DETAILED PROJECT REPORT

OF

EXPANSION OF SUGAR PLANT

CAPACITY TO 20000 TCD, COGEN
TO 73 MW & DISTILLERY 200 KLPD

FOR

THE UGAR SUGAR WORKS LTD.,

UGAR KHURD, TQ: ATHANI,
DIST: BELGAUM, KARNATAKA

PREPARED BY

UGAR CONSULTANCY LTD.,

UGAR KHURD, TQ: ATHANI, DIST:
BELGAUM, KARNATAKA
 CONTENTS
EXECUTIVE SUMMARY 1–9

HILIGHTS OF THE PROJECT

1. INTRODUCTION 10 – 16

2. NEED FOR THE PROJECT 17 – 18

3. PRODUCT SALE POLICY 19 - 21

4. TECHNO COMMERCIAL ASPECTS 22 – 27

5. TECHNICAL SPECIFICATION OF EQUIPMENTS 28 – 56

6. LOCATION & SITE ASSOCIATED DETAILS 57 – 60

7. RISK ANALYSIS & MANAGEMENT 61 – 65

8. PROJECT COST ESTIMATION 66 – 69

9. ANNEXURES

1 BAGASSE BALANCE 70

2 STEAM BALANCE DURING SEASON 71

3 POWER BALANCE DUSRING CRUSHING SEASON 72

4 STEAM BALANCE DURING OFF SEASON 73

5 POWER BALANCE DURING OFF SEASON 74

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Executive Summary

Preamble

1.1 Numbers of new sugar factories have increased in the nearby area of The
Ugar Sugar Works ltd., and also existing sugar plant expansions are taking
place in the nearby area. Hence the total cane crushing capacity is
increasing in the same cane growing area, which in turn reduces the
duration of crushing days. To maintain the ultimate sugar production target
it is essential to increase the crushing capacity of USWL. At the same time
expansion of cogeneration and distillery is also essential to balance the by-
products. In this line of action management of ugar sugar have decided to
go for Sugar Plant expansion in phased manner. It is proposed to expand
sugar plant capacity to 20000 TCD, cogeneration 76 MW and distillery to
200 KLPD. Before going into details of the project, we can have a look on
manufacturing procedure of sugar in the following paragraphs.
1.2 Sugarcane will be harvested at field and clean cane will be loaded in the
vehicles at field and brought to the factory. The gross weight shall be taken
and cane unloaded on the feeder table with the help of electric crane
unloader. The tare weight of the vehicle will be taken to arrive at the weight
of the cane.

1.3 Cane will be fed to cane carrier from the feeder table. The cane
preparatory devices viz. Kicker, chopper, Leveler, fibrizer etc., are
installed on the carrier for the preparation of cane. The prepared cane will
be taken to Mills by second carrier where juice is extracted using
compound imbibition process and hot water is applied for maximum
extraction before last mill. Mixed juice is strained and sent for processing.
Water for imbibition and mixed juice both are weighed in automatic
weighing scale & by mass flow meter respectively. Bagasse (residue of
cane after juice extraction) is used as fuel in the boiler and surplus
bagasse saved in the form of bales.

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1.4 Mixed juice will be clarified by sulphitation process by heating at 700C in a

juice heater, phosphoric acid; sulphur dioxide gas & milk of Lime are used
as clarificants. These are thoroughly mixed in juice sulphiter. Then the
sulphited juice is heated to 1050C in another juice heater. This juice is
passed on to continuous clarifier through flash tank for settling. The settled
mud is filtered with the help of vacuum filter where filtrates are separated
and sent back to process. Hot condensate water is used to wash the cake
& recover maximum sugar from the cake. The washed filter cake with
minimum sugar content is sent out as bye product. Decanted clear juice
from clarifier is taken to Evaporators (multiple effects). The concentration is
increased to syrup consistency. The heat required for heating and
evaporation is used from exhaust steam and the bled vapors from
evaporators. Exhaust steam is obtained from prime mover turbine of power
generation.
1.5 The syrup from evaporators is sulphited to pH of 5.0 – 5.2 & it is used in
vacuum pan boiling to produce ‘A’ Massecuite. The necessary seed
crystals are taken in the pan and boiled with syrup / melt at about 600C.
This gives ‘A’ massecuite. ‘A’ Massecuite from the pan is discharged into
crystallizer. Then the sugar crystals are separated from the surrounding
film of mother liquor in centrifugal machine. It is also washed by
superheated water wash. The liquor is called as ‘A’ Heavy molasses and
the white crystal sugar is dropped on the hopper from centrifugal machine.
The sugar is conveyed on hoppers graded & bagged. The crystal sugar
gets dried & cooled while conveying on hoppers.
1.6 ‘A’ heavy molasses is subjected to second boiling to get ‘B’ Massecuite
there by B- sugar is used as Seed and / or excess is melted & melt is used
in ‘A’ boiling. B-Heavy molasses is subjected to third boiling to get C-
Massecuite and there by C- sugar and final molasses. C- Sugar is
magmized and double cured. The mother liquor separated is called C-Light
molasses. It is used in C boiling. C-double cured sugar is melted and melt
is used in A boiling.

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Final molasses is weighed and stored in steel tanks (non duty paid). It is
then sold as bye product or used to distillery.
1.7 The sugar industry is the only industry blessed with captive regenerative
cellulosive matter to meet its own energy for processing sugar cane to
produce sugar. The optimal use of energy is the theme of the day. Cane
sugar industries having its own captive fuel till late were not very conscious
about the effective utilization of energy and to render surplus for other
utilization. In the present context newly developed technologies has proved
to be very effective in releasing energy (thermal & electrical) and
conservation of utilities.

1.8 The increasing concern about the effect of emissions from the power
industry, amongst others, on the environment is the driving force behind
the development of cogeneration and the utilization of renewable fuel
sources. The cane sugar industry is eminently suited, because it has been
in this field for 150 years or so as well as the fact that it uses a renewable
fuel that is C02 emission neutral.

1.9 Sugar factories, since inception are equipped with facilities for co-
generation of steam & power for captive use. However, in recent time the
meaning of the term “co-generation” has widened to denote the generation
of surplus power that can be supplied to the grid. The primary fuel in these
co-generation plants is bagasse, which is generated as a by-product of
cane crushing operations in the sugar manufacturing process. To extend
the operating days and to increase profitability, supplement fuel such as
coal can be used during off season.

1.10 India is one of the largest sugar producing nations in the world. There are
around 500 sugar factories in operation out of these two third are owned &
managed by cooperative sector & public sector. The estimated co-
generation potential from bagasse-based projects is 5000 MW, which
could be tapped by installing efficient co-generation plants.

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1.11 Realizing the vast potential of cane production and power generation from
sugar plant co-generation a task force was constituted by Government of
India to address the constraints to commercially exploit the co-generation
potential. The task force had recommended the policy, fiscal incentives to
overcome constraints based on the recommendations Ministry of Non-
Conventional Renewable Energy Sources (MNRE) has announced
incentives like one time capital subsidy to set up co-generation projects in
the sugar factories.

2. USWL Background:
2.1 M/s. The Ugar Sugar Works Ltd. is one of the pioneers in sugar industry in
the state of Karnataka, having started its operations way back in 1939.
USWL has distillery, IML section and Co-generation plant. The company
has expanded its capacity from time to time and the present capacity is
10,000 TCD and 44 MW co-generation, out of which 28 – 30 MW is
exportable.

2.2 The factory started Distillery in the year 1963 & the present capacity of the
distillery is 75 KLPD (30 KLPD batch type & 45 KLPD continuous type).
Company has further installed 20 KLPD Ethanol Plant & 50 KLPD ENA
Plant with blending & bottling of 9 different IML varieties. The company has
provided fully fledged effluent treatment plant which includes Chemical
digesters, concentration & spray drying of spent wash and mixed lagoons
anaerobic & aerobic treatment of sugar factory effluent & evaporation &
drying system for distillery spent wash etc.
2.3 The company has also provided Methane gas generated by biodegradation
of filter cake is used for domestic fuel requirement. The gas is provided to
170 residential quarters. Filter cake is a by-product of sugar factory.

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2.4 Present Director board of the company is as follows:

¾ Shri. R.V.Shirgaokar’ (C & M)

¾ Shri. P.V. Shirgaokar (E V C)

¾ Shri. S.S. Shirgaokar (MD)

¾ Shri N. S. Shirgaokar (JMD)

¾ Shri C. S. Shirgaokar (JMD)

¾ Shri M. R. Desai (Director)

¾ Shri V. Balasubramanyam (Director)

¾ Shri S. N. Inamdar (Director)

¾ Shri M. G. Joshi (Director)

¾ Shri A. B. Kage (Director)

¾ Shri D. B. Shah (Director)

¾ Shri S. K. Shirgaokar (Director)

3. Production Scheme
3.1 The main activity of the company is to manufacture white crystal sugar,
Electrical power, ENA, ethanol & IML.

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3.2 The daily Sugar cane crushing capacity of the plant after expansion will be
20000 TCD, which means the additional production as follows (maximum).

Product Production per Annum in MT

Maximum Minimum Average

Sugar cane crushing MT 30,00,000 24,00,000 27,00,000

Sugar in QT 34,50,000 27,60,000 31,05,000

Proposed Power 75.6 MW 65.7 MW 70.65 MW

Generation During
season
Proposed power export 50.20 MW 40.20 MW 45.20 MW

3.3 The raw material for manufacturing the above is Sugarcane i.e. 25 to 30
lakh MT which is sufficient for 120 to 150 days @ 20000 TCD. The
productivity of the sugar cane & yield depend on water supply & hence, the
cane can be grown in & around the Ugar. Which is on the bank of river
Krishna, has full & sufficient irrigation facility. It is expected that yield will
be 30 to 40 MT per Acre with recovery of sugar as 11% to 12%.

4. Co-generation scheme

4.1 The co-gen plant is configured keeping in view that the sugar factory
operations & also to meet peak steam & power requirement. The
installed capacity of co-gen plant is 77.6 MW with 4 numbers of boilers
having 310 TPH capacities @ 62 bar 490 deg C temp, one boiler having
100 TPH capacity @ 110 bar 540 deg Temp and one 50 TPH capacity @
32 bar 490 deg c & two back pressure TG sets of 22 MW each, one back
pressure TG of 12 MW and one extraction cum condensing turbo
alternator. of 20 MW
4.2 The total average cane crushing is envisaged 25 to 30 lakh MT every year
in the crushing period of 120 to 150 days with crushing rate of 20000 TPD
This would be achieved by the sugar factory from its past performance
data of unit I.

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4.3 The process steam consumption is assumed 41.5% on cane; this could
be easily achieved as the proposed modification in the boiling house is
proved one. The electricity consumption during season of sugar factory,
cogeneration, colony etc. is taken as 28 kwh / MT of cane crushed with
electric drives for mill.
4.4 The proposal for expansion is to add one new boiler of 100 TPH capacity
along with modification in the existing boiler. The modification Scheme
envisages the boiler with super heater outlet steam parameters of 32 bar
& 490 Deg. C. & turbo-alternator with the steam inlet parameters of 30 bar
& 480 Deg. C. New Boiler is of 110 bar with 540 deg C steam parameters
with suitable new TG set. All the necessary auxiliary plants & systems in
respect of boiler modification will be installed for the efficient operations of
the co-gen plant.
4.5 The power generation is at 11 KV voltage level from the co-gen plant.
The interconnection with the KPTCL grid is at 110 KV after stepping up
the voltage from 11 KV to 110 KV. The power evacuation feeder is
connected to 110 KV sub-station at ugar which is around 2 Kms from the
co-gen plant site.

4.6 It is envisaged that the co-gen plant would run on sugar factory Bagasse
for 120 to 150 days (normal crushing season) & on saved bagasse for
around 150 to 200 days in non-crushing season to optimize the utilization
of co-gen plant.
4.7 Other equipments remains same, which comprises high pressure boiler,
TG set. condensate system, DM water system, cooling water system, fire
fighting system, compressed air system, instrumentation & control
system, electrical system, LT / HT switchgears, distribution panels, step
down transformers, step up transformer, outdoor switchyard equipment,
data acquisition system etc. for efficient & trouble free operation of co gen
facility.

