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Prefeasibility Report: Proposed 19MW Cogeneration Project
Bhimashankar SSKL 1
PRE-FEASIBILITY REPORT
NEW 19.0 MW COGENERATION UNIT OF
BHIMASHANKAR SAHAKARI SAKHAR KARKHANA LTD
1.0 INTRODUCTION
M/s. Bhimashankar Sahakari Sakhar Karkhana Limited, at Dattatryanagar, P.O. Pargaon via
Awasari, Taluka: Ambegaon, Dist. Pune.410 406 is engaged in the manufacture of sugar and is
registered under the Co-operative Society Act, 1961 on 31.03.1994 vide registration
No.PAN/AGN/A/S-47/ 1994. In Nov. 1999, the first elected board of directors took charge of the
industry from government nominated director board under the chairmanship honorable
founder Shri Diliprao Walse Patil, speaker, legislative assembly, (Govt. of Maharashtra). The
initial installed crushing capacity of the factory was 2,500 TCD. Because of increasing
availability of sugarcane in the area of operation, the factory expanded its crushing capacity to
4,000 TCD. The management now plans to establish a 19.0 MW cogeneration plant to fulfill their
need of power and sell the surplus power to Maharashtra State Electricity Distribution
Corporation Limited (MSEDCL).
2.0 PROJECT SETTING
The sugar factory has a plan to set up a 19.0 MW co-generation project within its premises. The
plant is located off Pune-Nashik national highway No.50 just a 15.5 Km towards west. The
geographical coordinates of the site are 18058”N. and.74005’E.
During 2009-10 the crushing was 5,88,909 MT with average recovery of sugar of 12.0%. In
Season 2009-10 the bagasse production for these season 1, 55,471 MT. Bhimashankar SSK Ltd.,
is now planning to balance the sugar plant and increase the saving of bagasse by using biogas.
Further efforts will be made to procure surplus bagasse from the neighboring sugar units.
3.0 HIGHLIGHTS OF THE PROJECT
Name of the
Industry
Bhimashankar Sahakari Sakhar Karkhana Ltd.
Location of the
project
Dattatrayanagar, P.O. Pargaon via Awasari,
Taluka: Ambegaon, Dist. Pune 410 406State- Maharashtra
Email : [email protected]
Ph no: 02133-284231/32/41/46
Fax : 02133 - 284381
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Prefeasibility Report: Proposed 19MW Cogeneration Project
Bhimashankar SSKL 2
Land 18 acres built up area, 6 acres provided for green belt
development
Project 19.0 MW Cogeneration (Power) plant
Product Electricity Generation -18.0 MW
Running Days 236 Days
Main Raw Material Water as main raw material for steam generation.
Bagasse as a raw material for fuel.
Water Requirement 900 m3/day
Ghod River, Kathatpur KT Weir. (Permission available)
Fuel Bagasse – For season - 1074 MT/day
During Off season: 305 MT/day
Production
equipment and
machinery
Steam generators (Boilers), Condensate system, Turbo-generator
sets, Cooling tower, Fire protection system, Bagasse and Ash
handling system.
Boiler and Steam
Turbo Alternator
(STG Set)
Presently the factoryis having one boiler of 37 TPH capacity
working at 45 ata pressure and 445oC ± 50 C steam temperature.
For a new boiler is of 80 TPH capacities at 88 Ata pressure and
515OC± 50C steam temperature is planned to install. Operating load
of the new boiler is estimate to be about 71.50 TPH during normal
crushing season including the extraction of steam for process
requirement, HP heater and de-aerator heating steam
Manpower Total staff around 35
Project Cost Rs. 4461.25 Lakhs
EMP cost Rs.300.00 Lakhs
4.0 SITE SPECIFICATION
4.1 Connectivity
· The site is located off Pune-Nashik National highway No. 50, Distance- 15 km from
factory site.
· Pune is the nearest railway station 55 from the site.
