Pre Feasibility Report Of Sugar Unit

PRE-FEASIBILITY REPORT

Modernization cum Expansion of Sugar Unit from 5,000 to

8,000TCD Capacity and Cogeneration Project of 19.5 MW

Installed Capacity

M/s. Karmayogi Shankarraoji Patil Sahakari Sakhar Karkhana Limited

Mahatma Phule Nagar, Bijwadi, Taluka Indapur, District Pune, Maharashtra

Prepared By

VASANTDADA SUGAR INSTITUTE *

Manjari (Bk), Pune, Maharashtra 412 307

Telephone: (020) 26902100, 26902343/7/6, Fax (020) 26902244

Web Site: www.vsisugar.com

*Accredited by QCI/NABET (Provisional) for EIA consultancy services

Recognized R & D Center by Department of Scientific and Industrial Research (DSIR), Ministry of

Science and Technology, Government of India and P.G. and Doctoral Research Center by University

of Pune

March 2012

Prefeasibility Report Sugar and Cogeneration Project

Karmayogi Shankarraoji Patil SSKL, Indapur 2

PRE-FEASIBILITY REPORT

KARMAYOGI SHANKARRAOJI PATIL SAHAKARI SAKHAR KARKHANA LIMITED

EXPANSION OF SUGAR UNIT FROM 5,000 TO 8,000TCD AND 19.5MW COGENERATION

UNIT

1.0 INTRODUCTION

The Karmayogi Shankarraoji Patil Sahakari Sakhar Karkhana Limited (KSPSSKL), is

located at Mahatma Phule Nagar, village Bijwadi Tal-Indapur, Dist-Pune. It is 1.5km off

Pune-Hyderabad National Highway (NH 9). Initial crushing capacity of the KSPSSKL was

1750 TCD. On account of modernization of the plant from time to time and by effective

utilizing of in-built capacity of the plant the KSPSSKL has achieved a crushing capacity of

+5,000 TCD since 1999-2000. The sugar factory also operates a molasses based

distillery of 30 KLPD capacities.

2.0 HIGHLIGHTS OF THE PROJECT

Project

Proponent

Karmayogi Shankarraoji Patil Sahakari Sakhar Karkhana Limited

(KSPSSKL)

Geographical Location 18008N;

74057E

523 MSM

Nearest City/Town Indapur is the nearest town 08 km from the site.

Road The site is located off Pune-Solapur National highway

No. 09. Distance- 1.5 km from factory site

Railway Station Baramati railway station 45 from the site.

Air Port Pune is the nearest airport 135 km from the site.

East Village Rajwadi 2.5

West Kaulthali 3.5 Km

North National Highway 9 - 1.5km

South Village Ramoshiwadi 1.5Km



Location of the

project

Mahatma Phule Nagar, village Bijwadi Tal-Indapur, Dist-Pune

Maharashtra

Email : [email protected]

Ph no: 02111-2886103/123/144/146

Fax : 02111 - 286105

Land 18 acres built up area after expansion,

6 acres provided for green belt development

Project Modernization cum expansion of sugar unit from 5,000 TCD to

8,000 TCD along with cogeneration unit of 19.5 MW installed

capacity

Product i) White Sugar: 920 MT/Day

ii) Bagasse : 2240 MT/Day

iii) Molasses ; 320 MT/Day

iv) Press mud: 320 MT / Day

v) Power: 18.585 MW electricity

Running Days 210 Days

Main Raw

Material

i) Sugar Cane: 8,000 MT/Day

ii) Lime : 9.76 MT/Day (0.15% Cane )

iii) Sulfur: 4.64 MT/Day (0.05% Cane )

iv) Bagasse : 1,690 MT/day

Water

Requirement

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

Fuel Bagasse 1690 MT/day

3.0 Need of Project and its importance to the country and region:

India is the second largest producer of sugar over the globe. With more than 45

millions of sugar cane growers in the country, the bulk of the rural population in India

depends on this industry. One of the agro-based industries in India, the sugar industry is

the second largest agricultural industry followed after the textile industry. Maharashtra

Sugar Industry is one of the most notable and large-scale sugar manufacturing sectors in

the country.

