tank : 1 No.

Material of construction : M.S

Capacity : 50 MT

- FERMENTATION EQUIPMENTS

1. PROCESS TANKS

A] Fermenter : 2 Nos

Material of construction : MS

Capacity : 500m3

Equipped with roof manholes, air sparger in stainless steel construction, sight and light

glass assemblies, level indicator, defoaming oil sensor, pressure relief device and

required nozzles and fittings.

All internal surface will be sand blasted and epoxy coated ( 1 primer coat followed by

2 finish coats - min. DFT (150 micron ).

B] Propagation Vessel I

Design code : ASME VIII, Div. 1

Material of construction : SS 304

Capacity : 180 L

Equipped with sight glass, air sparger, cooling jacket, relief valve and necessary

nozzles and fittings.

C] Propagation Vessel II

Design code : ASME VIII, Div. 1


Capacity : 2000 L

Equipped with sight glass, manhole, air sparger, relief valve and necessary nozzle and

fittings.

D] Propagation Vessel III

Geometric Capacity : 100,000 L




51

Design code : IS 803

Material of construction : MS (epoxy lined)

Equipped with shell and roof manholes, air sparger, sight and light glass assembly and

necessary nozzles and fittings.

All internal surfaces will be sand blasted and epoxy coated (1 primer coat followed by 2

finish coats - min. DFT 150 micron).

E] Defoaming Oil Day Tank.

Capacity : 1000 L

Material of construction : MS

2. PROCESS PUMPS :

A] Molasses feed pump : 1 + 1 standby.

Type : Positive displacement

Material of construction : CI with SS wetted parts.

Shaft sealing. : Gland packing.

Drive : Variable speed

-Molasses storage to feed : 1+1

-Weighing to diluter : 1+1

B] Fermenter Cooling Pump : 2 + 1 standby

Type : Centrifugal


C] Fermenter Discharge Pump : 1 + 1 standby

Type : Centrifugal


D] Wash Transfer Pump : 1 + 1 No.

Type : Centrifugal


E] Sludge Pump : 1 + 1 No.

Type : Centrifugal


F] Recycle Pump : 1 + 1 standby

Type : Centrifugal


G] Propagation II Cooling Pump : 1 Nos.

Type : Centrifugal


H] Defoaming oil dosing Pump : 1

Type : Positive displacement.




52

Material of construction : GI

3. PLATE HEAT EXCHANGERS. [ Alfa Laval make ]

M.O.C of Qty

Plates Nos.

a] Prop II Temp. Control PHE SS 316 1

b] Fermenter Cooling PHE SS 316 2

(Min.AK 20 FMI 168 plates each with back flushing arrangement)

4. MISCELLANEOUS :

A] Positive Displacement Blowers : 1 + 1 standby

Type : Twin lobe

Material of construction : CI body, cast steel.

Braided with suction/discharge silencers, relief valve, non-return valve & suction filter.(

water cooled) OR

Alternatively Vacuum Pump may be considered for same duty.

Capacity : 1700nm3/hr+900nm3/hr

Head : 9 MWC

B] Carbon-di-oxide Scrubber : 2 Nos.

Type : Sieve plate column


Plate material : SS 304

Diameter : 600mm

With water spraying arrangement in AISI 304, sight glass and packing support grid.

C] Strainers - : 3 Nos.

For : 1) Fermented wash

2) Recycle.

3) Diluted Molasses

Type : Basket

Material of construction : AISI 304

Hole size : 0.6 mm

D] Sterile Air filters : 2 Nos.

Capacity : 20 M3/Hr. & 120 M3/Hr

E] Water molasses static mixer in AISI 304 : 1 No.

F] Air Compressor for Instrumentation Air : 1No+1No (Common for entire

plant including Mol. Sieve plant)




53

5. YEAST RECYCLING SYSTEM :

A] Yeast Separator [Alfa Laval make] 2 + 1 Nos.

Indigenous model DX 409

B] Chain Pulley block with travelling trolley : 1 No.

Capacity 1 MT

C] Cleaning table for separator in MS : 1 No.

D] Yeast Cream Funnel : 3 Nos.

Material of construction : SS304

E] Hydrocyclones : 1 Set.