· Pune is the nearest airport -55 km from the site
4.2 Land use pattern
Since the project is going to be commissioned within the existing sugar factory premises and no
additional land is required, hence the project is not causing any land use change in the area.
4.3 Ecologically sensitive attributes: There is no tropical forest/ biosphere reserve/ national
park /wildlife sanctuary /wetland/Tiger reserve/area with threatened/reserved forest etc
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Prefeasibility Report: Proposed 19MW Cogeneration Project
Bhimashankar SSKL 3
under wildlife protection act (1972)within radius 10 km study area. The nearest sanctuary to
the site is ‘Bhimashankar Wildlife Sanctuary’ located at a distance of 60km.
4.4 Social and Existing Infrastructure in the study area
As explained earlier this area is covered in Ambegaon taluka. The study area is decided as an
area within 10 km radius from the proposed unit. Altogether there are 36 villages in the study
area. The infrastructure such as school, college, medical centers, roads, electricity and supply of
drinking water is available to the local people. The factory is actively involved in several socio-
economic developmental activities of the region, finance for cane development, housing facility
to its workers, helping the member farmers for various purposes such as educational, social,
health, and cultural.
Education Facilities: 24 primary schools, 4 middle schools, within study area.
Health Services: The overall health facilities such as public health center, private clinics,
dispensaries and nursing homes, etc. availability in the study area are adequate to serve the
localities’ .
Veterinary Center: The study area contains sizable cattle population consisting of cows,
buffaloes, bullocks, goats, sheep, poultry etc. The bullocks are used for ploughing, harrowing,
sowing and intercultural operations whereas buffalo, cows, sheep, goats and hens are kept as
subsidiary source of income.
Drinking Water: Drinking water supply for most of the villages is made available by
Maharashtra Jivan Pradhikaran
Communication: There are 19 Post offices and Telegraph within study zone
Electricity: All villages have power supply from Maharashtra State Electricity Board.Road and transport: Asphalted roads are present throughout the study area, those connects to
each of the village. There is a regular service of State Road Transport Corporation (MSRTC) bus
available in the region.
5.0 CLIMATIC INFORMATION INCLUDING BASE LINE ENVIRONMENTAL CONDITION
Climate Ambegaon taluka falling in the moderate rainfall intensity zone. Average
rainfall is around 800.44mm. The annual average temperature is varies from
19-33oC
Relative humidity - Early summer (January to March)42-55% o In monsoon it
ranges 75-81%
Wind The predominant wind direction observed during the study period was west
direction; with 22 % of the 0-7 kmph Calm conditions constituted about 27.78
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Prefeasibility Report: Proposed 19MW Cogeneration Project
Bhimashankar SSKL 4
% of the total time observed.
Geology The district forms part of Western Ghat and Deccan Plateau. This Taluka falls
to the foothill of Sahyadri Mountain range. The study area largely falls in the
Basin of Bhima- Ghod River.
Hydrology The district has three major drainage system namely, Bhima–
Ghod. River
system in the northern, north eastern and eastern part, of which Bhima River
has a total length of about 355 km. and Ghod River has a drainage of about 196
km. River Ghod approx 2 km away from the factory site in North direction.
Soil The type of soil in the area is black to calcarious soil. Deep black soils have
good water holding capacity due to rich humus content. Excepts certain
packers, the soil have good drainage. These soils contain less 'Humus' Organic
Matter. The pH of the soil is 8.0 to 8.9.
Land-use
Pattern
It is observed from the available data that, the project surrounding land is
mainly used for agricultural purposes, followed by residential purpose
agricultural activities, partly for the pasture and other uses.
Ecology The wild vegetation in the study area consists of semi-aired with significant
thorny species. Mainly agricultural (cultivated) vegetation is dominant in the
study zone. There is no wildlife sanctuary or national park or biosphere
reserve exists in the 10 km radius area. Also, there are no rare or endangered
floral or faunal species recorded in the 10 km radius zone.