There are few major reasons for the expansion of the sugar factory and

increasing availability of cane and pressing demand of the local share holder farmers to

crush all the cane they grow is the foremost reason. Since, the Karkhana is located



towards east of the Pune district, where an excellent network of canals exist. The

command area of the KSPSSKL comprises 112 villages from Indapur and Daund talukas

of Pune district and Karmala, Malshiras & Madha talukas of Solapur district. Out of total

command area of the KSPSSKL, 70% area is irrigated by Ujani and 30% area is under

well irrigation. Nira right bank canal project also covers some area under irrigation.

Hence the availability of water is ample in the area; and thus the area under cultivation

of sugar cane is going on increasing every year. Increase in the cane production can also

trace though the figures of cane crushed by the KSPSSKL during previous 10 years.

Table 1: Production of Sugar cane and cane crushing for last 10 Years

Sr. No. Year Total Cane crushed

(MT)

Total Cane production in area

(MT)

1 2000-01 5,91,560 87,000

2 2001-02 8,08,516 3,53,000

3 2002-03 7,49,863 8,00,000

4 2003-04 4,16,597 5,00,000

5 2004-05 3,98,077 5,00,000

6 2005-06 8,76,907 10,46,000

7 2006-07 12,34,935 13,50,000

8 2007-08 12,11,128 13,25,000

9 2008-09 9,89,976 11,00,000

10 2009-10 12,83,800 14,00,000

In season 2010-11 the expected crushing will 13, 59,500 where as the production or

availability is about 16, 00,000 MT. The above table infers that there is ample sugarcane

available in the command area of the KSPSSKL. However, the crushing capacity is a

limiting factor to fulfill the demand of the local farmers. The sugar cane cultivation is

anticipated to grow at least for next few seasons. Thus, the KSPSSKL has to develop its

infrastructure to crush all available cane in the command area. Hence, the management

has decided to modernize the existing 5,000 TCD sugar factory and install a 3,000 TCD

unit so as to increase the cane crushing capacity of the KSPSSKL to 8,000 TCD.

The present peak demand of power is more than 16,000 MW and only 13,000 MW is met

thorugh various sources. Considering the immediate requirements of energy and till the

end of the present period, about 5,737 MW shall be installed during the next four years,

hence the government of Maharashtra permitted such an sugar factory to utilize the



resource-able energy fuel and to make a power which will helps to decrease the energy

deficit.

While doing this, optimum utilization of the available resource is strived by the

management, by using a renewable energy source of bagasse. Bagasse is a by-product of

sugar factory, used as a fuel for boilers that produces process steam. Bagasse-based

cogeneration project is an effort for efficient use of available bagasse and steam to

generate the power for to fulfill the captive need and export the surplus to the state grid.

Hence, the KSPSSKL is installing a new 15MW capacity steam turbine, in addition to

existing 1.5 and 3MW. Thus, it will have an installed capacity of 19.5MW and it will

produce an electricity of 18.585MW.

4.0 Demand- Supply Gap

The present peak demand of power is 15,988 MW and only 11,800 MW is met during the

period 2009. Including the present deficit and projected growth rate, about 18,759 MW

shall be added till the end of 12th plan period. Considering the immediate requirements

of energy, another 5,600MW shall be added during 11th plan period ending 2012; hence

the Government of Maharashtra permitted such an sugar factory to utilize the resource-

able energy fuel and to made a power which will helps to decrease the energy deficit.

Table 2: Data on Monthly Demand~ Supply gap in MW in the state for Year 2009

2009

Month Demand Availability Short fall*

Jan-09 14,926 10,151 4,775

Feb-09 15,272 11,010 4,262

Mar-09 15,332 11,536 3,796

Apr-09 15,195 11,325 3,870

May-09 15,304 11,179 4,125

Jun-09 14,387 11,175 3,212

Jul-09 13,044 10,317 2,727

Aug-09 15,171 11,384 3,787

Sep-09 14,800 11,598 3,202

Oct-09 15,572 11,714 3,858

Nov-09 15,988 11,883 4,105

Dec-09 15,386 11,713 3,673

*Peak shortfall on a particular day of the month

V. Import vs. Indigenous production



The process is straight line and the technology even for the pollution control/disposal is

available indigenously

VI. Export Possibility

The finished products viz. Sugar, have export possibility and the surplus power

generated form cogeneration will be export to the local grid.

VII. Domestic / export markets

Local as well as international market is available for sugar and molasses. Electricity will

be exported to the local grid of MSEDCL.