5. Project Finance & Implementation:

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5.1 The total estimated capital cost of the sugar plant expansion is around
16626 lakhs. This includes land development, civil works, main plant
equipment, auxiliary plants, miscellaneous works, preliminary &
preoperative expenses, contingencies, interest during construction,
financing & other soft costs.
5.2 Project Cost Rs.16626 lakhs
Means of finance
Equity 25% : 4156.5
DEBT 75% : 12469.5
Total = : 16626
5.3 The financial analysis is based on the sugar plant operation. Other
benefits during crushing season as well as Bagasse saving.

6. Synchronization & Interfacing Scheme:

6.1 Synchronization & interfacing equipments will be added in the existing
system suitable for the expanded capacity..

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HIGHLIGHTS OF THE PROJECT

Name of the company : The Ugar Sugar Works Ltd.,

Registered office : Mahaveer Nagar, Wakhar Bhag, Sangli
Pin Code:416 416
Manufacturing unit : At: Ugar Khurd village, Tal: Athani,
Dist: Belgaum.
Constitution : A Public Limited Company.
Contact person : Shri ‘R.V.Shirgaokar’, (C & M)
Shri P. V. Shirgaokar (Ex Vice Ch)
Shri S. S. Shirgaokar (MD)
Shri N.S. Shirgaokar (JMD)
Shri C.S. Shirgaokar (JMD)
Products : Sugar, Bagasse & Power, Spirit
Expanded Capacity : Sugar 20000 TCD
Cogen 76 MW during season
Distillery : 200 KLPD

Power Export capacity : 47.43 MW during normal operation

Total project cost : Rs. 16626 Lacs

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CHAPTER 1

INTRODUCTION

A. INTRODUCTION ABOUT THE UGAR SUGAR WORKS

1. Background
1.1 The Ugar Sugar Works Ltd. is one of the pioneers in sugar production in the
state of Karnataka; the Company was incorporated on 11th September 1939,
under the able guidance and kind patronage of his late highness The
Rajasahab of Sangli with a crushing capacity of 500 tons per day.
1.2 Vaidya and Company was the first Managing Agents. In the year 1940, M/s.
Shirgaokar Brothers were called to manage the affairs of the Company and
they were the Managing Agents till 31st December 1969. M/s. Shirgaokar
Brothers who had by then made the Kolhapur Sugar Mills outstanding and
notable success proved to be successful in bringing up the Ugar Sugar
Works Ltd., also.
1.3 Under the overall supervision and control of M/s. Shirgaokar Brothers the
crushing capacity of the factory has been increased from time to time as
detailed in Table No. 1.1. At present the cane crushing capacity 12,000 TCD.
Table 1.1 growth in crushing capacity of the plant
Sr. CRUSHING PERIOD
No. CAPACITY IN
TCD
1 800 1955-56
2 1200 1960-61
3 2000 1969-70
4 5000 1988-89
5 6500 1994-95
6 7500 1997-98
7 10000 2002-03

1.4 The company has introduced number of irrigation schemes for the

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development of sugarcane in the area.

1.5 The company has started its own distillery during the year 1962-63 and liquor
section in the year 1967-68. New distillery plant unit with production capacity
of 45000 liters of rectified spirit has been commissioned in March 1995.
2. Cane availability
2.1 In Belgaum District where the plant is located, sugar cane is available from
the month of October to April even many times the season has to extend up
to the end of May. Typically, sugar cane availability is for a period of 7 to 8
months in a year. The registered area under sugar cane cultivation allocated
to Ugar Sugar Company is 60,000 acres. The important factor with regard to
the operation of USWL is that the cane arrival is fairly uniform and the plant
reaches the maximum crushing rate within a month of season
commencement. The total cane availability during a season is approximately
40 Lakh tones and most of it reaches the plant during the crushing season.
But now, due to new sugar plants installed in the nearby area, crushing
season days have reduced from 8 months to 5 to 6 months.

3. Steam Generation System

3.1 The main source of energy for the plant is bagasse and on an average the
bagasse generated is about 29% of the cane crushed. About 1 % of the
bagasse generated is utilized for juice filtration and the balance is available
for steam generation. While operating on a steady load the savings achieved
by the plant is about 2 to 3% on cane.
3.2 At present, the sugar plant supplies the entire steam requirement of the
distillery, which is around 10 to 15 tons per hour.
3.3 The existing steam generation system consists of 4 high pressure & 1 low
pressure water tube boilers and the details of these boilers are as given in
Table 1.2.

3.4 About 90% of the sugar plant's process steam requirement, which is at 2.5 kg

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per cm2 abs., is met through exhaust of the backpressure turbines and the
balance requirement, which is at 9 kg per cm2, is met through extraction from
turbine.
Table 1.2 Details of existing Boilers at USWL I
Steam Generators Make Year Capacity Pressure Temp. °C
T/Hr. kg/cm2 (g)
Babcock & Wilcox * 1998 75 62 490
Babcock & Wilcox * 1998 75 62 490
Krupp I 2000 80 62 490
Krupp II 2002 80 62 490
Walchandnagar Industries** 1989 55 32 490
* Purchased old which are manufactured in 1959
** modification proposed to increase capacity by 5 TPH & temp from 380 to 490
deg C

4. Power Generation System

4.1 From the above steam, total power is generated through three turbines,
which meets the in-house requirement as well as exportable power to
KPTCL grid. The rating of which are as given in Table 1.3 and 4th Turbine
will be idle during season as it is condensing turbine.
Table 1.3 Details of power gen. system
Year Capacity Pressure Temp.
Turbine
make
Siemens* 1998 18 MW 60 kg/cm2 485 °C
Shin Nippon 1 1998 22.8 MW 60 kg/cm2 485 °C
Shin Nippon 2 2003 22.8 MW 60 kg/cm2 485 °C
* Siemens Turbine is old and fully condensing type which is modified
to take extraction from HP to LP loop, hence it needs minimum 30 TPH
steam in condensing.
4.2 During the crushing season for the present capacity all the 3 turbines and 4
Boilers are in operation.

4.3 The average own power generation is about 120.00 million units per year.
The major electrical load of the plant comprises boiler fans, feed pumps,

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DC drives, cane cutter motors, centrifugals, injection water pumps and

cooling water pumps.
4.4 In addition to steam turbine generators, there are four diesel generators
available with USWL and the total capacity of the DG sets is 4600 KVA.
These DG sets are utilized as standby source of power during emergency
requirement and during start up operation as well as off-season operation.
5. Water and Condensate System
5.1 Only Exhaust steam condensate is recovered from the major process
equipment like Kestners and evaporators. The water from the above
recovery is utilized as feed water for the boilers. In addition, DM water is
available for feed water make up requirement.

6. Major Process Equipments

6.1 The plant follows standard three and half-massecute system for sugar
production.
6.2 The unit has got 2 milling tandems. The WIL mill having a size of 33" x 66"
is capable of crushing 4500 TCD and a second mill namely Shantaram
Machineries Pvt Ltd. having a size of 42" x 84" is capable of crushing 6500
TCD. The milling tandem along with the fibrizer is driven by DC drives.
6.3 The juice evaporation system comprises a quadruple effect evaporation
system. Earlier there was double effect semikesteners followed by
quadruple effect. In all, there were three numbers of SK1 bodies and two
numbers of SK2 bodies + 1 No. Robert’s Body in the pre-evaporators. The
quadruple effect evaporation system has three trains namely A, B & C and
two trains will be always on line. During last modification the above system
has been converted and made straight quad system.

6.4 The quadruple effect evaporation system has three trains namely A, B & C
and two trains will be always on line. The disposition of the heat transfer
surfaces for the streams is as given in Table 1.4

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1.4 details of existing evaporation system

Existing set up Quadruple

I II III IV

5000 M2 6400 M2 3500 M2 1500 M2

(9000 M2) (10134) (5384) (2300)
SK 4000 + R 3200 (DE)
SK 1200 + R 1440 (DE)
SK 1000 + R 1200 (DE)
SK 1200 + SK 1200 (DE)
SK 800
SK 800
R 1027 R 1027 + R730 R 730
R 1027 R 1027 + R730 R 730
R 1040 R 1040 + R830 R 830

6.5 The raw juice heating is done in two stages. In the first stage heating up to
50° C is carried out through Vapour Line Juice heater and the heating from
50° C to 75° C is achieved by Dynamic juice heater between 3rd & 4th Body..
6.6 The second effect of evaporator supplies vapors to part of A and B pans and
1st effect vapor is utilized for the C pan. 3rd effect vapors to A continuous pan.
The temperature raise in different stages are as given in

Table 1.5
Raw Juice Heated by Rise in temperature
Stage I III body vapors 30 to 50 C
Stage II I body vapors 50 to 75 C

Sulphited
Juice
Stage I I body vapors 75 to 90 C
Stage II SKI vapors 90 to 100 C

6.7 The centrifugal section encompasses 8 numbers of A centrifugal machines,

6 numbers of B centrifugal machines and 5 numbers of CFW & 2 Nos. CAW
centrifugal machines. The total 27 number of Crystallizers installed in the
plant, and that are 9 numbers A Crystallizers, 11 numbers B Crystallizers
and 7 numbers C Crystallizers.

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6.8 There are eight cell induced draught cooling towers for removing the heat
absorbed by the re-circulating water from the process.
7. Water supply system
7.1 The complete raw water requirement of the plant is drawn from river
Krishna, which is very near from the plant. The pumping station has got six
pumps out of which two pumps are utilized for sugar plant operation and the
pump ratings are as under:
Pump 1: Capacity: 390 M3/Hour. Head: 36.6 meters.
Pump 2: Capacity: 170 M3/Hour Head: 36.6 meters.
7.2 The raw water, from the river is brought to the plant by a 600-mm
underground RCC pipe and finally discharged into a constant level water
pond.
8. Boiler Feed Water System.
8. The raw water is passed through the pre-water treatment plant comprises
1 solid contact clarifier and chemical dosing system. This clarified water is
passed through DM plants having the capacities of 30m3/hr, 60 and 72
m3/hr. (3 bed de-ionization plants). Exhaust condensate received from the
process and turbine condenser is used directly as Boiler feed water.
Softener water is being used as makeup water for power plant cooling tower
and drainage of this water is used as makeup water for sugar plant cooling
tower.
9. DISTILLERY
9.1 There are two distilleries available with the USWL. One is of very old with
the capacity of 30 KLPD and another one is of 45 KLPD. Total existing
capacity is 75 KLPD. Usw is having IML section also wherein bottling with
their own brand are being manufactured. There is a separate effluent
treatment plant ie evaporation and drying effluent to form a powder is
available with USW.
10 Fire Fighting System.
10. Sprinkler system is provided all through bagasse carriers. Hydrants and
1 portable fire extinguishers are available at other places.

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11 Compressed Air System.

Three Horizontal Chicago pneumatic air compressors and Two vertical air
compressors having a total discharge of 2160 CFM are available for
instrument and service air supply.

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CHAPTER 2
NEED FOR THE PROJECT
1.0
1.1 All the nearby plants are going for the expansion and the forecast is total
crushing days will be reduced. Previously it was only one sugar factory in
Athani taluka, now there are 6 – 7 sugar factories in the radius of 20 to 30
KM.
1.2 Athani Farmers is going for expansion to 5000 TCD
Krishna SSK is going for expansion to 5000 TCD
Renuka Sugar – Kokatnur is going for expansion to 15000 TCD
Renuka Sugar Raibag SSK is going for expansion to 5000 TCD
Mohanrao Shinde Arag is 2500 TCD.
New plant Shirguppi sugar is coming up with capacity – 5000 TCD
New plant Shivshakti sugar is coming up with capacity 2500 TCD.
1.3 To achieve maximum crushing in minimum crop days with maximum sugar
recovery it is essential to go for expansion. Present overheads at Ugar are
already high, which leads to face difficulties in arriving at competitive cane
price. Hence Ugar Sugar management is proposing to expand the sugar
plant capacity to 20000 TCD.

2 Ugar Sugar has already taken steps to overcome the bottlenecks faced to
crush 416.66 TCH (10000 TCD in 24 hrs) and during last season USWL
has crushed almost 416.66 TCH. One of the bottlenecks is still exists i.e.at
cane unloading station of 42 x 84 mill. Due to space constraint and lower
capacity cane un-loaders they are unable to maintain uniform cane feeding.
Bagasse moisture will be on higher side, which leads to fluctuations in boiler
steam working parameters and in turn affects the crushing. Along with cane
unloading station the other parameters, i.e. reduction in crop days in future,
higher overheads per ton of cane and competitive cane price, sugar plant
expansion seems to be essential. Hence USWL proposing to expand the
crushing capacity.