Scio-
Economic
Environme
nt
The infrastructure such as school, college, medical centers, roads, electricity
and supply of drinking water is available to the local people. The Karkhana is
actively involved in several socio-economic developmental activities of the
region, finance for cane development, housing facility to its workers, helping
the member farmers for various purposes such as educational, social, health,
and cultural.
Historical
Sites
No historically important sites are present in the study zone of the proposed
site
6.0 BENEFITS OF BAGASSE BASED COGENERATION
Cogeneration offers energy, environmental, and economic benefits, including:
· Saving money
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Prefeasibility Report: Proposed 19MW Cogeneration Project
Bhimashankar SSKL 5
· By improving efficiency, cogeneration systems can reduce fuel costs associated with
providing heat and electricity to a facility.
· It saves the fossil fuel consumption by using the as well as and related foreign exchange.
· It does not increase the foreign exchange cut flow, as the plant and machinery are
indigenously available
· It has lower installation and operating cost compared to the thermal power plant.
· The profit made by incomes through exportable power improve financial position of the
sugar factory
· Improving power reliability
In cogeneration systems, it is located at the point of energy use. It provide high-quality and
reliable power and heat locally to the energy user. It helps by reducing congestion on the
electric grid by removing load. In this way, cogeneration systems effectively assist or support
the electric grid, providing enhanced reliability in electricity transmission and distribution.
· Reducing environmental impact
Cogeneration reduces the amount of fuel burned for a given energy output and reduces the
corresponding emissions of pollutants and greenhouse gases.
· Conserving limited resources of fossil fuels
Cogeneration requires less fuel for a given energy output, the use of cogeneration reduces the
demand on our limited natural resources—
including coal, natural gas, and oil—
and improvesour nation's energy security.
7.0 RAW MATERIALS
Bagasse and water will be main raw material. The total requirement for the unit (including
domestic and other.) 900m3/day .The bagasse is fuel material for this plant will be made
available from the attached sugar factory. Bagasse requirement for cogeneration plant will be
1074.0 MT/day during season and 305 MT /day during non-crushing season.
8.0 WATER REQUIREMENT
The water for sugar/cogeneration plants will be drawn from existing overhead service water
tanks and will be recycled after cooling separately. Water from the reservoirs will be used for all
plant and fire-fighting purposes. To achieve better efficiency and to maintain the plant and
machinery in good condition, it is necessary to have proper water treatment system. Process
water will be treated in a water treatment unit as well as a water-softening unit. By having
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Prefeasibility Report: Proposed 19MW Cogeneration Project
Bhimashankar SSKL 6
proper water supply system such as clear water pumps etc, the distillery can have good water
supply arrangement.
Table 1: Water Consumption Details Cogeneration
Water Consumed for Consumption M3 /day
Domestic Use (Drinking, Toilet, etc.) 5.0
Gardening Nil
Industrial purpose
1. Process* Nil
2. Washings* Nil
3. Boiler feed** 80.0
4. Cooling tower make -up water ** 810.0
5. Others (Pump gland sealing) 5.0
Total 900 m3/day
* Treated water from ETP will be utilized for gardening purpose
**One time – startup - requirement for boilers and cooling towers = 20,808 m3
Table 2: Water budget for 19 MW proposed cogeneration plant
Sr.
No Station
Input
m3/day
Loss
m3/day
Effluent
m3/day Sent to
Recycle
m3/day
1. Boiler 85 35 50 Sugar ETP 50
2.
Cooling
Tower/
Spray Pond
810 810 00 Sugar ETP 00
3. Domestics 5 2 3Septic Tank
Soak pit Nil
Total 900 847 53 50
9.0 STEAMDuring cane crushing season, the steam will be generated from two boilers, one is of 80TPH
capacity, 88 Ata pressure and 515oC ± 50 C temperature; second is of 37 TPH capacity with 46
ata Pressure and Temperature 445 ± 50C. Produced steam will be supplied to a new TG set of 13
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Prefeasibility Report: Proposed 19MW Cogeneration Project
Bhimashankar SSKL 7
MW and existing 6 MW. The exhaust steam from cogeneration unit will be utilized in sugar
factory, distillery, and other subunits.
