PREFEASIBILITY REPORT PROPOSED 45 KLPD MOLASSES BASED DISTILLERY UNIT, AT RAVADEWADI, TAl. SHIRUR, DISTRICT PUNE, MAHARASHTRA STATE PARAG AGRO FOODS & ALLIED PRODUCTS PRIVATE LIMITED (PAFAPPL) Ravadewadi Ta. Shirur, District Pune, Maharashtra State, 412218
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PREFEASIBILITY REPORT...vacuum distillation produces ethanol of international quality standards and there is a lot of demand of ethanol from the vacuum distillation process. Alcohol
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PREFEASIBILITY REPORT
PROPOSED 45 KLPD MOLASSES BASED
DISTILLERY UNIT,
AT
RAVADEWADI, TAl. SHIRUR, DISTRICT PUNE,
MAHARASHTRA STATE
PARAG AGRO FOODS & ALLIED PRODUCTS
PRIVATE LIMITED (PAFAPPL)
Ravadewadi Ta. Shirur, District Pune,
Maharashtra State, 412218
Page 1
1.0 Introduction
Parag Agro Foods & Allied Products Private Limited (PAFAPPL) is a private registered
sugar factory located at Ravadewadi Tal. Shirur, District Pune, Maharashtra State. The
factory is duly registered under Companies Act 1956 as Private Limited Company
having Registration No. U15122MH2013PTC244143 dated 07 June, 2013.
The project location is at 4.5 km distance from Ghod River. Water will be lifted from
Kolhapur Type KT Weir at Nimgaon Dude. There is an ample cane potential is in the
command area since very good irrigation facilities are available in Tehsil Khed and
Shirur from Pune district and Parner from Ahmednagar dist. Most of the farmers have
their own lift irrigation facilities.
The existing crushing capacity of sugar unit is 4500 TCD. The project is proposed to be
set up 45 KLPD distillery Unit & 1.5 MW Power unit on slop fired boiler located at
Ravadewadi Ta. Shirur, District Pune, Maharashtra State
1.1 Nature of the Project
Proposed 45 KLPD distillery will be based on molasses as a raw material. The distillery
proposes to achieve zero discharge by implementing multi effect evaporation followed
by spent wash incineration boiler.
1.2 Need of the Project
In order to further improve in financial strength of the mill society by tanking benefit of
the ethanol blending program of the Govt. of India, present demand of Extra Neutral
Alcohol and trend of fast increasing demand for fuel ethanol as well as ENA for potable
liquors, the management of the mill society has decided to set up a distillery for
production of 45 ENA and fuel ethanol as alternate products by utilizing the by-product
of the sugar mill i.e. molasses . The installation of the distillery will not only utilize its by
product for value addition but also generate employment opportunities and ancillary
business opportunities to local people thus will lead to all round development of the
area.
Page 2
As the well being of sugar mill is dependent on the full utilization of the by-products
from sugar production, The molasses is one of the most valuable by-product of the
sugar mill is a ready source for the production of alcohol which has many consuming
centers and hence is a valuable product. Hence, the management has rightly chosen to
install a distillery to produce ethyl alcohol from the molasses from the mill.
Page 3
2.0 Project Description
2.1 Project Location
The project is located at Sr.no13, 14, 15/1, 15/2, 83/1,341/2, 342, 343/2/A,
,346, 347,351, 352, 353,355/1, 428/1 Ravadewadi Tal. Shirur, District Pune,
Maharashtra State. Site is geographically located at 18°52'29.47"N,74°12'40.60"E.
Figure No.1 Project Location
Page 4
Figure No.3 Project layout
Page 5
2.2 Size or Magnitude of Operation
The PAFAPPL proposes 45 KLPD distillery to manufacture ENA, Rectified spirit,
technical alcohol from molasses. The products and by-products considered for
The raw spent wash of composition as detailed in above table, has a TDS of 17 to 18%
along with suspended solids at 4%. This needs to be concentrated to 60% to make the
Page 17
same suitable for burning. The hot spent wash at about 70 deg. C from analsyser
column is pumped into a storage tank where suspended solids are allowed to settle.