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2.1 Alongwith the expansion of the sugar plant capacity to 20000 TCD it is also
proposed to expand cogen power plant capacity to 76 MW with distillery of
200 KLPD capacity.

2.2 The main areas covered under the sugar plant expansion is mill and Boiling
house..

2.3 Mill Expansion: it is proposed to reshuffle the cane unloading system and
enhancing the unloader capacity from 7.5 MT to 12.5 MT to overcome the
existing cane feeding bottle necks and addition of Zero Mill of size 50” X
100” and last mill of 50 X 100 with GRPF for existing 42 X 84 mill to crush
at the required capacity.

2.4 Boiling House capacity to be increased to 20000 TCD, for new additions
capacity shall be suitable for 909 TCH. One parallel boiling house set has
been proposed for the expansion.
2.5 The viability of the sugar factory is improved due to cogeneration, which is
also a need of the State to have more power to meet the growing power
demand in the State.
2.6 Alcohol plays one of the important role in the countries economy. Alcohol is
by product of sugar industry, which is linked to agriculture. There alcohol
produced from molasses deserves the preferential place as a substitute
feed stock for chemical industry and to bridge a gap in our every need. The
gap between the availability of alcohol and requirement by the industry has
been avoiding.

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CHAPTER 3
PRODUCT SALE POLICY
1.0 Sugar Sale Policy

A) Sugar sales are governed by sugar control order of Central Government

& the releases are given to the Sugar Factory in proportion to their
production / stock of season with the factory. Factory will follow these
rules for sugar sale & abide by the rules. Sugar is sold to Government
nominees & or wholesale dealers registered with the Government.

2.0 Molasses Sale Policy

A) Molasses sales are governed by State Excise. Factory will possess M1
license issued by the Commissioner of State Excise, which will permit to
produce the molasses, hold in stock & sell molasses to authorized
parties. Factory will find the parties i.e. Distilleries, Cattle Feed producer
or otherwise exporter of molasses who can purchase the molasses at
remunerative price. This will be followed till such time as own distillery
is established.

3.0 Filter Cake Sale Policy (Press Mud)

A) Filter cake is produced as a by-product at the rotary vacuum filter where
the muddy juice is filtered. This filter cake is rich in minerals, potash as
also the phosphate, sulphites & organic matter which means rich
manure. Hence, this is most suitable for soils. The factory will adopt the
policy to return the rich manure to soil by selling the filter cake
particularly to cane growers who have supplied the cane to factory. It is
general experience that cane growers are very much interested to
purchase filter cake at a nominal price fixed by the factory.

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4.0 KERC guide lines

A The Karnataka Electricity Regulatory Commission approves the draft
standard PPAs for each category of the NCE projects on dated 18th
August 2005 duly incorporating the changes as approved in the Order
dated 18th august 2005. The main points are

1 Power purchase is at the rate of Rs. 3.59 per kilowatt-hour (“the

base tariff”) for energy delivered to the Corporation at the Metering
Point with an escalation at a rate of 2% per annum over” the base
tariff” every year. This shall mean that the annual escalation will be
at the rate of Rs.0.056 per Kwhr.
2 Power purchase agreement period would be 10 years from the date
of commissioning of cogen project.
3 The Company shall undertake at its own cost construction/up
gradation of (a) the Interconnection Facilities and (b) the
transmission lines as per the specifications
4 The Company shall achieve Scheduled Date of Completion within
one and half years from the date of Financial Closure.
5 The benefits accruing on account of carbon credit shall be shared
between the Company and the Corporation in the ratio of 50:50, after
deducting all expenses incurred by the company in this regard
6 The Developer shall pay to the KPTCL, at the rate of Rs. 37,000/-
[Rupees Thirty Seven Thousand only] per MW of Installed Capacity
and for fractions thereof on a pro rata basis as a one time lump sum
payment for the sole purpose of providing the required MVAR
capacity at the sub-station of the KPTCL to which the Project is
interconnected to supply the requisite reactive power to the Grid
system.
7 Payment 15 days from the date of bill.
8 KPTCL to provide start up power required for the plant.

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9 The metering equipment shall be electronic trivector meters of

accuracy class 0.2% required for the Project (both main and check
meters).
1 Presently tariff has been revised by KPTCL to Rs 5.5 for two months
0 period. Up to May end 2010
5.0 Government of India policy
a) To cater to the ever increasing demand of energy, Government of India
(GOI) had declared a policy in 1995 to promote generation of energy
from non-conventional sources to supplement the power generation.
MNRE issued guidelines for obtaining interest subsidy / capital subsidy
for biomass / Bagasse based cogeneration projects. GOI has
announced following fiscal incentives.

i) Where renewable energy components (including raw materials,

components & assemblies) are used, Central Excise Duty is
exempted.
ii) Customs Duty livable for non-conventional renewable sources of
energy (NRSE) power projects of less than 50 MW capacity is
20% if it falls under project import category.
iii) 100% depreciation is allowed in the 1st year itself.
iv) Income tax holiday for first 10 years followed by reduced tax
liability (30%) for next five years.
v) Central Sales Tax is exempted for renewable energy devices
including raw materials, components & assemblies.

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CHAPTER 4

TECHNO COMMERCIAL ASPECTS

1 Description of operating Scheme:

a) The plant operating scheme envisages both mill tandems of Dia 33” X
66” and 42” X 84” will operate at 6000 & 14000 TCD respectively to
the total capacity of 20000 TCD. Boiling house is also being expanded
to take additional load of expanded capacity.
b) 33’’X 66’’ mill with minor modifications will crush 6000 TCD as per the
existing past data. It is proposed to modify and enhance the capacity
of 42 X 84 Mill to 14000 TCD by adding zero mill of 50’’ X 100’’ and
last mill also 50” X 100” along-with the modifications in the cane
unloaders, cane preparatory devices and existing mills.
c) Juice heaters will be added to balance the mass and temperature i.e.
wide gap plate type heat exchanger is proposed to operate on vapour
condensate. Existing juice heaters will be modified to suit the
expanded capacity.
d) Juice sulphiter and syrup sulphiter are proposed to be added suitably
to handle the total juice flow for the expanded capacity
e) It is proposed to add juice clarifier to maintain the required retention
time for juice clarification.
f) Plate type juice heaters are also proposed in addition to the existing to
operate on 1st body vapours
g) It is proposed to add evaporator body for 1st and 2nd effect in the
existing set up, for Heat & mass balance. There will be total 3 streams,
two operating and one set will be cleaning so that every 10 to 15 days
clean set will be online.
h) In addition to the existing Batch type A pans and continuous pan it is
proposed to add one more continuous pan for A massecuite boiling. It
is proposed to add continuous horizontal pans for B and C massecuite
handling.

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2 nos batch type A centrifugal machines are prposed for the expanded
capacity
Four numbers of continuous centrifugal machines are proposed for B
and C massecuite for the expanded capacity
Modification is proposed in the sugar drying and sugar hoppers. There
is no change in sugar silo system
One additional sugar bagging and conveying system up to sugar go-
down is proposed
One additional cooling tower is proposed to take additional heat load
generated by condensers
For cogeneration 1 new Boiler of 100 TPH with working parameters of
110 ata and 540 deg C temperature. Alongwith new Boiler one old
Boiler of 32 bar 380 deg temp is proposed modify to get outlet
temperature 490 deg C.
For above Boiler Two TG sets have been proposed, 1 no 12 MW back
pressure TG set suitable for 32 bar steam and one 20 MW double
extraction cum condensing TG set suitable for new Boiler steam.
Switch yard with transmission line is also to be expanded suitably.
Existing Distillery capacity is 75 KLPD, additional 125 KLPD distillery
to be added.
b) Bagasse saving for 135 days operation with 909 TCH increased
crushing & 90 PLF nearly 137696 MT of bagasse can be saved. Total
Bagasse saving in a season for 909 TCH will be about 137696 MT
c) During season as well as off season USW needs steam to distillery 25
TPH and for evaporator drier of ETP about 25 TPH. This requirement
will be fulfilled by operating cogeneration during season & off season.
d) When cogeneration is in operation distillery steam requirement can be
met through the turbine extraction. Hence it is essential to operate
cogeneration during off season with saved bagasse.
e) Accordingly during off season one of the Boilers will be operated on
saved bagasse for maximum possible days.

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2 Operation of the Plant During Crushing Season:

a) 310 TPH Steam will be generated from 4 nos Boiler at 62 bar and 55
TPH from modified Boiler at 32 bar, 490 deg C temperature, 100 TPH
steam will be generated from new Boiler of 100 TPH capacity.
The entire steam generated in the boiler is fed to four turbines. 260
TPH for SNM Turbine, 92.50 TPH for DEC Turbine and 80 TPH to
new Back pressure Turbine. The uncontrolled extraction from the
turbine at 9 ata gives 37.5 TPH of steam approximately at a
temperature of 270 Deg. C. The controlled extraction from the turbine
at 2.5 ata provides 380.06 TPH of steam approximately at 140 Deg. C.

b) A quantity of 30 TPH of steam, being the difference between the

generation and input to SNM Turbines at 62 bar will be mixed with 32
bar 50 TPH steam from modified Boiler through PRV to get 80 TPH.
c) With the above given steam input & extractions from the turbine, the
co gen TG generates 72890 KW, at the generator terminals. Part of
the generated power is used for meeting power requirement of the
auxiliaries of the co gen plant & the power requirement of the sugar
factory.
d) Only the exhaust steam condensate from the sugar factory process &
the condensate from turbine surface condenser are being used as the
feed water for the boilers. The cycle make up water for the operation
of co gen plant will be DM water.

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TECHNO-COMMERCIAL ANALYSIS

Sr Description Unit Total Qty

No
PROCESS STEAM REQUIREMENT
1 CRUSHING CAPACITY TCD 20000.00
HOUR
2 WORKING HOURS S 22.00
3 CRUSHING CAPACITY / HOUR TCH 909.09
4 BAGASSE PERCENT CANE % 29.00
5 BAGASSE PRODUCTION AFTER DEDUC OF 1% TPH 254.55
6 PROCESS STEAM REQUIREMENT AT 2.5 ATA % 40.00
QUANTITY OF STEAM AT 2.5 ATA TPH 363.64
7 PROCESS STEAM REQUIREMENT AT 8 ATA % 1.50
QUNANTITY OF STEAM AT 8 ATA TPH 13.64
8 SEASON WORKING DAYS DAYS 135.00
8 STEAM REQUIRED FOR PROCESS 377.27

TOTAL STEAM REQUIRED FOR SUGAR

8 PROCESS TPH 377.27

8.1 FEED WATER REQUIREMENT TPH 467.16

8.2 FEED WATER TEMPERATURE Deg c 77.32
8.3 STEAM REQUIRED FOR DEAERATOR TPH 22.57
8.5 STEAM REQUIRED FOR DISTILLERY TPH 25.00
8.6 STEAM REQUIRED FOR SSP TPH 25.00
8.6 STEAM REQUIRED FOR CONDENSER TPH 15.00
8.4 SPRAY WATER REQUIRED FOR DESUP (8 ATA) TPH 1.19
8.5 SPRAY WATER REQUIRED FOR DESUP (2.5 ATA) TPH 6.15
8.6 STEAM REQUIRED AT TURBINE OUTLET 8 ATA TPH 37.45
8.7 STEAM REQUIRED AT TURBINE OUTLET 2.5 ATA TPH 380.06
8.8 STEAM REQUIRED FOR EJECTOR & GSC TPH 0.50

9 TOTAL STEAM TO BE GENERATED TPH 458.00

10 CONDENSATE RECOVERY
a FROM SUGAR PROCESS (2.5 ATA) % 90.00
QUANTITY TPH 327.27
b FROM SUGAR PROCESS (8 ATA) % 0.00
QUANTITY TPH 0.00
c CONDENSER % 95.00
QUANTITY TPH 14.25
d DEAERATOR TPH 22.57
f TOTAL CONDENSATE RECOVERY TPH 364.09
g BOILER STEAM GENERATION TPH 458.00
h BLOWDOWN WATER & STEAM LOSSES % 2.00