Table 3: Steam Balance
10.0 BOILER
The factoryis having one boiler of 37 TPH capacities working at 45 ata pressure and 445oC ± 50 C
steam temperature. For new boiler 80 TPH capacities at 88 Ata pressure and 515oC± 50C steam
temperature is planned. Operating load of the new boiler is estimate to be about 71.50 TPH
during normal crushing season including the extraction of steam for process requirement, HP
heater and de-aerator heating steam.
Table 4: The boiler details
Sr.no.
Boiler Pollution ControlEquipment
Steamgeneration
1New 80 TPH @ 88 ATA Pressure and
temperature 515 ± 50C
Electrostatic
precipitator71.1 TPH
2.Existing 37 TPH @ 46 ATA Pressure
and temperature 445 ± 50C
Multi cyclone dust
collector35.4 TPH
Total Steam generation during crushing season 106.5 TPH
Table 5: Steam Turbine Generator (STG)
Sr.
No.Steam Turbine Generator Power generation (MW)
1. 13 MW (New) 12.100
For season Off season
Total steam generation 106.53 TPH 28.25TPH
Steam required for Sugar process @2.5ata 72.73TPH --
Steam for distillery and ENA units @ 2.5 ata 6 TPH 6TPH
Steam to De-aerator 7.0 TPH 3.0 TPH
Steam to H.P .Heater @7ata 7.8TPH --
Condensing flow steam 13TPH 19.25TPH
Total steam consumption 106.53 TPH 28.25 TPH
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Prefeasibility Report: Proposed 19MW Cogeneration Project
Bhimashankar SSKL 8
2. 6 MW (Old) 5.900
Total power generation 18.000
11.0 BAGASSE HANDLING SYSTEM
There will be provision for handling excess bagasse which will not be used in the boiler (during
season) to a storage area. The Bagasse will be supplied to boiler from elevated carriers and belt
conveyors.
For the non-crushing season the fuel handling system will also used to handle alternative fuels
such as cane trash.
12.0 ASH HANDLING SYSTEM
Ash generated in the Boiler consists of bottom ash and fly ash. Fly ash handling system shall
consist of dense phase handling system. Fly ash collected at various generation points will be
collected and conveyed to a fly ash silo.
13.0 PROCESS
The proposed cogeneration, aims at significantly improving the energy efficiency of the sugar
factory, enabling the plant to generate surplus power from its cane cursing operation. This
surplus power could be exported to the state electricity grid.
The proposed co-generation system is designed to utilize the present boilers & T.G. sets for
steam generation and surplus electrical power generation.
Figure 1: Schematic of Cogeneration Project
Exhaust
Boiler Bagass
Power
Sugar Process
Surplus to Electricity grid
De-aerator
HP Heater
Captive Power
SteamTurbo
Generator
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Prefeasibility Report: Proposed 19MW Cogeneration Project
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14.0 COGENERATION SCHEME
The co-generation schemes operations during crushing season (160 days) are designed to use
bagasse as a biomass fuel, which is as per the guidelines and qualifying norms stipulated by
MERC.