VIII. Employment Generation:

The KSPSSKL requires educated and skilled staff at expanded sugar factory as well as

cogeneration unit. This requirement is furnished table 3. The indirect employment is

anticipated to be plenty, since the project is going to produce surplus power. This power

may be used to run various businesses and agricultural activities

Table 3: Employment Potential of Sugar & Cogeneration Project

Engineer Department Manufacturing

department

Additional Manpower

Designation Number Designation Number Designation Number

Assistance Engineer 04 Manufacturing

Chemist

04 Instrument engineer 01

Electrical engineer 01 Juice Supervisor

04 Mechanical Engineer 01

Electrical supervisor 04 Pan In charge 04 Electrical Engineer 01

Mill & Boiling House

Fitter (A grade)

08 Pan man 04 Instruments

Technician

04

Mill & Boiling house

Fitter (B grade)

04 Quadruple

met

04 Electrical

Supervisor

01

Turbine attendant 04 Centrifugal Met

04 Mechanical Supervisor

01

Electrician 04 Sugar house

Clerk

04 Switch board

attendant

03

Wireman 07 -------- ------ ------ -----

Total Staff 40 Total 28 Total 12

Total man power for sugar expansion along with

Cogeneration (Engineer + Manufacturing + Additional )

80

Expected indirect man power Plenty



2.0 Project Description

I. Type of project

The project is modernization cum expansion of sugar unit from 5,000 TCD to

8,000 TCD along with cogeneration unit of 19.500MW installed capacity. Bagasse is a

byproduct of sugar unit has tremendous potential as a renewable source of energy.

Hence, cogeneration unit is interlinked with sugar unit.

II. Location with coordinate

project boundary :

Project coordinate : 18008N; 74057E 523 MSM



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

The proposed project is actually modernization cum expansion of sugar factory and

installation of 15MW turbine. KSPSSKL already possess adequate land i.e. more than 200

acres, for the new set up as well as its ancillary units such as pollution control system,

greenbelt, etc. Considering these facts, the point of alternative site search becomes

irrelevant.

IV. Size or magnitude of operation

Modernization cum expansion of sugar unit from 5,000 TCD to 8,000 TCD along with

cogeneration unit of 19.500 MW installed capacity

V. Project description with process details

Proposed Sugar Unit

Proposed

mill house

Proposed

Cogeneration house



a) The Process Sugar

Figure1: Flowchart of sugar manufacturing process

Cane Supply

Milling

Sulphitation

Clarification

Evaporation

Pan boiling

Crystallizer

Centrifugals

Sugar

Packing

Boiler

Lime & Sulphur House

Rotary vacuum filter

Bagasse

Press mud

Juice

SUGAR MANUFACTURING

PROCESS Steam



Extraction of Juice

The sugarcane is passed through preparatory devices like knives for cutting the stalks

into fine chips before being subjected to crushing in a milling tandem comprising 4 to 6

roller mills. In the best milling practice, more than 95% of the sugar in the cane goes into

the juice

Clarification

The treated juice on boiling fed to continuous clarifier from which the clear juice is

decanted while the settled impurities known as mud is sent to rotary drum vacuum

filter for removal of unwanted stuff called filter cake is discarded or returned to the field

as fertilizer.

Evaporation

The syrup is again treated with sulphur dioxide before being sent to the pan station for

crystalization of sugar. Crystalization takes place in single-effect vacuum pans, where

the syrup is evaporated until saturated with sugar. At this point seed grain is added to

serve as a nucleus for the sugar crystals, and more syrup is added as water evaporates.

Centrifugation

The massecuite from crystallizer is drawn into revolving machines called centrifuges.

The perforated lining retains the sugar crystals, which may be washed with water, if

desired. The mother liquor molasses passes through the lining because of the

centrifugal force exerted and after the sugar is purged it is cut down leaving the

centrifuge ready for another charge of massecuite.