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QUANTITY TPH 9.16

I TOTAL FEED WATER REQUIREMENT TPH 467.16
j MAKEUP WATER REQUIREMENT TPH 103.07

TEMPERATURE OF FEED WATER AT FT 77.32

11 BOILER CAPACITY REQUIRED TPH 458.00

EXISTING BOILER CAPACITY @ 62 bar steam TPH 310.00

EXISTING BOILER CAPACITY @ 32 bar steam TPH 55.00
TOTAL BOILER CAPACITY AVAILABLE 365.00

NEW BLR TO BE ADDED (CAPACITY) TPH 93.00

12 STEAM DISTRIBUTION TO TG SETS 62 BAR

1 SNM 1 & SNM 2 TPH 260.00
2 8 ATA EXTRN TPH 30.00
3 2.5 ATA EXTRN TPH 230.00
4 LP TG SET THROUGH PRDS 25.00

1 NEW DEC TG SET TPH 92.50

2 8 ATA EXTRN TPH 7.45
3 2.5 ATA EXTRN TPH 70.06
4 CONDENSER TPH 15.00

1 NEW 32 BAR TG SET TPH 55.00

2 STEAM TO 32 BAR TG SET 80.00

13 POWER BALANCE
1 POWER GENERATION 2 - SNM MW 43.33
2 POWER GENERATION DEC MW 17.55
3 POWER GENERATION FROM LP STEAM MW 12.00
4 TOTAL POWER GENERATION MW 72.89
5 TOTAL CAPTIVE POWER MW 25.45
6 EXPORTABLE POWER MW 47.43

14 BAGASSE BALANCE IN SEASON

1 BAGASSE PRODUCTION TPH 254.55
2 BAGASSE REQUIRED FOR BOILER TPH 208.18
3 BAGASSE SAVING TPH 46.36
4 BAGASSE SAVING IN A SEASON MT 137696

15 OFF SEASON OPERATION ON SAVED BAGASSE

1 STEAM GENERATION TPH 86.00
2 STEAM TO TG SET TPH 85.50
3 8 ATA EXTRN TPH 50.00

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4 2.5 ATA EXTRN TPH 10.35

5 CONDENSING TPH 15.15
6 BAGASSE REQUIRED TPH 41.95
7 NO OF DAYS ON SAVED BAGASSE 136.76
8 POWER GENERATION MW 11.94
9 CAPTIVE POWER MW 1.67
10 SUGAR PLANT & COLONY LIGHTING MW 0.25
11 EXPORTABLE POWER MW 10.02

1 TOTAL POWER EXPORT SEASON 1383.10

2 TOTAL POWER EXPORT OFF SEASON 295.92
3 TOTAL POWER EXPORT 1679.02

1 SUGAR CANE CRUSHING MT 27,00,000

2 SUGAR PRODUCTION @ 11.5% RECOVERY QTL 31,05,000
3 PRESS MUD PRODUCTION @ 4% MT 1,08,000
4 MOLASSES PRODUCTION @ 4% MT 1,08,000
5 SPIRIT PRODUCTION FOR 300 DAYS KL 60,000

Detailed profitability statement is given separately

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CHAPTER 5
TECHNICAL SPECIFICATIONS OF EQUIPMENTS

The expansion proposal covers 4 main areas, 1 Mill section, 2. Boiling house,
3.Cogeneration and 4. Distillery. It is proposed to expand the crushing capacity from
10000 to 20000 TCD Co-gen capacity from 44 MW to 76 MW and distillery from 75
KLPD to 200 KLPD
A) MILL EXPANSION
1) All existing 9nos (5 nos for 42 X 84 mill and 4 nos for 33 x 66 mill) cane
unloaders with all its accessories to be replaced by 12.5 MT capacity unloaders.
2) One additional new complete cane unloader of 12.5 MT capacity with gantry,
support structure, feeder table with all accessories to be added to 42 X 84 Mill.
Minimum gantry height should be 12 mtrs.
3) All existing Gantry height to be increased to minimum 12 mtrs height with
necessary strengthening of gantry and columns.
4) Increase in CC No. 1 depth by 300 mm & Width to 2750 mm suitable for 682
TCH crush rate. (Size after increase will be 1400 mm straight & 2750 mm width)
5) One additional strand Chain, replacement of Slats, replacement of tail end shaft
and modification in drive shaft of CC 1. If modification is not possible it is to be
replaced by new one. Suitable motor gear box etc to be added.
6) Chopper to be installed at existing Kicker location with necessary modification
and increasing the RPM.
7) Kicker to be installed at existing chopper location with necessary Modification.
8) Leveler – new shaft with additional knives to be installed.
9) Fibrizor has to be designed to achieve 89 to 90 PI. Complete new assembly to
be installed, swing diameter to be considered as minimum 2130 mm.
10) New 2500Kw 750RPM HT motors – 2 Nos. to be added with starter and control
panel to Fibrizer.
11) New Cane Carrier No.2 suitable to 50”x100” Mill for 682 TCH capacity to be
added.
12 Rotary Strainer identical to existing to be added.
13 Inter Rake Carrier – Depth of carrier truff to be increased
14 Bagasse Elevator – Minor modification (depth of trough and height of rakes to
be increased.)
15 Zero mill and last mill of 50”x100” (2 Nos.) with TRPF & TUFR to be added. Mill
RPM shall be 4 rpm for ultimate capacity i.e. for 682 TCH crush rate. 1250 KW
DC motor removed from Fibrizer to be installed for zero mill. Planetary Gear
system with rope coupling suitable for 1250 KW power transmission.

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17 TRPF to be added for 2nd Mill of 42 X 84.

18 Required modifications will be carried out for existing 4 mills to crush the
proposed capacity.
19 Modification in Mill EOT crane (from 40 to 50 MT).
20 Imbibition pump and mass flow meters 2 Nos.
21 Miscellaneous equipments

Detailed specification of new equipments

1. Cane Unloader – 10 Nos.
¾ Bridge with trolley of 12.5 T for trucks having sling bar system – Two
motion type.
¾ The crane shall be 2 motions, of 12.5 tons, electrically operated overhead
unloading crane conforming to Class IV IS specifications and capable of
20 lifts per hour. In each lift, sling shall lift at least 12.5 tons of cane.
¾ The height of the lift shall be 12 meters.
¾ The width of the gantry shall be suitable to accommodate the trolley and
shall also have gangway on side with statutory safety provisions such as
hand rails, toe plate, grating etc.
¾ The crane shall be complete with its accessories, attendant platform along
the length of the gantry on both the sides, cat ladder 2 nos., etc.
¾ It shall be heavy duty type and suitable for continuous outdoor working.
¾ All operations shall be electrically controlled from the “Operator'’ platform
at level above feeder table.
¾ The crane span shall be 30 meters.
¾ Design Code - IS: 3177 & 807.
¾ All electric motors shall be of crane duty T.E.F.C. enclosures suitable for
300 operations per hour with following specifications :
Particulars duty Type of Motor H.P. Rating
Hoisting drum drive Squirrel cage 30 1 hour S4
Holding drum drive Squirrel cage 30 1 hour S4
Cross travel drive Slip ring 7.5 ½ hour S4

¾ For operation of these motors, push button type panel shall be provided
and its location shall be in the cabin attached to the trolley.

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¾ The following speeds shall be provided for various motions :

Hoisting 12 meters / minute
Holding 12 meters / minute
Cross travel 20 meters / minute
¾ All gear boxes shall be totally enclosed, dust proof, helical type gear and
shall be designed with crane duty service.
¾ All couplings shall be flexible gear type.
¾ All brakes shall be of electro-hydraulic thruster operator type.
¾ Suitable shed to be provided on trolleys.
¾ The bridge shall be of box type construction made of IS-2062.
¾ The cranes shall be operated from a common centralized operators cabin
for cranes & feeder table.

2. Feeder Table -1 No. ne addition

¾ One No. below the bridge.
¾ The feeder table shall be of inclined top rising towards cane carrier and
installed perpendicular to the cane carrier located below the 12.5 T
bridge.
¾ Cane feeder table of minimum 7 meters width and 8 meters in length to
be installed at right angle to the cane carrier.
¾ The feeder table shall be of all steel construction fitted with 8 strands of
150 mm pitch heavy duty steel drag type chains having breaking strength
of minimum 60,000 kgs.
¾ The feeder table shall be complete with cast steel machine cut sprocket
wheel, shafts, bearings etc.
¾ The feeder table shall be driven by a 15 BHP, T.E.F.C., squirrel cage
motor and coupled to a variable speed drive and a planetary reduction
gear box so as to provide speed regulation from 1 to 3 mtrs / min.
¾ The feeder table shall be suitably supported on steel structure designed
to withstand heavy shocks. It shall be installed in a manner so that it is
horizontal.
¾ Common operator’s cabin on a suitable height shall be provided to have a
clear view of the loading of the cane carrier. A suitable ladder shall be
provided to this cabin.

3. Mill – 2 Nos.

¾ two nos. of Ø 1270 X 2540 mm nominal roller size five roller Integrated

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type mills with Toothed roller pressure feeder to be installed. The mills
shall have toothed roller pressure feeder driven by top and feed roller
through chain sprocket to give surface speed of about 30% higher than
mill roller surface speed.

¾ All the mill rollers will have bearing journal of minimum 620 mm dia. and
770 mm length and central shaft dia 670 mm and running in gun metal
liner fitted in cast steel housing. The rollers will have circumferential 'v'
grooves. The headstock to headstock centre distance shall be @ 3850
mm.

¾ The roller will be of coarse grain cast iron having hardness 180-210 BHN.
The composition of the shell material will conform to IS 11201:1985 and
will be-

Total Carbon - 3.2 to 3.6 %

Manganese - 2.2 to 3.2 %
Silicon - 1.2 to 2.2 %
Phosphorus - 0.5 % max.
Sulphur - 0.15 % max.

¾ The cast iron shell will be hot shrunk fitted on forged steel shaft of 45C8
quality conforming to IS:1570-1979 or equivalent having a minimum
tensile strength of 58 Kg/mm2. All the shafts will have square ends not
less than 500 x 500 mm. Top roller will have stationery collars duly hard
faced and fixed with head stock. The bottom roller will be provided with
juice rings and removable guards to prevent entry of juice into the
bearings. The cast steel crown pinions will have minimum, 750 mm face
width and conform to IS: 2708 Grade III with well dressed well ground and
matched and good profiled cast teeth and will use tangential key's on
roller shaft for pinion fitting and suitable mild steel guards and troughs will
be provided. The apex angle of mill will be limited to 750 max. approx.

¾ The headstocks will be of cast steel as per IS: 1030 - 1974 grade 260/520
W. The head stock supplied shall be suitable to integral type Five Roller
Mill of our patented design.

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¾ These will be of pin type head stock. Removable gun metal wear plates
on feed side as well as at discharge side of top roller bearing with
lubricating arrangement between bearings and wearing plates will be
provided. The top and side caps will be of cast steel as per IS: 1030-1974
grade 260/520 W and will be securely locked in position for quick
assembly. Stainless steel strip of 8 mm thick will be provided on the side
roller bearing face of the headstock. The eccentricity between top roller
bearing center and hydraulic top cap center will be minimum 45 mm
towards the feed side of the head stock.

¾ All rollers will be coated with surface roughening electrode material and
its bearing will be of cast steel housing with renewable gun metal liner
with water cooling arrangement. The top and side roller bearing will be of
cast steel housing with renewable gun metal liner as IS: 318-1981. The
housing will have water cooling arrangement. All top roller bearings will
be interchangeable. Similarly all feed side and discharge side roller
bearings will be interchangeable by their respective bearings.

¾ Mill to be provided with cast steel trash beam as per IS 1030 grade
260/520 W and supported on heavy steel brackets with pivoted journals
fitted in the headstocks and adjustable by means of tie rods and fitted with
renewable CS trash plate as per IS: 1030 grade 22/45, bolted by high
tensile bolts and nuts. Meschaert groove scrapers will be of spring steel
secured on square shaft and supported on cast steel blocks and provided
with lever or other suitable adjusting device. Scrappers for top and
discharge roller shall have renewable tips.

¾ Mill will be provided with hydraulic loading system, consisting of hydro-

pneumatic accumulator, one for each of the journal for the top roller, one
extra as a spare and accessories such as pumping set, receiver tank,
gauges, remote control panel and roller movement indicator either
electronic type or liquid magnification type. The dia. of the hydraulic ram
for top cap will be minimum 465 mm. The hydraulic system will be
designed for a pressure 350 Kg/Cm2g.

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¾ Centralized lubrication system should be provided with one spare pump.