Table 6: Power balance for crushing season is as follows
Total Generation of power
from T,G set of 13 MW and 6 MW
18.000 MW
Sugar Factory power consumption 5.100 MW
Distillery, cogeneration unit and administration, colony load. 0.900 MW
Total Captive consumption 6.000 MW
Surplus power to be exported to state grid 12.000 MW
Table 7: Power balance for off- season
Captive consumption
Distillery, Sugar factory administration, Cogeneration Plant
auxiliaries
1.250 MW
Exportable Power 4.700 MW
Total Power generation 5.950 MW
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Prefeasibility Report: Proposed 19MW Cogeneration Project Bhimashankar SSKL
11
Figure 2: Process flow chart for season
Bagasse as Fuel 29.95 T/hr
Boiler
80TPH
Total Steam 71.1TPH
45 k /cm2 a 485oC
84 Ata pressure at - 505 o C
13 MW T.G. Set
12100KW
Captive consumption 6000 KW
Boiler 37 TPH
~5900 KW
18000 KW
Bagasse as Fuel 14.80 T/Hr
Export Power 12000 KW
Total Steam 35.4 TPH
45 k /cm2 a 485oC
6MW T.G. Set
43Ata pressure at – 440 o C
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Prefeasibility Report: Proposed 19MW Cogeneration Project
Bhimashankar SSKL 13
Figure 3: Process flow chart for off-season
15.0 ENVIRONMENT PROTECTION AND WASTE MANAGEMENT
Environment protection and the control of solid, liquid, and gaseous effluent or emissions
are key element in the design of all steam and power generating system. At present the
most significant of these emissions are sulfur dioxide (SO2), Oxides of nitrogen (NOx) and
fine airborne particulate matter (SPM) and gases.
Bagasse being a biomass, a renewable fuel does not add any net CO 2 to the atmosphere,
because of the carbon recycling during the growth of cane. The same is applicable even for
the other biomass fuel propos to be used in the plant during the off-season operation.
15.1 Air Environment
Atmospheric emission arises primarily from the by-product of the combustion process SO2,
NOx, particulate fly ash are exhausted from the stack. A second source of particulate matter
and gases is fugitive dust from bagasse/Biomass/Ash handling equipment. A final source of
air emission is the cooling tower and associated thermal rise plume, which contains heat
and some trace materials along with the water vapor.
Boiler 37TPH
Power 5.95 MW
~
Total Steam 28.7 TPH
Captiveconsumption
Surplus power 4.7 MWexported
Bagasse 12.7 TPH
6 MW T.G. Set
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The element polluting the air that are discharged from the proposed unit are,
q Dust particulate from fly ash in flue gas
q Sulfur-di-oxide in the flue gas (Very minor)
15.1.1 Control Measure
1. Electro Static Precipitator(ESP) for effective control of fly ash
2. The existing stack height is 60 m which is as per norms, considering the particulate
matter emission. There is very little sulfur in biogas (1.5% of total volume). hence
the criteria for fixing stack height based on SO2 emission is applicable. The
temperature encountered in the steam generator while burning high moisture
bagasse and biomass is low enough to minimize the NO2 production.
3. Moreover, the tender specification for stem generation will stipulate over fire air
system with staged combustion, which will also ensure reduction in Nitrogen –oxide
emission. Hence, no separate measures are taken to nitrogen oxide pollutants.
4. Fly ash collected from the dust hoppers and the air heater hopper and the ash
collected from the furnace bottom hoppers can be used for two purposes.
1) The high potash content in the bagasse ash makes the ash good manure.
2) It could be sold to brick manufacturing units as per their requirements.
15.2 Water Environment
Aqueous discharge arises from a number of sources. Theses include cooling tower blow-
down, sluice water from the bottom ash handling system, boiler chemical cleaning solution,
and gas side water washing waste solution.
15.2.1 Effluents and Sewage Disposal
Effluent: Wastewater from power plant does not have any significant BOD/COD level. All
wastewater will be neutralized prior to discharging .An effluent treatment plant for sugar
mill is already in operation for the wastewater and provided with aerators, to meet the
norms prescribed by MPCB. The total waste water generated from various units is
estimated to be about 50-55m3/day. The existing ETP of sugar factory (1000m3capacity) is
adequate to treat the effluents from cogeneration unit.
Sewage: Existing sewage system, which is connected to common septic tank and it
discharges as per the normal accepted local practices. (Refer Figure 4)
15.3 Solid Waste Generation and Management
The solid waste will be mainly, the ash generated in the boiler, which collected by
electrostatic precipitator. Total ash generation during crushing season will be 21.48 MT per
day. It will be 6.091MT per day during off season. The boiler ash is usually rich in Potash;
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Prefeasibility Report: Proposed 19MW Cogeneration Project
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hence it could be directly applied int o agriculture field or sold to the brick manufacturers as
per their demand. Figure 4
15.4 Thermal Pollution
The hot effluents are the spray pond overflow. The hot water will of about 42 0C
temperature and the quantity will be in minor quantity around 4-5 m3/day. This hot water
will be cooled down to normal temperature in cooling pond and then recycled. Hence, there
will be no thermal pollution of any surface water body around the project site.