Material of construction :

- Body : AISI 304

- Cone : Ceramic

6. CIP SYSTEM :

I CIP tank/Hot water tank : 1 No each.

Capacity : 2000 L

Material of Construction : AISI 304

II CIP Pump : 1 No.

Type : Centrifugal


7. Cooling Tower : 2 Nos. 400 Cu.m./ hr.

SECTION II : Distillation

1 Analysing Column (Vacuum) Material of Construction : SS304

Type of Trays : Sieve

No. of trays : 50

Tray spacing : 750mm

Diameter : 1698mm / 2195mm

(min. diameters mentioned)

2 Rectifying Column (Under pressure) Material of Construction : SS304


No. of trays : 144

Tray spacing : 300

Diameter : 1790mm





54

3 Aldehyde Column Material of Construction : SS304


No. of Trays : 60

Tray spacing : 250mm

Diameter : 710mm


7 Beer Pre-heater : Shell & Tube type

Material of Construction : SS 304

Tube length : 3000mm

Tube thickness : 1.25mm

8 Analysing coloumn Reboiler : Shell & Tube type

Material of Construction : Shell: 304Tubes: SS316



Qty : 1+1

9 Stripper Rectifier Column Reboiler

Type: Shell & Tube

MOC: Tubes : SS304 Shell : CS, Ends : CS

Qty : 1 Nos.

10 Final Condensor : Shell & Tube type

Material of Construction : Tube and tube sheet are in

SS 304, water side in CS



11 Aldehyde Condensor : Shell & Tube type




12 Aldehyde Vent Condensor : Shell & Tube type




13 Final Product Cooler : PHE

Material of Construction : SS 304 plates

Area : Suitable




55

14 Fusel Oil / Heads Spirit Cooler : Vertical type


15 Fusel Oil washer decanter : Vertical type


16 Steam Chest : 1 No.

Material of Construction : MS

17 Hot water tank

Capacity : 1 M3

Material of Construction : MS

18 Reflux Tanks : 2 Nos.

19 Plate Heat Exchangers:

Sr. Description M.O.C. (Plates) Qty.

I Wash Pre-heating PHE SS316 2

II Recycle Wash Cooler (Recycle) PHE SS316 1

III Spent Wash Cooler PHE SS316 1

20 Pumps : With flame proof motors, mechanical seals & back pull out rotor design.

Sr. Description M.O.C. Qty.

IV Rectifier Reflux Pump SS316 1+1

V Weak Alcohol feed pump SS316 1+1

21. Cooling Tower : 2 Nos. 375 Cu.m. / hr.

SECTION III: Molecular Sieve Dehydration:

1 Mol Sieve Superheater

Type: Shell & Tube

MOC: Tubes: SS304 Shell: CS Bonnets: CS

Qty : 1 Nos

2 Mol Sieve Unit

Type: Dished ends; with packed bed of Molecular Sieves

MOC: SS

Qty: 2 Nos

3 Mol Sieve Condenser

Type : Shell & Tube

MOC: Tubes: SS304 Shell: CS Bonnets: CS




56

Qty : 1 Nos.

4 Mol Sieve Product Cooler

Type: PHE

Qty : 1 Nos.

5 Mol Sieve Regenerant Condenser

Type: Shell & Tube

MOC: Tubes : SS304 Shell : CS Ends : CS

Qty : 1 Nos.

6 Mol Sieve Regenerant Drum

Type: Dished top & bottom

MOC : SS

Qty: 1 Nos

7 Mol Sieve Vacuum Pump Drum

Type: Dished top & bottom

MOC : SS

Qty: 1 Nos. 1

8 Mol Sieve Recirculation Cooler

Type: PHE

Qty : 1 Nos.

9 Mol Sieve Regenerant Pump

Type: Centrifugal

MOC: Impeller:SS Casing: CI

Qty: 1 + 1 No.

10 Mol Sieve Vacuum Pump

Type: Liquid Ring

Qty : 1 No+1No

11 Rectified Spirit Day Tanks: 2 Nos. MS , Capacity : 100 KL Each.

Additional Columns for ENA Production.

Extractive Distillation Column

Recovery Column

Polishing Column




57

6.2 Residential Area (Non Processing area):

Facilities like canteen, rest room and indoor games facilities will be provided in the proposed

expansion project.