¾ Juice trough under the mill will be made of 6 mm thick S. S. 409M plates.
The trough will be welded to the headstocks. Joints will be suitably sealed
to prevent any juice leakage. The trough will have 900 included angle. Mill
will be high set, so that no part of the juice tank and pumps are situated
below floor level. All the mills will have common gangway on both sides
having width not less than 1000 mm with gratings and minimum 3 Nos of
stair cases, two for crusher side, and one from mill drive platform along
with the cross connection between each mill. Access from mill platform to
cane carrier drive platform, and rake elevator drive platform with suitable
cat ladders shall be provided. All gangways and staircases will have hand
railings.

4. Mill Drive – 2 Nos.

¾ Existing 1250 HP DC drive (panel and motor) will be used.

6. Planetary Gear Box with fls (lubrication system) for Mill drive

¾ The planetary gear box shall be of foot mounted design, ratio 1000: 4.0,
suitable for 900 KW continuous rating with 2.0 minimum service factor.
The shafts of the planetary gear box shall run in antifriction bearings. The
gear box shall be complete with forced oil lubrication system, geared type
input coupling and rope type output coupling, base plate etc.

7. Toothed Roller Pressure Feeder -

¾ A pair of Toothed Rollers of minimum 1350 mm swing dia. will be

mounted on forged steel shaft with journals of minimum 350 mm dia. and
minimum 400 mm length. These rollers will be rotating in gun metal
bearings in cast steel/ fabricated bearing housing. The bearing housings
will be mounted in integral heavy headstocks. The bearings will be
provided with lubrication arrangement. The roller shell will be hardened by

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welding the roller shell all over by hard facing electrodes. TRPF top roller
is driven by mill top roller by 3” pitch duplex chain and sprocket similarly
bottom roller is driven by mill feed roller by 3” pitch duplex chain and
sprocket.

8. Closed Feed Hopper (Donnelly Chute) - 1 No.

¾ Closed feed hopper fabricated out of 6 mm thick SS409 M plate duly M.S.
reinforced to be provided for each mill. It will have arrangements to adjust
the blanket thickness from adjustable front plate. The feeding height in
each hopper will not be less than 2.5 meters and its inclination will be 900
with the horizontal. The closed feed hopper will have electronic/electro-
mechanical suitable level sensing device to control the cane feeding.
Suitable indicators may be provided to indicate level of bagasse in
donnelley chute.

9. Rake Type Intermediate Carrier - 1 No.

¾ Generally constructed and fabricated as per cane rake carrier and

installed between the mill and rake carrier will have suitable length
between the drive and driven sprocket centers.

¾ The centre to centre distance between mill will be @ 10 m. The rake

elevator will have minimum feed height of 2.5 mtrs. Above top roller
centre to feed the Donnelly chute to the mill. The mill have bagasse
discharge chute for entire length of roller and discharging bagasse into
rake/ bagasse elevator. The Rake intermediate carrier will have 60 kw
TEFC foot mounted motor having 'F' class insulation coupled to planetary
gear box having services factor 2.0 to get 25 m/min apron speed. The
Rake carrier trough will be fabricated from 8 thick MS plate with SS lining
3.15 mm. Rake type intermediate carrier will have suitable width trough to
accommodate 2540 mm effective rake width inside the sprockets. The
maximum inclination of rake carriers will be limited to 450 with the

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horizontal. The head shaft will be on 45C8 quality, dia 200 at centre and
dia 175 at journal running in G.M. bearing. The tail shaft will be of forged
steel having MS drum running in dia 150 mm G.M. liner. The size of
chain 229 mm pitch block forges type with 80 ton breaking load.

10. Juice Imbibition Tanks and Pump - 1 Set :

¾ Mill shall be provided with conical bottom cylindrical whirler tank having
1250 mm dia. made of 5 mm thick SS 409M material connected to mill
juice trough through 3.2 mm thik SS gutters.

¾ The juice pumps all running at 1000 RPM shall be following capacities
and heads shall be supplied along with all its suction, delivery piping
valves, along with TEFC motors etc.

i)Unstrained juice for mill - 600 m3/hr. Plus 20% solids

20 mtr. Min. head
at 1000 rpm, 2 Nos.

¾ All pumps in mill house shall be of choke-less type with stainless steel
body and stainless steel impeller with full bore discharge and capable of
pumping mill juice with min 20% solids, at head specified above. The juice
from 1st mill shall be separately pumped through choke-less pump with
SS metal body and impeller with full bore discharge and capable of
pumping 600 m3/hr net juice plus min. 20% solids and 20 M head through
piping to rotary juice screen. The speed of the motors driving these
pumps shall not be more than 1000 RPM.

11. BOILING HOUSE:

¾ RJ1 heating – it is proposed use Existing VLJH with modification –

(Number of passes to be reduced) – 300 to 400C.

¾ RJ 2 heating by excess condensate – from 400 to 500C. – addition of New

Liquid to Liquid (PHE)

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¾ RJ 3 heating – it is proposed to use existing Dynamic heater with

modification – (Number of passes to be reduced.) 3rd vapour – 500 to
640C.

¾ New clarifier to be added with flash tank 42’x25’ (555) - 1020C.

¾ New pumps for Clear juice

¾ PHE for 2nd stage heating of clear juice

¾ Addition / Modification of syrup sulphiter

¾ New Evaporator 4000 m2, 3200 m2 & 2000 m2

¾ New A pan Continuous type 65 TPH capacity to be added

¾ New B Pan Continuous 40TPH capacity 2 Nos to be added – 2nd Vapour

¾ New C Pan Continuous 25TPH capacity 2 nos to be added – 2nd Vapour

¾ New B Crystallizer

¾ New C Crystallizer

¾ Centrifugal machines

¾ Sugar hopper, Sugar bagging & conveying system

¾ Vibro screens

¾ Cooling Tower

¾ Condenser Automation

¾ Pipe & fittings modifications etc

¾ Structural supports

¾ Miscellaneous equipments

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During production of sugar, valuable by- products like Molasses, Bagasse

and press mud are produced. At present all molasses produced is sold to the
parties getting allotments of molasses from this factory. The commissioner of
excise controlling authority for molasses distribution. The molasses production
of this factory is round 60000 Tons per annum, because increased availability
of sugar cane and the capacity of the factory to crush all the available
molasses. The factory approached Government of Karnataka for grant of
license to establish a Distillery suitable capacity. Now the Government of
Karnataka has granted for state excise 200 KLPD capacity Distillery. In order to
run the distillery through the year, the factory shall get an allotment of about
96000 to 1,20,000 Tones of Molasses is available from their own sugar plant.
Balance requirement of about 100000 MT of molasses has to be procured from
the market. If therefore the Distillery shall have a daily capacity 200000 liters of
Rectified spirit by adopting proven technology of continuous fermentation the
factory can have higher productivity.

In order to operate the distillery throughout the year say about 300 days/
annum, it is proposed that the Distillery shall have separate boiler in off season
of suitable capacity with T.G. set.

They shall have its own arrangement for steam & electricity. The Power
generated will full for operating the distillery as well as for lightening the roads
& buildings.
Distillery will discharge spent wash effluent at the rate of 10 to 12 liters
per liter of Alcohol produced. Daily production of spent wash shall be 2000 m3
to 2400 m3. The spent wash has high B.O.D. to the extent of 80,000 to 90,000
mg/l. As per the standard laid down by the Government the BOD should be
brought down to 100 to 30 mg /l. Before it is charged over land or water
respectively. There is no suitable and economical method to achieve these
standards. The method of concentration and drying of spent wash besides
being very costly, pose number of problems, as regards it maintenance and
repairs due to high temperature and corrosive nature of spent wash.
The alcohol produced in the distillery shall be sold as per the
Government’s directives to the parties getting allotment. The distillery shall
make good profits, besides getting better price for its molasses. It provides
good opportunity for the further diversification. The distillery project is very
attractive as the demand for alcohol will be increasing for manufacturing
chemicals.

During distillation of Rectified Spirit by product known as fusel oil is

produced to the extent of 0.2 to 0.3 per cent of the total alcohol produced.
Fusel oil is a mixture of higher alcohol such as propyl alcohol, butyl alcohol and
amyl alcohol. Amyl alcohol content ranges from 50 to 60 per cent in fusel oil.
Spent wash discharged from distillation column is a valuable by-product if
it is used properly. If neglected, it becomes hazardous causing pollution of
environment. It is rich in nutrients, for use in fertilizers. It is also capable of
generating energy. In anaerobic digestion of spent wash, methane gas is

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produced which can be used as a fuel in boiler. The quantity of gas produced is
almost sufficient to generate the steam required for generation. It requires
secondary treatment for the Distilleries are as under:

1. Rectified Spirit Grade 1

2. Impure Spirit Grade 2
3. Fusel Oil
4. Methane Gas
5. CO2
6. Yeast sludge
7. Ethanol 98.6
8. E.N.A.( Extra neutral alcohol)

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Specification of Boiling house equipments

1. JUICE CLARIFIER 42’ – 555

One no. 36’ dia with 5 Nos. compartments of 1525 mm height. Clarifier shall
have separate juice & mud outlet from each compartment.
The flocculating compartment complete with skimmer & feed well shall be
installed separately. The clarifier shall be made of mild steel plates having
following minimum thickness:
Particulars

Type : 555
Quantity : 1 No
Capacity : 36 Feet Dia
Accessories : Flash tank
PLATE THICKNESS : Carbon Steel as per IS 2062
1. Bottom : 12 mm
2. Shell : 10 mm with stiffeners
3. Tray (intermediate) : 12 mm
4. Tray (top) : 10 mm
5. Top cover : 10 mm
6. Flocculating compartment : 10 mm
Mud Liquidation Pump
Quantity : 1 No
Capacity : 50 m3/hr & 20 m head
Drive : Suitable
Flocculating dosing system
Tank : Adequate Capacity
Dosing pump with drive : One set
Juice liquidation pump
Quantity : 1 No
Capacity : 50 m3/hr & 20 m head
Drive : Suitable

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The continuous clarifier shall be complete with mild steel flash tank &
withdrawal boxes 2 Nos. for clear juice & 1 No. for mud with sleeves,
telescope pipes & O rings, hinge type squeezers, driving mechanism with
variable speed drive head with motor consisting of sprocket, chain & drive
guards, all inside & outside clear juice piping & mud piping, all valves & pipe
fittings etc. & complete with peripheral walkway, angle iron bracket supporting
angles, piping for railing, rail support etc. 5 manholes one for each
compartment, each manhole to have platform, railing & access ladder. Each
pump with receiving tank & support. Insulation material of mineral wool 50 mm
thick with PP etc to be included in the scope of vendor. Mud liquidating and
juice liquidating pump of CI construction with bronze fittings.
Mud boot sealing arrangement to be done from topside of mud boot bottom
plate.

1) EVAPORATOR BODY 4000 M2 SK

The bodies shall have a vapour space height (between the top tube plate and
the bottom of the catch all or cylindrical portion of the vapour space) shall not
be less than 1.5 times the calendria height. Suitable arrangement for light and
heavy noxious gas removal shall be provided. Boxes shall be provided for
easy removal of condensate from calendria. Manhole shall be provided in
bottom saucer and vapour space & catch all. Suitable connection for soda
washing and draining for juice shall be provided. Suitable relief valve spring
loaded or dead weight lever type shall be provided on calendria and in the
vapour space of evaporator to ensure the pressure in the body does not
exceed working pressure.

Condensate outlet pipe shall have sight glasses at eye level in addition to
sight glasses in extraction columns. The cock shall be provided at all units
individually for testing condensate for sugar traces and suitable drain
connection shall be provided to drain the condensate.
Evaporators shall be complete in all respect with fittings for satisfactory
operation.