15.5 Noise Pollution
The principal source of noise generation is the boiler and DG. However the noise generated
in the boiler section will be localized and will not dissipate because of the enclosures
provided. Additionally, transportation and handling of bagasse also could raise the levels of
noise. The noise generated will be only temporary and during the period of operations.
Considering these facts, the project will have minor negative impact on noise environment.
Figure 4: Schematic of waste management
Bagasse feeding
Boiler/Furnac
Ash is rich in potash,
mixed with press mud
and sell to farmer as
manure Or Brick
manufacturers
Fly Ash and bottom ash(21.48 MT/day
Steam Turbine
19MW
ElectricityBoiler feed water
Boiler blowdown from
power plant
Neutralized
Reuse for cooling
tower make up OR Mixed in sugar ETP
Sluice water from the
bottom ash handling
system, boiler
chemical cleaningwater
Sent to ETP of sugar factory
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15.6 Hazardous Waste
Spent oil from the gear boxes and automobile batteries will be disposed to the authorized
vender as per the Hazardous waste (Management and handling) Amended Rules, 2003.
15.7 Rain Water Harvesting SchemeRain water is one of the purest sources of water for improving the water table in the sub soil
and also the quality of water. Rain water which is otherwise wasted has to be recharged in
to the soil. This can be adopted either using traditional way or by modern technologies. The
various types of rain harvesting schemes are, diverting rain water collection through proper
channels to the nearest pond or open wells and run off from built in areas mainly roofs are
diverted to storm water drains, which is again taken to the nearest lake / pond.
Building up of recharge structures should be in scientific way. Recharge structures of size
approx. 2x2 m and 3m depth can be dug and filled with pebbles/rubbles of sizes more than
2”. At the center of this structure 6” or 8” pipe is driven to the depth of approx.10m, with
perforation of 1or2.” Such structures can be built at pre-defined places (minimum 4 or 5
places, depending up on the site situation) so that maximum quantity of rain water within
the premises of sugar factory can be collected. The water diverted through channels, from
roof tops and other means can be collected in this recharge structure, which will definitely
improve the water table as well as quality of the water and feed water to the plant during
drought season.
The industry has planned to implement the rainwater-harvesting project. It will appoint a
special consultant, under his guidance the project will be designed and implemented.
15.8 Fire protection system
Fire protection system shall be provided in accordance to the LPA regulations.
· It consists of a network of hydrants
· One electric driven pump, one diesel engine driven pump, one jockey pump.
· Portable fire extinguishers shall be provided at strategic locations
· Fire alarms
· All safety devices such as lightening arresters, trippers, etc
15.9 Rehabilitation and Resettlement
Proposed Cogeneration power plant located in existing sugar factory premises; therefore
there is no rehabilitation and resettlement problem.
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16.0. Cost Estimates
Financial Projection1 Net Sales to MSEDCL 32995.8
2 Total cash cost of production
without depreciation and interest:
Variable Cost
9765.18
3 Profit before depreciation and
interest
23230.63
4 Less:
(Rs. lac)
Depreciation : 3904.37
Interest on term loan:1385.41Interest on SDF loan : 418.18
5707.95
5 Profit after depreciation and interest 17522.67
6 Add back depreciation 3904.37
Total Cash Accruals 21427.04
Estimated Environment
management cost
Rs. 300.00lakhs
Sr.
No.
Category Investment(Rupees in
lakhs)
1 Bagasse and Ash
handling
250.00
2 Fire protection 20.003 FD/ID fans 25.00
4 Greenbelt 05.00
Total 300.00