The evaporation is done in a quintuple effect evaporator system. A variety of
combinations of evaporator system can be envisaged. Tentatively a combination of
falling film and forth circulation evaporator is used.
Feed at 70 deg. C taken into 2nd effect, a falling film type evaporator and from thereon it
flows into 3rd to 4th to 5th bodies which are in increasing vacuum. 5th body is forced
circulation rising film type The last body (5th effect) is under 640 to 660 mm vacuum.
Concentrated spent was at about 40% concentration from 5th effect is pumped to first
effect which is a forced circulation evaporator and is at atmospheric pressure and is
supplied with live steam as heating medium. The final product is drawn at 60% solid
concentration from this effect (also called finisher effect). Vapours from each effect
condense in the next effect calandria and finally the last effect vapours at 660 mm.
vacuum go to a surface condenser and the non condensables are drawn out by a
vacuum pump. The vacuum pump also maintains the vacuum in the evaporation
system. The steam condensate from first effect is returned to boiler while the process
condensate from the rest of the effects is collected and treated in the Condensate
Treatment Unit in order to reclaim water and thus effect water conservation
Incineration based Steam Generation Plant
A steam generation plant generally in conformity with IBR code of practicing and
operation shall be provided. It consists of one No. coal cum slops fired traveling grate
water tube drum type boiler suitable to generate 16 tonne/hr of capacity super-heated
steam at 45 kg/cm sq. pressure and 400 deg. C temp. with steam heated air heater and
economizer with a view to obtain a boiler efficiency of 65 % on GCV of mixed fuel, is to
be provided. The boiler should be provided with ESP / bag filter for limiting the solid
particulate matter (SPM) level in stack gases to 100 mg/NM3 to meet the environmental
standards.
Boiler shall utilize spent wash concentrate with coal as supporting fuel. Boiler shall be
single / double drum type with fusion welded construction. The drum shall be provided
with dished ends, manhole doors etc. as per IBR.
Page 18
Boiler Details
Type of Boiler : Double-Drum type boiler
Design code : IBR 1950 with latest
amendments, as applicable
Boiler capacity at MSSV outlet Kg/hr (MCR) 16000
Steam pressure at MSSV outlet Kg/cm2 g 45
Steam temperature at MSSV outlet (OC) 400
Fuel : Coal
Water temp at Economizer inlet (OC) 140˚C
Fuel characteristics Coal Slops
GCV 3650 k cal/kg 1705 k.cal/kg
Moisture 50% 30%
C 22%
H2 2% approx.
H2S 2% v/v
Flue gas temperature at Air heater
outlet °C
160 °C
Ambient Temperature °C 40
Electrical data for motors
- LT Volt (V) : 415 ± 10
- Frequency (Hz) : 50
- Type : AC 3 phase, 4 wire
Electrical data for instruments
- LT Volt (V) : 220 ± 10 %
- Frequency (Hz) : 50 ± 5 %
- Type : AC single phase
Compressed air pressure : 7 Kg/cm2 (Oil and Moisture free)
Page 19
Solid Waste Management :
Solid wastes such as boiler ash, ETP sludge are produced from the industrial activity.
These are disposed to farmers for their use as soil conditioner in land.
Solid waste generation
1 Ash 325 MT/M
2 ETP Sludge 1.5 MT/M
Boiler Ash: During burning of bagasse in boiler ash will be generated. It contains silica,
and other metal oxides. It is a non-toxic material. It will be directly sold brick and
cement manufacturer unit. Ash generated from Slop fired boiler will sold to brick
manufacturing.
ETP Sludge: ETP sludge contains plant growth nutrient therefore it will be used for
manure in agro-field
4.0 Rehabilitation & resettlement plan Nor habilitation or resettlement will occur. Hence no rehabilitation or resettlement plans. 5.0 Project schedule and cost estimate
The cost of project has been estimated at Rs 73 cr. which comprises of land, civil