1 Heating Surface 4000 m2

2 Tube Size 45mm OD x1.6 mm thick x 4000 mm SS 304
3 No. of tubes As per the requirement

Evaporator body is required in M.S. Welded construction. It should consist of

the following.
Catchall -Body Shell - Calendria - Bottom cone - Vapour Deflector
CATCHALL

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SS-304 Poly baffle type suitable to pass all the vapours generated and 100%
guaranteed design against entrainment, Following connections to be provided
on Catchall of minimum 18 mm thk.
1 100 NB for water washing nipple with coil 1 No
3 Vapour outlet suitable for 120 T/hr. Vapour at 25 mtrs/sec. 1 No
velocity.
5 400 mm manhole hinge type 1 No
6 Other balance connections required.
BODY SHELL
Cylindrical vapour space 600 mm dia more than the Calendria dia with
minimum height 1.5 times more than tube length, shell thickness 18 mm thick.
The cylindrical portion should be with required stiffeners rings.
1 200 mm dia sight glass first assembly and first glass at 200 2 Nos
mm from top tube plate.
An inverted umbrella type vapour deflector placed at 2 m. height from top tube
plate of 16mm thick.
2 200 mm dia light glass assembly 1 No
3 500 mm dia manholes 2 Nos
4 100 mm connections for soda connection 1 No
5 150 N.B water connection 1 No
6 150 NB Temperature gauge connections 1 No
7 Pressure gauge connection 1 No
CALENDRIA
1 Shell plate 18 mm thick
2 Tube Plate 32 mm thick
3 Ligament 15 mm (min)
4 Pitch 60 mm
Peripheral down take with 2 Nos. Juice outlets 4 Nos. stools
Bolted/welded connection with bottom cone.
4 Steam entry 1200mm dia with flange & nipple. 1 No
5 150 N B water connection with flange & nipple 1 No
6 150 N B Condensate connections with flange & nipple 4 Nos
80 N B Noxious gas connections each for light & heavy gas complete with
interconnecting piping of SS 304. Moreover removal of noxious gases from
centre of Calendria of 80 N B 6 Nos minimum. OR as per your design so that
100% noxious gases shall be removed to get the required evaporation rate.
7 Pressure gauge connection 1 No
8 Temperature gauge connection 1 No

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BOTTOM CONE
Bottom /Welded connections with Calendria shell cone thickness 25 mm thick
consisting of Juice coil and Juice deflector etc.
1 250 N B Juice inlet connections 1 No
2 250 N B Juice outlet connections 2 Nos
3 150 N B drain connections 1 No
4 500 mm hinged manholes 2 Nos
5 150 NB wash out connections 1 No
Standard fittings as per requirement
Condensate receiver and pumps with motor including all valve and fittings.
Supply & application of 50 mm thick LRB mineral wool with PP
Right angle valve for the steam inlet

4. EVAPORATOR BODY 3200 M2 RB

1 Heating Surface 3200 m2

2 Tube Size 45 x1.2 mm thick 2450 mm long. SS 304 Tube.
3 No.of tubes As per the requirement
Evaporator body is required in M.S. Welded construction. It should consist of the
following.
Catchall -Body Shell - Calendria - Bottom cone
CATCHALL
Outwards flow Centrifugal vane type effective one having shell of 18 mm and
internals of 12mm thick, top cover of 16mm thick and well stiffened. Following
connections to be provided on Catchall.
1 150 NB for water washing with coil 1 No
2 250 NB Vent at Top 1 No
3 I.D. Vapour outlet 1 No
4 100 NB Juice drain 4 Nos
5 450 ID manhole with hinge cover with 3 to 4 bolts 1 No

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BODY SHELL
Cylindrical one with suitable stiffener rings cylindrical portion 18 mm thick,
minimum height 2 times the height of the tubes.
1 200mm dia sight glass first one at 200mm from top tube plate. 3 Nos
2 200mm dia light glass assembly 1 No
3 500mm dia manhole(to be fixed as per the site requirement) with 4 Nos
hinge type cover having 3 to 4 bolts
4 150mm soda connection 1 No
5 150mm water connection 1 No
6 150 NB relief valve connections 2 Nos
7 Pressure gauge connection 1 No
8 200 N B peripheral juice outlets 4 Nos
CALENDRIA
1 Shell plate 18mm thick
2 Tube Plate 32mm thick
3 Ligament 15 mm (min)
Central sealed down take 12 mm thick 4 Nos. stools
Bolted/welded connection with bottom cone.
4 Vapour entry to Calendria 2 Nos
5 150 N B water connection 1 No
6 150 N B Condensate connections 4 Nos
7 80 N B Noxious gas SS 304 12 nos
Connection each for light & heavy gas complete interconnecting piping and 2
Nos. 100 N B outlet with valves. of SS 304.
7 Pressure gauge connection 1 No
8 Temperature gauge connection 1 No
BOTTOM CONE
Bottom /Welded connections with Calendria shell cone thickness 25 mm thick
consisting of Juice distribution coil.
1 250 N B Juice inlet connections 1 No
2 250 N B Juice outlet connections 1 No
3 200 N B drain connections 1 No
4 500 mm hinged manholes 2 Nos
5 150 NB wash out connection 1 No
STANDARD FITTINGS

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1 Spring loaded safety valve 150 N B 2 Nos

2 Juice inlet valve 250 N B 1 No
3 Juice outlet valve 250 N B 1 No
4 Cold water valve 150 N B 3 Nos
5 Top vent valve 250 N B 1 No
6 Wash out valve 110 N B 1 No
7 Noxious gas valves 100 N B 2 Nos
8 Sight & light glass with rubber rings 4 Nos
9 Temperature gauge 6'' dial 2 Nos
10 Pressure gauge 6'' dial 2 Nos
11 Drain valve 150 NB 1 No
Condensate receiver and pumps with motor including all valve and fittings
(Suction, discharge valve & NRV)
Booster juice pump having capacity 200 M3/hr. 15 Mtrs head including all valve
and fittings.
Supply & application of 50 mm thick LRB mineral wool with PP

6) CONTINUOUS VACUUM PAN FOR B MASS – 40 TPH

1 Type Horizontal Pan with mechanical stirrer in last

compartment

2 Capacity 40 T/hr ‘B’ massecuite

3 Tubes Material S.S. 304

4 Tube Size As per the requirement

5 No. of Compartments As per the requirement

6 Working height of Mass In tightening zones and boiling zones not

above tube plate more than 350 mm

7 Overall Approx. sizes of Pan As per the requirement

8 Vapour Temp./ Pressure 95 to 102 deg C (2nd body of Quad)

9 S/V Ratio Above 10

heating surface Area minimum 900 m2

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Retention time min 3 hrs

10 Body thickness 18 mm

11 Tube Plate Thickness 32 mm

12 Calendria thickness 18 mm

13 Bottom part thickness 20 mm

14 Catchall Internals 12 mm

15 End plate thickness 20 mm with stiffeners

16 Side partition plate 12 mm

17 Central partition plate 12 mm

18 Vapour outlet Size As per the requirement

19 Steam Valve As per the requirement

20 No. of manholes 5 Nos. minimum of 500 mm dia hinge type

with 3 bolt design

21 Sight and light glasses 2 Nos. minimum to each compartment

22 Discharge connection size As per the requirement

23 Sample proof keys with SS For Each compartment

wash Basin

24 Cutover valve size 250 mm dia

25 AH and BH Molasses Conn 100 mm NB to each compartment

26 Hot Water heater Conn. 65 mm NB x 1 No

27 Body washing Conn 150 mm NB x 1 No each

28 Vacuum Break Conn. 150 mm NB x 1 No each

29 Compartment drains 150 mm NB

30 Compartment drain header 300 mm NB x 2 Nos

and
Cutover line

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31 Body and Calandria water 100 mm NB x 2 Nos

32 Compartment feed 65 mm NB x 4 Nos

Manifold Conn. 50 mm NB x 4 Nos

33 Hot water and steam to 25 mm NB

Manifold Conn.

34 Steam Conn. To 25 mm NB
compartment. Drains

35 Sight glass washing Conn. 25 mm NB x 1 No / 50 NB with valve

& Header

36 Compound gauge, 200 mm 2 Nos

dial dia, Range: 0-2.5
Kgs/cm2g and 0-760 mmHg

37 Vacuum gauge, 200mm dial 2 Nos

dia, Range:0-760 mmHg

38 Temp.gauge,200mm dial 2 Nos

dia, Range: 0-2.5 Kgs/cm2g

39 Pump for seed drive and PSP pump with VFD drive
gearbox capacity 15 T/Hr @
40 m head-1x

40 Footing/Seed As per the requirement

41 Final Cryst. Size in 300 micron (minimum)

massecuite

42 Final Brix 95 to 96 deg Bx approx.

43 Purity Drop 20 – 22 units average under normal feeding

conditions

44 Feedings As per the requirement

45 NCG Gas Line Isolation

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Valve

46 Specific steam As per the requirement

consumption: vapour/ton of
massecuite with Automation

47 S.S. Single entry condenser

of suitable capacity with SS
304 tail pipe with all its
accessories

48 Steam valves butter ply type As per the requirement

49 W shape bottom cone shall be provided with 6 mm thick plate jacket to

heat the internal material by second body vapors in case of stoppage

50 Supply & application of 50 mm thick LRB mineral wool with PP

7) CONTINUOUS VACUUM PAN FOR C MAS – 25 TPH

1 Type Horizontal Pan with mechanical

stirrer in last compartment

2 Capacity 25 T/hr ‘C’ massecuite

3 Tubes Material S.S. 304

4 Tube Size As per the requirement

5 No. of Compartments As per the requirement

6 Working height of Mass above tube In tightening zones and boiling

plate zones not more than 350 mm

7 Overall Approx. sizes of Pan As per the requirement

8 Vapour Temp./ Pressure 105 to 115 deg. C.(1st quad)

9 S/V Ratio As per requirement

H.S.A 900 m2 minimum
Retention Time Min 4.5 hrs

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10 Body thickness 18 mm

11 Tube Plate Thickness 32 mm

12 Calendria thickness 18 mm

13 Bottom part thickness 20 mm

14 Catchall Internals 12 mm

15 End plate thickness 20 mm with stiffeners

16 Side partition plate 12 mm

17 Central partition plate 12 mm

18 Vapour outlet Size As per the requirement

19 Steam Valve As per the requirement

20 No. of manholes 5 Nos. minimum of 500 mm dia

hinge type 3 bolt design.

21 Sight and light glasses 2 Nos. minimum to each

compartment

22 Discharge connection size As per the requirement

23 Sample proof keys with SS wash For Each compartment

Basin

24 Cutover valve size 250 mm dia

25 BH and CL Molasses Header Conn 100 mm NB each compartment

26 Hot Water heater Conn. 65 mm NB x 1 No

27 Body washing Conn 150 mm NB x 1 No each

28 Vacuum Break Conn. 150 mm NB x 1 No each

29 Compartment drains 150 mm NB

30 Compartment drain header and 300 mm NB x 2 Nos

Cutover line

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31 Body and Calandria water 100 mm NB x 2 Nos

32 Compartment feed 65 NB X required nos

Manifold Conn. 50 mm NB X required nos

33 Hot water and steam to Manifold 25 mm NB

Conn.

34 Steam Conn. To compartment. 25 mm NB

Drains

35 Sight glass washing Conn. & 25 mm NB x 1 No / 50 NB

Header

36 Compound gauge, 200 mm dial dia, 2 Nos

Range: 0-2.5 Kgs/cm2g and 0-760
mmHg

37 Vacuum gauge, 200mm dial dia, 2 Nos

Range:0-760 mmHg

38 Temp.gauge,200mm dial dia, 2 Nos

Range: 0-2.5 Kgs/cm2g

39 Pump for Grain 6 “ PSP pump with suitable VFD

drive-1 No

40 Footing/Seed As per the requirement

41 Final Cryst. Size in massecuite 150 micron (minimum)

42 Final Brix 100 deg Bx minimum

43 Purity Drop 22 – 24 units average under normal

feeding conditions

44 Feedings As per the requirement

Feed liquor : Molasses 75 deg C &
75 Brix (min)

45 NCG Gas Line Isolation Valve 80 mm – 2 Nos

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46 Specific steam consumption: As per the requirement

vapour/ton of massecuite with
Automation

47 Condensate water outlet 100 mm

48 S.S. single entry condenser of

suitable capacity with tail pipe of
SS 304 and all its accessories

48 Steam valves butter ply type As per the requirement

49 W shape bottom cone shall be provided with 6 mm thick plate jacket to

heat the internal material by second body vapors in case of stoppage

50 Supply & application of 50 mm thick LRB mineral wool with PP

INSTRUMENTATION & CONTROL FOR ‘B’ & ‘C’ PAN

Functional Requirements -
The system as a minimum, shall meet the following requirements without
the supervisory computer:
1) Control
2) Data acquisition & monitoring
3) Alarming
4) Logging & report generation
5) Historical data storage
6) Trending
7) System shall have free memory space available for the user and CPU
shall have the additional capability to perform advance control functions,
process optimization programs or generate management reports. The
availability of process control language shall be preferred.