Gradation & Packing

The final product in the form of sugar crystal is dropped through pan section and this

sugar is graded and picked in 50 kg bags. The grade of the sugar depends on the size of

the crystal viz. Small (S) and Medium (M)

b) Process of Cogeneration

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

significantly and enabling the plant t o generate surplus power from its cane crushing

operation. This surplus power will be exported to the state electricity grid. Energy

efficiency and the export of power to the grid are made feasible due to the availability of

high pressure and high temperature steam and by the utilization of the available

bagasse. The flow chart for generation of the power in cogeneration as shown in

following figure



Figure 2: Process flow diagram of Cogeneration power plant

VI. Raw materials required along with estimated quantity, like source market

area final product, mode of transport of raw materials and finished good

products

Table 4: Availability raw materials & finish product and transport mode

Raw

materials

Estimated

quantity

MT/day

source

market

final

product

Estimated

quantity

MT/day

source

market

Transport

mode

Sugar

Cane 8,000 local Plantation

White

Sugar

920 Maharashtra

India

Truck

Tractor

Bullock card

Lime 9.76

Pune

Mumbai

Solapur

Bagasse 2,240 Pune Truck

Tractor

Sulfur 4.64

Pune

Mumbai

Solapur

Molasses 320 Maharashtra Tankers

Exhaust Steam

Boiler Bagasse

Power

Sugar factory and allied

units

Surplus to Electricity grid

PRDS

HP Heater

Captive Power

Steam

Turbo

Generator



Bagasse 2466 Own

sugar

factory

Burnt in

boiler

1690 Local Conveyor

Power

MW

18.585 Local grid By cable

VII. Resource optimization / recycle and reuse envisaged in the project

Modernize of the existing 5,000 TCD sugar factory and install a 3,000 TCD unit so as to

increase the cane crushing capacity of the KSPSSKL to 8,000 TCD. While doing this,

optimum utilization of the available resource is strived by the management, by using a

renewable energy source of bagasse. Bagasse is a by-product of sugar factory, it will be

used as a fuel for boilers that produces process steam. Bagasse-based cogeneration

project is an effort for efficient use of available bagasse and steam to generate the power

for to fulfill the captive need and export the surplus to the state grid. Hence, the

KSPSSKL is installing a new 15MW capacity steam turbine, in addition to existing 1.5

and 3MW. Thus, it will have an installed capacity of 19.5MW and it will produce an

electricity of 18.585MW.

Water and its source

Table 5: Water requirement and availability

Particular Estimated quantity Source

Water

Ujani dam

Permission is

available

Domestic Use (Drinking, Toilet, etc.)

10.00

Gardening* Nil

Industrial purpose

Process 1800.00

Washings 300.00

Boiler feed** 200.00

Spray pond ** 500.00

Others (Pump gland sealing) 5.00

Total 2835.00

Bagasse 1690 MT/day Own factory

Power 10.50 MW Own factory



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

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

Cogeneration unit

Bio-compost unit

Fly and bottom

ash (Max. 33.80 MT/Day) Steam

STGs

18.585 MW

Electricity

Boiler feed water

Boiler blow down 200m3/d

Cooling

treatment

Recycled to sugar

factory OR spray pond make-up

Treated water for greenbelt/irrigation

Sugar factory ETP

capacity 1700m3 Effluent 850m3

Sugar unit

Sugar

Cane

Effluent

from sugar unit

800m3/day

Boiler/furnace

Other wastewater ~50m3/day

Filter cake 320MT/day

Molasses 320MT/day

Sent to own

30KLPD distillery unit

Exhaust Steam

Sludge

Sludge drying bed



Figure 3: Quantity of waste to be generates & scheme

Table 6: Waste Management

Waste

Material

Type Quantity Upshot

Bagasse Solid 2466MT/day Used as a Fuel at sugar/Cogeneration and

distillery project

Molasses Liquid 320MT/day Used as a raw material for distillery

Pressmud solid 320MT/day Used as a raw material for making bio-

compost, final disposal system for the

spentwash i.e. distillery effluent

Ash Solid 33.80MT/day Used as a filler material for bio-compost,

final disposal system for the spentwash i.e.

distillery effluent

X) Schematic representation of the feasibility drawing which give information of

EIA purpose

4. Site Analysis

I) Connectivity

Table 7: Connectivity of the project

Nearest City/Town Indapur is the nearest town 09 km away from the site.

Sugar factory modernization

and expansion capacity

from 5,000 to 8,000TCD

Bagasse based Cogeneration

Project i.e. Thermal power

plant based on biomass energy

Capacity: 19.500MW

Categorization as per EIA notification 2006 (SO

1533), as amended on Dec. 2009 (SO 3067)

Sugar industry 5 (i)

Screening category B1

Scoping: State Expert Appraisal Committee

And State EIA Authority

Power plant 1(d)



Road The site is located off Pune-Solapur National highway No. 09.