6.3 Green Belt:

Total 1/3rd of the total area including existing will be developed in the Plant premises.

Greenbelt development plan

Local DFO will be consulted in developing the green belt.

Greenbelt of 45 acres will be developed in the plant premises as per CPCB guidelines.

15 m wide greenbelt will be developed all around the plant.

The tree species to be selected for the plantation are pollutant tolerant, fast growing,

wind firm, deep rooted. A three tier plantation is proposed comprising of an outer most

belt of taller trees which will act as barrier, middle core acting as air cleaner and the

innermost core which may be termed as absorptive layer consisting of trees which are

known to be particularly tolerant to pollutants.

6.4 Social Infrastructure:

Social infrastructure will be developed as per need based in the nearby Villages.

6.5 Connectivity:

Component Description

Road The site can be well approached by a SH # 4 (Zaheerabad – Bidar)

Rail Nearest Railway station located at 5.8 Km (Mettalkunta)

Air port Nearest Airport located at Hyderabad which is at distance of 100 Kms

from the Plant site

Sea Port Krishnapatnam port is at a distance of 450 Kms from the Plant site

6.6 Drinking water management:

Drinking water required for the workers will be met from ground water resources.

6.7 Sewerage system:

Domestic waste water generated will be treated in septic tank followed by Sub-surface

dispersion




58

6.8 Industrial waste management:

6.8.1 Waste Water Management

Waste water generated from the proposed Project will be treated in Effluent Treatment

proposed which is furnished under paragraph 3.10.2

6.8.2 Solid Waste Management

Solid wastes disposal in the existing and expansion project is discussed in paragraph 3.11

6.9 Power requirement & Supply / Source:

The power required for the project will be met from Cogen & Captive power plant during

season and Captive power plant of 4 MW during off season.




59

7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

No rehabilitation or resettlement plan is proposed as there are no habitations in the in the

Plant site.

8.0 PROJECT SCHEDULE & COST ESTIMATES

The total cost of the project has been estimated at Rs. 252 Crores.

Detailed breakup of the Cost is given below.

S.NO. DESCRIPTION RS. Crores

1. Land preparation cost 2.0

2. Civil works –Building /Foundation 15.0

3. Plant & Machinery 130.0

4. Electrical works 10.0

5. Miscellaneous works 5.0

6. Distillery 70.0

7. Working capital & I D C 20.0

Total 252.0




60

9.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

With the implementation of the proposed expansion project, the socio-economic status of the

local people will improve substantially. The land rates in the area will improve in the nearby

areas due to the proposed activity. This will help in upliftment of the social status of the people

in the area. Educational institutions will also come-up and will lead to improvement of

educational status of the people in the area. Primary health center will also come-up and the

medical facilities will certainly improve due to the proposed expansion project.

EMPLOYMENT POTENTIAL

The following will be the man power requirement for existing and expansion Project

S.No. Particulars No. Employees

1. Technical & Administrative Staff 20

2. Skilled & Semi Skilled (Contract basis) 60

3. Unskilled & Helpers (Contract basis) 40

Total 120

OTHER TANGIBLE BENEFITS

The following are the other benefits to the area due to the proposed expansion project.

Educational status will improve in the area

Medical standards will improve due to the proposed expansion project.

Overall economic up-liftment of socio-economic status of people in the area.

Ancillary developmental activities like CO2 plant, Cattle feed plants will be created due

to the establishment of the proposed unit.

SOCIO-ECONOMIC DEVELOPMENTAL ACTIVITIES

The management is committed to uplift the standards of living of the villagers by undertaking

following activities / responsibilities.

Health & hygiene

Drinking water

Education for poor

Village roads

Lighting

Helping locals to conduct sports

Training to the unskilled manpower




61

HEALTH & HYGINE

1. Personal and domestic hygiene,

2. Maintaining clean neighborhood,

3. Weekly health camps offering free-check up & medicines

4. Ambulance services

5. Education & drug de-addiction, aids.

DRINKING WATER

Making drinking water available at centralized locations in the village,

SUPPORTING EDUCATION

1. Providing books to all poor children,

2. Conducting annual sports festival in the village schools,

3. Providing amenities like fans, lavatories,

4. Maintain play ground etc.

pre- feasibility report -...

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