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Control System –

Control system for PAN automation shall be PLC based with latest
technology available. The system shall be designed with redundant
controller. Controller make & model to be informed before finalizing. No.
of IO shall be as per the requirement of the PAN control. Additional 20%
IO’s to be considered in the system for future use. The communication
between PLC controller & Operator station shall be Ethernet only.
PLC Make : Honeywell HC-900, GE

Software –

Software required for control system/PLC should be licensed including

operating system. Vendor has to be considered latest operating system
available.

SCADA -

SCADA software shall be suitable to work with latest operating system

available (Windows XP/Windows 7) with upgradation possibilities.
SCADA software shall be of unlimited Tags. SCADA shall be supplied
with development & runtime for all the operator stations.
Operator Station –

Operator station hardware shall be the latest available at the time of

delivery with adequate memory space and shall be suitable for real time
applications. The operator station screen shall be of 22 inches min.
Make : DELL - Optiplex series
Operator Station Quantity : 2 Nos. for each PAN

Printer –
One no. of LaserJet printer shall be supplied with system for report &
trend printings.

Control Valves –

All required control valves for feed control (masscuite & water) should be
of Butterfly type only with double acting rotary actuator. The actuator
should have smart positioner with position feedback output. All other
valve required for steam/vapour shall be of globe type with pneumatic
actuator & smart positioner. All required air filter regulators to be
considered in scope of supply.
Feed Valve Mark : El-O-Matic
Valve Positioner: YTC
Air Filter Regulator: Janatics

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Transmitters –

All Filed Instruments like Conductivity Transmitter/Analysers, Pressure

Transmitters, Differential Transmitters, Vacuum Transmitter, Level
Transmitters, Temperature Sensors, Flow Sensors etc. along with
required fitting required for erection/installation. Transmitters should be
of 2 wire SMART type & HART Protocol with local display of PV. Input
Supply 24 VDC loop Powered. Transmitter should supply with all
required standard mounting accessories. Protection Class IP67/IP65.
Accuracy: ±0.1% Output: 4 to 20 mA.
Make – Emerson, E+H, Yokogawa, ABB, Honeywell

Conductivity Sensors –

Conductivity sensor shall be of auto retractable type, with self cleaning

mechanism. Conductivity sensor shall be designed with 100% leak
proof. Conductivity sensor shall be with inbuilt Temp. Sensor for
compensation. Suppliers shall include 1 no. of spare conductivity sensor.

Conductivity Transmitter / Analyzer –

Conductivity Transmitter/Analyzer shall be programmable with inbuilt

temp. Compensation. Conductivity Transmitter/Analyzer shall be of 2
wire SMART type & with HART Protocol with local display of PV. Input
Supply 24 VDC loop Powered. Transmitter should supply with all
required standard mounting accessories. Protection Class IP67/IP65.
Accuracy: ±0.1% Output: 4 to 20 mA. . Suppliers shall include 1 no. of
spare conductivity Transmitter/Analyzer.
Make – Emerson, E+H, Honeywell, Yokogawa, ABB,

Flow Meters –

All required flow meters should supply with required accessories along
with meeting Flanges. Remote type Flow Transmitter with display and
programmable to be supplied with min. 10 mtr. cable from flow tube.
Electromagnetic Flow meter sizing calculation should inform to us before
finalizing. Make: Krohne, Emerson, Yokogawa

Temperature Sensors –

All required temperature sensors should be with head mounted

transmitter. The probe length has to be considered according to the line
sizes. Temperature sensor has to be supply along with the thermo well.
Make: General Instruments, Eureka

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SYSTEM FURNITURE -

Two numbers Operator Control Desk shall be supplied suitable for

accommodating 2 numbers OS stations for each PAN.
Control Desk MOC should be Metal with Powder coated and in arc
shaped.
Necessary power supply distribution / network components arrangement
within the console shall be part of the supply. However, GA drawing
approval shall be taken from the purchaser during detail engineering.
The control desk shall be provided with Fans.
2 Nos. good quality high back, cushion wheel chairs shall be supplied as
a part of scope.
Printer tables shall be included.
Necessary mounting arrangement shall be done for Ethernet Switches.

UNINTRUPPTED POWER SUPPLY SYSTEM (UPS) -

Online UPS system with required capacity with minimum 2 Hrs. battery
backup to be considered in the scope of supply. The batteries to be shall
be Tubular type and industrial grade only with min. 5 years warranty.
The input cable for UPS system shall be in supplier’s scope. Minimum
10 mtr.cable to be considered for input supply of UPS system. The cable
between batteries & UPS shall be also in supplier’s scope. Minimum 5
mtr. Cable to be considered from UPS to battery bank.

The system shall normally operate on uninterrupted power supply.

However the system shall be capable of operating at the following power
supply specifications:
Voltage: 230V + 10%
Frequency: 50 Hz + 2 Hz
Harmonic contents: Less than 5%
Static transfer time: Max. 5 millisecond

UPS make: Emerson, APC

Battery make: EXIDE EL+

8) WATER COOLED HORIZONATL CRYSTALLIZER 100 T x

2 NOS

Horizontal type water cooled crystallizer 2 nos for B massecuite shall be driven
by planetary drive, suitable for continuous working, complete with suitable
reduction gear unit, suitable design to give a stirrer speed of not more than 60
RPH, The cooling surface (m2) to volume (m3) ratios shall be minimum 2.

The shell of the horizontal crystallizer shall be made of minimum 12 mm and end
plates 18mm thick MS plate.

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2 Nos pumps 50 TPH (1 + 1) with suction valve and delivery bypass

arrangement with valve for pumping B massecuite from receiver crystallizer to
Centrifugal machines for each cryst. Suitable pulp type valve for outlet of
crystallizer.
Complete crystallizer with mounting valves, fittings and planetary drive.

9) TWIN TYPE VERTICAL CRYSTALLIZER FOR C MASS

250 T EACH.

1 Duty ‘C’ Massecuite

2 Type Twin type vertical Crystallizer. Riser type

3 Capacity 250 M. Ton each

4 Quantity 1 No

5 Cooling Surface / Volume Ratio 2

6 Cooling Surface As per the requirement

The difference between height of inlet massecuite in the shell and overflow
gutter will be 2 mtrs. and the vertical crystallizer shall have sufficient cooling
surface so as to cool the massecuite from 65 deg C to 40 deg C, in 20 hrs,
when supplied with cooling water at 30 deg. C provision in the design will be
made for a maturing period of 4 – 5 hrs.

7 Tentative Dimensions

a) Shell Dia As per the requirement

b) Shell height (TOTAL) As per the requirement

8 Plate Thickness

a) Shell plate 12 mm, 10 mm, 8 mm with equal vertical

height

b) Bottom plate 20 mm

c) Trough Shell 8 mm

d) Hollow Shaft 12 mm

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e) Stirrer RPM 0.26 RPM

10 Drive

a) Electric Motor Suitable HP / 1440 RPM

b) Planetary Gear Box Suitable model

c) Final stirrer Speed 0.26 RPM

11 Cooling Coil 80 NB ‘C’ Class Pipe, as per IS: 1239

Hydraulic test pressure 6 kg/cm2(g) with
suitable pump & motor.

12 Accessories

a) Isolating Valves 80 NB to each coil

b) Manhole Dia 500 MM At different heights hinge type 3 bolt

design

c) Temp. gauges Dial 200 NB 4 Nos

Twin type Vertical type water cooled crystallizer for 'C' massecuite shall be
driven by electric motor for 250 T capacity suitable for continuous working,
complete with suitable reduction gear unit, suitable design to give a stirrer
speed of not more than 0.26 RPM, with Planetary gear box.
Necessary cooling surface shall be provided so that the temperature of the
massecuite is cooled from 65 deg C to 40 deg C in 20 hours, when supplied
with cooling water at 30 deg C. Provision in the design shall also be made for a
maturing period of 4-5 hrs in case of low grade continuous crystallizers. The
cooling surface (m2) to volume (m3) ratio shall be minimum 2. The heat
exchange elements shall be tested at pressure of 6 – Kg/cm2 g. suitable for
continuous working.

12 CO-GENERATION
Existing boiler modification to enhance the generation capacity from 50 TPH to
55 TPH and temp up-gradation from 380 to 500 deg C. One no new 12 MW bk
pr TG set suitable for these working parameters is proposed
In order to meet the process steam demand it is also proposed to add one new

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boiler of 100 TPH capacity with working parameter of 110 bar pr and 540 deg
C temp. one 20 MW Double extraction cum condensing turbine suitable for
new Bloiler steam working parameter is also considered.

¾ Total existing steam generation capacity is 310 TPH @ 62 bar

pressure, and 50 TPH @ 32 bar
¾ It is proposed to modify 32 bar pressure Boiler to enhance the
steam generation capacity to 55 TPH and temperature up-
gradation to 500 deg C. and addition of 100 TPH new Boiler @
110 bar pressure
¾ Total steam generation capacity after expansion will be 465 TPH
¾ It is also proposed to install DCS for all Boilers to maintain
uniform fuel feeding as well as uniform load sharing among all
Boilers.
¾ For the expanded capacity bagasse saving will be in tune of 800
to 1000 Tons per day

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CHAPTER 6

LOCATION & SITE ASSOCIATED DETAILS

1) Location of Site & Features:

a) The proposed modification is for 42 x 84 milling tandom and boiling

house. This complex presently consists of the sugar plant with the
crushing capacity of 10000 TCD, co-gen plant of 44 MW capacity and
distillery of 75 KLPD. The plant is located at Ugar Khurd Tq Athani, Dist
Belgaum of Karnataka state. It is 10 km away from Maharashtra border.
The nearest Railway Station is Ugar Khurd & is about 2 KM from the
sugar factory.
b) The following specific features of the site have been discussed in this
section of the report.
i) Availability of adequate space for locating the zero mill, cane
unloader and space for the construction activities.
ii) Suitability of the site for installation of boiling house equipments
such as juice heaters (PHE) juice clarifier, evaporators, pans,
crystallizers, centrifugal machines and sugar grader.
iii) Availability of adequate space for locating the New Boiler and new
Turbine.
iv) Availability of adequate space for locating the Distillery unit and
effluent treatment plant.
v) Availability of road connections for material movements.
vi) Ecological impact.

2) Land Availability:
a) The layout of the sugar complex is studied in detail & land required for
addition of zero mill is available between fibrizer and first mill. Last mill
addition is replacement of 42 X 84 mill. There is no need of any
additional space for modifications to be carried out in the milling section.
b) Area required for Clarifier is near existing clarifier on north side.

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c) Evaporator to be located towards north side of existing evaporator

bodies.
d) Pan C to be located on west side of the existing C pan.
e) Pan B shall be located on south side of the existing Pan B.
f) Two Centrifugal machines to be located in the series of existing battery
and two machines near melter on east side of the battery.
g) Sugar grader to be located adjacent to the existing grader.
h) Boiler to be located near 50 TPH Boiler south side of the WIL boiler
i) Turbine to be located adjacent to the existing turbine
j) Distillery unit to be located adjacent to the existing distillery
k) Effluent treatment plant to be located in the existing ETP area, adequate
space is available.
3) Inter Connection Aspects:
The area identified for the expansion is inside the existing sugar complex.
Hence there will be little obstruction for the material shifting. But it can be
managed.
4) The nearest railway station Ugar khurd 2 KM from the sugar factory. The
state highway connecting sankeshwar to Bijapur is near to the sugar factory.
National Highway No 4 is 70 KM from the factory site. The plant is therefore
well connected by road facilities for the transportation of equipments.
5) Water Availability:
The raw water for the sugar plant is required for meeting the following
requirements.
a) Make up water to the steam generator.
b) Make up water to the cooling tower.
c) Ash disposal
d) Other plant services
The estimated additional quantity of raw water requirement for the expanded
capacity given in the enclosed sheet. The sugar plant presently draws water
from River Krishna which has adequate water flow. It is therefore envisaged
that the sugar plant water requirement will be met from the same facility.
6) Availability of Fuel:

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a) The project is based on the in house generation of bagasse from the

sugar factory. Plenty of bagasse will be surplus after meeting own
requirement during season.
c) Surplus Bagasse will be stored in the available area. And same can be
used during off season for co-generation.
7) Interconnection with Grid:
Grid interconnection facility is already available with the factory, expansion of
the unit can be accommodated adjacent to the site.
8) Ecological Impact:
a) All the necessary measures are planned to be taken in the plant design
for minimizing the impact on the ecology of the environment. All those
equipment required for ensuring a safe atmosphere will be provided for
the project & located within the sugar complex premises.

d) The detrimental effect of SO2 & Nos will be partially mitigated by a

green belt along the boundary of the plant generally in line with
Karnataka State Pollution Control Board requirement. The plantation
will also help in oxygen replenishment.

c) The particulate emission from the co-gen plant shall be controlled to

less than 150 mg/Nm3 by the use of high efficiency ESP/ wet scrubber.

d) There will be little thermal pollution of water as a closed cycle concept

has been proposed for the sugar plant. The condenser will be designed
with temperature rise limited to 10 Deg. C. above cooling water entering
the condenser. The hot water will be cooled through induced draft
cooling tower & cooling tower blow down will be discharged into the
nearest drain.