Distance- 1.5 km from factory site

Also a network of State highways and Zilla Parishad roads

exist in the vicinity

Railway Station Baramati the nearest railway station 45 from the site.


II) Land form land use and ownership

The project is proposed within existing sugar factory premises, the land is already used

for industrial purpose. It is owned by the KSPSSKL. The terrain is almost flat and

requires hardly any leveling.

III) Topography

The terrain is almost flat, no hills in the surroundings. The geographical coordinates of

the area are 18008N and 74057E. The proposed site is 523 meter above the mean sea

level.

IV) Existing land use pattern (Agriculture, non agriculture, forest, water bodies

including CRZ), shortest distance from the periphery of the project forest, national

park, wild life sanctuary, eco- sensitivity area, water bodies Distance from HFL

line, CRZ notification for notified industrial area.

Table 8: Information of reserve and notified land in area

The project is proposed within existing sugar factory premises, the land is already used

for industrial purpose. The project surrounding land is either fallow land or used for

agricultural purpose. Followed by agriculture, the land is used for residential purpose.

There are 23villages in the study area 10 km radius. The canals of river Nira is flowing in

west to East direction at a radial distance of 1.0 Km from the plant site. The Ujjani dam is

Within 10km Area Any sensitive stations are safe away

There is no tropical forest

There is no biosphere reserve

There is no national park

There is no wildlife sanctuary

There is no coral formation

Pune-Solapur National Highway (NH 9) 1.5 km

Ujani back water at a distance of 8.00 km

Nearest Railway station Baramati 45km and Bhigwan

40km from the site

Nearest airport Pune 150 km from the site



at an aerial distance of about 8 km from the site towards north and north-east. The

nearest residential area to the factory is at a distance of 1.5 km towards south. Towards

east west and north the settlement areas are beyond 3km distance. There is an

agricultural and fallow land in the surrounding area of the site. A small artificial pond is

present towards west of the site at a distance of 2.5km.

There is no sanctuary, bio-sphere reserve or national park in the 10km radius area. The

nearest sanctuary to the site is Great Indian Bustard bird sanctuary at Nanaj, district

Solapur approximately 140km from the site.

VI) Existing Infrastructure

Raw Material: Sugar Cane:

The viability of the proposed expansion of sugar unit as well as cogeneration unit

depends on the availability of sugar cane. Table 8, describes the cane production of the

operational area of the KSPSSKL and the cane crushing performance of the KSPSSKL for

last ten years.

Table 8: Production & crushing performance for last ten years

Sr. No. Year Total Cane production in area

(MT)

Total Cane crushed (MT)

1 2000-01 87,000 5,91,560

2 2001-02 3,53,000 8,08,516

3 2002-03 8,00,000 7,49,863

4 2003-04 5,00,000 4,16,597

5 2004-05 5,00,000 3,98,077

6 2005-06 10,46,000 8,76,907

7 2006-07 13,50,000 12,34,935

8 2007-08 13,25,000 12,11,128

9 2008-09 11,00,000 9,89,976

10 2009-10 14,00,000 12,83,800

Above table shows the raw materials potential in the command area

Irrigation and transportation Facilities:

The KSPSSKL is located in the vicinity of back water of Ujani reservoir (approx. 8Km

towards north). Thus more than 70% of the area of agricultural land is under irrigation,

where as remaining area found very good ground water level. Hence, farmers prefer a

cash crop such as sugar cane. Another important factor is proximity of National Highway

(NH 9) and also network of state and Zilla Parishad roads in the operating area of the

KSPSSKL



Fuel

The availability of bagasse is mainly dependent upon the crushing of cane at

sugar factory. The cane crushing data of the factory for five seasons i.e. 2005-06

up to 2009-10 has been tabulated as follows.

Table 9: Bagasse production for last five seasons (i.e. 2005-06 to 2009-10)

Year Sugarcane Crushed (MT) Bagasse produced (29%)

2005-06 3,98,077.00 1,15,442.00

2006-07 8,76,907.00 2,55,173.00

2007-08 12,34,935.00 3,58,131.00

2008-09 12,11,128.00 3,51,227.00

2009-10 9,89,976.00 2,87,093.00

Thus, from the above data it can be inferred that the sugar factory is having adequate

source of fuel i.e. bagasse.

Water:

At present sugar factory draw water from Ujani dam the permission letter attached at

the end of report as an annexure. The water requirement for proposed project will be

around 2835m3/day. Water conservation will be achieved by recycling of water. Water

from the reservoirs will be used for all plant and fire-fighting purposes diesel driven

pump (capacity as per TAC recommendation) along with one electrical pump will be

installed for supply to all fire hydrants and sprinklers

Table 11: Water consumption details

Activity Consumption (M3 /day)

1. Domestic Use (Drinking, Toilet,

etc.)

10.00

2. Gardening* Nil

3 Industrial purpose

4. Process 1800

5. Mill Washings 320

6. Boiler feed** 200

7. Spray pond ** 500

8. Others (Pump gland sealing) 5

Total 2835



Power

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

Table 12: Power generation & consumption

Power Generation

From 15 MW BP type TG set 14.085 MW

From De-aerated 1.5MW BP type TG Set 1.500 MW

From 3MW BP type TG set 3.000MW

TOTAL 18.585 MW

Power Consumption

Sugar Factory 10.500MW

ETP 0.075MW

Office, Colony, Workshop, Other 0.350MW

Total 10.925

Surplus exportable power (During season only) 7.660 MW

VI) Soil classification

These soils have less depth and course texture thereby making them less fertile than

black soils. On the other hand deep black and medium deep soils

VIII) Social Infrastructure available

Schools (Primary as well as secondary)

Colleges (Science, commerce, Arts, engineering, medical, pharmacy, education)

Health centers, dispensaries, hospitals

ST bus

Electricity

Drinking water supply

Banks (Cooperative as well as nationalized) and credit societies

Veterinary centers

The present project is proposed by one of the leading and progressive cooperative sugar

industry from western Maharashtra. During the period of establishment, the industry

received a strong leadership in the form of Late shri. Shankarraoji Patil. Presently

Honorable Minister Shri Harshavardhanji Patil is leading the KSPSSKL.

The sugar factory has already initiated several activities for the development of the

region. Some of the prime activities are as follows.



It is providing good quality seed (Cane) material and fertilizers to member farmers.

It has established an educational facility through which academic as well as technical

education has been made available to the nearby students

It is running a cooperative consumer society.

It is operating soil testing facility and provides bio-fertilizers at very nominal price

It helps farmer to obtain loan from local credit societies and banks

5. Planning

I) Planning concept

Type of industry : Modernization cum expansion of sugar unit from 5,000 TCD

to 8,000 TCD along with cogeneration unit of 18.585 MW

total power generation capacity

Facilities for transport: KSPSSKL is situated just 1.5 Km off the National

highway 9. All the villages from the command area of KSPSSKL are accessible by

asphalted (pucca) road, operational year around. Hence, public transportation is

available. State transport (ST) buses ply on schedule and connect almost all the

villages of the command area.

Town and country planning / Development authority classification:

The project is located at village Bijawadi Grampanchyat is the local authority. The

Bijawadi panchyat has issued No Objection Certificates (NOC)for this proposed

project. This industry was established since 1984-85. Since, then the land is used for

industrial purpose and will be used for the same purpose only.

II) Population projection: No population flux is anticipated due to the project

III) Land use Planning: 18 acres for sugar and cogeneration (including expansion and

new turbine set), 6 acres provided for green belt

development

IV) Assessment of infrastructure Demand (Physical & Social)

The basic infrastructure such as roads, electricity, transportation, drinking water

supply, health centers and hospitals, school, colleges, sanitation facilities are available

in the vicinity. The proposed project is not going to exert any unbearable load on any of

these resources. In fact, the project could reduce the electricity load by generating

18.585MW of power.

V) Amenities/ Facilities

KSPSSKL is already having following facilities.

Canteen, Laboratory, Guest house, rest room, petrol pump, Hotels, medical facilities,

drinking water plant, soil & water testing laboratory etc.



6. Proposed Infrastructure

I) Industrial Area : (Processing Area) : 18 Acres

II) Residential Area (Non processing Area): 25 Acres already exist

III) Green belt : 06 Acres (in addition to existing)

IV) Social Infrastructures : All type of infrastructure is already available in

the vicinity.

V) Connectivity : National highway 9 and state highway as well as zilla parishad

road infrastructure exist

VI) Drinking water management

KSPSSKL draws water from Ujani reservoir. It operates a special water treatment plant

to supply the drinking water to factory as well as the staff colony

VII) Industrial waste management

The sugar factory has been upgraded in previous year and installed the

additional bio-tower for reduce the organic load and enhance the treatment capacity up

to 1,700m3/day to treat the effluent coming from sugar unit along and cogeneration

unit. Wastewater from other sources such as spray pond, excess condensate, etc will be

collected cooled in the cooling pond. This effluent dont have any significance COD or

BOD or any polluting content, except high temperature, hence all collected effluent will

be cool and directly used for the irrigation purpose. The treated water shall be mainly

reused for gardening/irrigation activity. The sanitary wastewater shall be disposed

by using septic tank and soak pit system. Thus, due to proper treatment of

effluent and disposal of treated water within the factory premises, overall impact

of wastewater from the unit on the surrounding water bodies or land is

envisaged to be minor negative impact.

Road Pune-Solapur National highway No. 09. - 1.5 km from factory site

Railway Baramati the nearest railway station 45 from the site.




Table 13: The ETP scheme

Preliminary Treatment Secondary treatment Disposal

Oil and grease

removal machine

screen chamber

Equalization,

Neutralization chamber

primary clarifier

Bio-tower

Activated Sludge Process

for irrigation

Figure 3: schematic structure of ETP

Table 14: Solid waste generation, treatment & Disposal

Waste

Material

Type Quantity Upshot

Bagasse Solid 2466MT/day Used as a Fuel at sugar/Cogeneration and

distillery project

Molasses Liquid 320MT/day Used as a raw material for distillery



Pressmud solid 320MT/day Used as a raw material for making bio-compost,

final disposal system for the spentwash i.e.

distillery effluent

Ash Solid 33.80MT/day Used as a filler material for bio-compost, final

disposal system for the spentwash i.e. distillery

effluent

VIII) Power Requirement and source

Proposed cogeneration will generates the power which is the source for all industrials

utilization as well as all subunits and needful uses the generation and consumption of

power is as follows

Table 15: Power balance

Total Generation of power

from T,G sets of 15 MW and 1.5 & 3.0 MW

18.585 MW

Sugar Factory power cogeneration unit consumption 10.500 MW

administration, colony load. Workshop and ETP 0.425 MW

Total Captive consumption, 10.925 MW

Surplus power to be exported to state grid 07.660 MW

The total energy exported by the cogeneration power plant during the crushing

season would be 26.473 MU (7.66 MW X 160 days X 24 hrs/day X 0.9) @90 %

factor.

7. Rehabilitation and Resettlement (R & R) Plan

Proposed expansion of sugar unit along with additional 15MW turbine to make

cogeneration of 19.5MW installed capacity, will be located within the existing sugar

industry, hence there is no need of rehabilitation and resettlement (R & R) Plan.

8. Project Scheduled & Cost Estimates

Table 16: Project scheduled & cost estimate

1. Date of start of constriction (Anticipatory) Aug. 2012

2. Date of completion (Anticipatory) Oct.2013

3. Project cost Rs. 121.00 crores



4. EMP cost Rs. 4. 50 crores

9. Analysis of proposal (Final Recommendations)

a) Improvement in the social infrastructure: Some prime benefits of the project

are highlighted below

The sugar factory expansion will fulfill the pressing demand of farmers to crush all

the available cane, so local farmer will get benefitted

It will save the money indirectly for reduce in the transportation of cane to nearby

other factory, and reduce the environmental consequences due to it

Shareholders are likely to get good rates for the cane

Captive power demand of the factory is going to be fulfilled

Cogeneration is of back pressure route, which requires lesser fresh water and

wastewater generation is also minimal and mild polluted

The process is straight line and the technology even for the pollution

control/disposal are available indigenously

Waste products generated in the sugar factory are useful as a raw material and

fuel at sugar factory and its own distillery

Direct employment opportunities for 80 local youths

Indirect employment to many since, the project will be exporting electricity to

local grid

The aggregate effect of the project is likely to boost the local economy

The employment opportunity will be for local people

Factory will be go for take a CDM benefits in the form of money after this project

b) Improving power reliability

Proposed cogeneration system is focused on effective utilization of energy. It will

provide high-quality and reliable power and heat energy to the industry. It also helps to

reduce the electricity load of local grid. In this way, cogeneration project effectively

assist or support the electric grid, by providing enhanced reliability in electricity

transmission and distribution.

Pre Feasibility Report Of Sugar Unit

Documents

sugar factory

white sugar

tcd capacity

prefeasibility report

mw cogeneration unit

need of project

university of pune

district pune