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e) There will, however, be some contribution to thermal pollution of the

atmosphere by the discharge of hot flue gases. The effect at ground
level will be minimal, as the heat will be dissipated into higher layers of
the atmosphere.

f) Liquid wastes from the milling plant and boiling house, This water will
be diluted and discharged into circulating water pit after checking for
dissolved solids and pit.

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CHAPTER 7
RISK ANALYSIS & MANAGEMENT

1) USWL Performance:

a) Risk of Performance for next 15 years.

i) The Ugar Sugar Works Ltd., has achieved excellent performance,
Hence there is no risk of performance

b) Management Stability / Political Environment

i) The management of the USWL has been steady in the past. It has
been working as one united team.

ii) USWL has a vast pool of technically qualified staff, which has
gained ample training & experience. Steady management control
mitigates the risks of management instability.

iii) State support for the sugar industry as a whole mitigates the risk of
unfavorable political environment.

2) Cane Availability Risk:

a) Availability of water for cane production
i) The risk of non-availability of water for cane production is mitigated,
as sufficient amount of water is available from River Krishna as well
as irrigation on wells & also Lift Irrigation Schemes (LIS) by sugar
factory as well as irrigation pumps of individual cultivators.

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iii) Average Rainfall is 600 mm from June to September. The river

Krishna is flowing at 1 km distance from factory. As a result of
availability of water from River, tank & borewell the sugarcane
production is expected to increase.

iv) Risk regarding effects of deregulation & exposure to international

market is mitigated as the sugar factory has already started cutting
costs to remain price competitive by increasing the crushing
capacity & optimizing capacity utilization.

b) Cane Development in the area

i) Significant potential exists for cane development in the area.

ii) Area of operation consists large no. of villages from athani, taluka,
on river bank Krishna. At present cane area is covered by river
irrigation & as well as well irrigation.

iii) Well irrigation area is also benefited by percolation of irrigation

tanks. The cane area is also expected to increase due to addition
of new irrigation schemes.

iv) In addition, the sugar factory has a separate agricultural department

headed by qualified Cane Manager (CM). The agricultural
department takes complete responsibility of the command area for
development of cane.

c) Risks of farmers shifting to cash crops other than cane

i) Farmers are not likely to shift to other cash crops as the sugar
factory offers an assured market for cane & take complete
responsibility of command area whereas other cash crops are
market driven & there is no assured take off.

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ii) The relative profitability per hectare of different crops in India as per
the draft report of World Bank is the highest for sugar cane.

3) Fuel Risk:
a) Risk of non-availability of bagasse will not arise as bagasse generated
from the own mill will be more than sufficient.

4) Technology Risk:
Technology adopted for the expansion plant is an established technology & in
operation in the same plant for the past 75 years.

5) Construction Time:
i) Total expansion work requires hardly 6 to 7 months. Hence there is no
risk of work completion before start of the coming crushing season.

6) Environment Risks:
i) The compliance with the Indian environmental standards will be ensured
from the time of project design. It is proposed that factory will undertake
rapid Environmental Impact Assessment (EIA) & Disaster Management
Plan through a reputed agency.

ii) Further during the construction phase an environment management plan

will be designed & will be monitored by the management of factory.

7) Performance of Sugar Plant:

i) Performance risk of sugar plant is mitigated by installing established
technology.

ii) Procuring the plant & machinery from proven & established equipment
manufacturers.

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iii) Engaging experienced staff for the operation & maintenance of the
cogen plant.

8) Cost Overrun risk:

i) The actual costs are expected to fall within the estimated range.

ii) The estimated project cost conservatively on the basis of quotes

available from the various suppliers & contractors.

iii) Individual components of the project will be executed under EPC with
fixed price EPC contract thereby minimizing the risk of cost overrun.

iv) The total project cost includes significant amount of contingency

premium, which is sufficient to meet the cost associated with any
foreseen delays, change orders & other unforeseen events.

9) Risk of Non Payment by product purchaser:

i) Obtaining two months revolving letter of Credit (LOC) could mitigate risk
relating to buyer’s payment capacity & willingness to pay backed by
functional escrow account.

10) Operational Risks:

i) The technology of operation of sugar plant is not a new; there will not be
any problem of operation as trained manpower is available with the
plant.

ii) Conservation cost projections mitigates the risk of sharp increase in

operating costs. USWL rely on the technical, operating & management
expertise of the equipment supplier & is confident of meeting the
operating cost target. Even in the unlikely event of operating cost
increase, the impact on the project returns is not significant.

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11) Price & Margin Risks:

As factory is already entered into EPA with power trading agency /KPTCL as
per the Energy Purchase Policy of KPTCL taking into account adequate
returns to investment the price & margin risk is taken care off.
12) Risk Management - Insurance:
a) Pre – Completion
The company is expected to take a seamless comprehensive project
insurance package covering all construction risks from effective date of
construction contract until completion.
b) Post completion
From the date of physical completion of the plant the company is
expected to maintain a package of operational insurance consisting of:
i) Fire policy & other perils (like earthquake, flood, storm, lightening
etc.) covering physical loss or damage to the plant including
ancillaries.
ii) Loss of profits on account of business interruption due to fire,
machinery breakdown & related perils.
iii) Third party liability, covering all legal & contractual liability arising
out of maintenance & operations of plant on occurrence basis.
iv) Theft policy covering burglary, house breaking instances of plant on
occurrence basis.
c) Indian legislation requires that all insurance relating to activities
undertaken in India be affected within the territory. The insurance
market is influenced by major international reinsurance supports
particularly for large projects. Indian insurance companies have the
practice of seeking reinsurance from International Insurers to the extent
of & upwards of 90% in some cases.
d) With the recent opening up of the insurance section to the private sector
it is expected that the company will benefit from the increased
competition as new insurance companies will offer policies, which will be
specific to users requirement. Policies may be offered to cover fuel risks
& other risks specific to the power section.

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CHAPTER 8
PROJECT COST ESTIMATION

1) Cost Structure:
a) General
i) This section of the report gives the estimation of the total cost of the
new equipments like boiler, turbine, boiling house equipments,
distillery along with the modifications in the existing set up is estimated
on the basis of the prevailing prices & rates as in Dec 2011 & the
estimation is for the installation of power generation & service
facilities. The estimate is based on the in house cost data compiled
from the other similar jobs executed in the recent past No provision
has been made for any escalation in these estimates & the project is
expected to be implemented shortly. However the estimates include a
contingency provision of 2% on the estimated cost.

ii) The cost of the conversion cost of the plant, presented in this report,
covers all the costs associated with the construction cost, cost of plant
& includes the civil construction cost, cost of equipment, cost of
auxiliaries & utilities. The total project is arrived at by adding to this
cost, the pre-operative expenses inclusive of project design &
engineering, interest during construction.
The detail of the estimate of the total project cost which includes the
contingency & pre-operative expenses, IDC & the working capital is
given in a separate table at the end of this chapter.

b) Land & Site Development

A provision is included in the cost estimate for adjusting the compound
wall land leveling, along the land contours. The cost of laying additional
roads for the cogeneration plant cost of fencing etc.

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c) Civil & Structural

i) The civil work includes the earthwork & concrete work for the
equipment foundations, etc. The cost of laying of in plant roads,
fencing drains & sewers, is also included as part of civil cost.

ii) The civil work quantities & the cost of civil worked out are only
estimates & will have to be suitably modified & firmed up after the
equipment supply is finalized & adequate data regarding the loading
& dimensions of the equipment are available from the manufactures
& suppliers during the engineering stage & also on the actual soil
conditions encountered at different stages of construction. The
estimates given here are based on the expected soil bearing capacity
of 25 tones / sq. m.
iii) The total cost of civil works including equipment foundations,
buildings, cost of land development, roads, miscellaneous foundation
etc. is considered.

d) Mechanical & electrical Works

i) The cost of the addition of new equipments, modification and
upgradition of Mill section, Boiling house, steam generator & its
auxiliaries, TG set & its auxiliaries, Distillery and ETP & their
auxiliaries are based on the in house data available with the
Technical Consultants. In the estimation of cost for other items for
this project, the price of some of the recently finalized orders has
been considered.

ii) The cost estimate includes the cost of Pipelines, Ash handling
system, bagasse feeding system.

iii) The cost estimate also includes the modification cost of the bagasse
handling system. This includes all the conveyors, their supports,

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electrical interlocks cost of from end loaders & tractors. The cost also
covers the complete ash handling system for the plant.

iv) Cost towards the plant erection, testing & commissioning have been
included in the equipment cost indicated. Also the cost estimates
given in the report are inclusive of the taxes & duties, freight &
insurance.
e) Contingency Provision
A provision of about 2% of the cost of civil & structural work, mechanical &
electrical equipment & other costs has been provided towards
contingencies, during the construction of the project.
f) Preliminary & Preoperative Expenses
A provision is made towards the preliminary expenses to cover project
management expenses, travel, startup, training etc.

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PROJECT COST ESTIMATION

No Equipments Rs Lakhs
1) Mill Section 1800
2) Boiler 2500
3) Boiling House 2500
4) Fuel & Ash handling 500
5) TG Set 2000
6) Distillery 2500
7) Molasses tank 200
8) Sugar Bag handling & sugar go-down 400
9) Switchyard 400
10) Civil 1200
11) Miscellaneous 300
12) Total 14300
13) Taxes Duties & transport (@ 14.%) 2000
14) Contingency @ 2% 326
Total = 16626

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PROPOSED BAGASSE BALANCE

Crushing per day 20000 TPD

Average Cane Crushed 909 TPH

909 TPH

Bagasse Production
(At 29%) 263.6 TPH

263.6 TPH

Bagasse for Oliver filter & Spillage

(Losses at 1%) 9.09 TPH

254.5 TPH

Bagasse required for Old Boiler to generate steam – 22.72 TPH

Bagasse required for other boilers to generate Steam – 185.45 TPH

46.36 TPH

Bagasse Saving per Hour 46.36 TPH

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PROPOSED STEAM BALANCE

46.36 TPH
Bagasse Production Bagasse Saving
254.55 TPH 46.36 TPH
22.72 TPH 185.46 TPH

22.72 TPH 185.46 TPH

1 x 55TPH, 32 ata 310 TPH, 62 ata

& 480 Deg C 100 TPH 110 ata
50TPH 59.28 TPH

PRDS
80 TPH
130 TPH 130
92.5 TPH
22.8 MW SNM 22.8 MW SNM
1Turbine 1Turbine
New DEC 20 MW TG

12 MW Turbine 15 TPH
7.4 TPH 15 TPH Condenser 15 TPH
15 TPH
distillery
8 ata 37.4 TPH

80 TPH 70 TPH @ 2.5 ata

115 TPH 115 TPH

TO PROCESS 380.06 TPH (2.5 ata)

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PROPOSED POWER BALANCE

POWER GENERATION
From SNM TG Set – 43.33 MW
From New TG Set – 12 MW
From Siemens TG Set – 17.55 MW
Total Power Gen. – 72.89 MW

72.89 MW

POWER CONSUMPTION
Captive for Sugar Plant –20 MW
Captive for Cogen Plant –5.45 MW
Total Captive Power = 25.45 MW

47.43 MW

EXPORTABLE POWER to
KSEDCL Grid – 47.43 MW

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STEAM BALANCE – NON CRUSHING SEASON

Bagasse 41.95 TPH

110 ata
500 Degree C
1 X 100 TPH

86 TPH

10.35 TPH 50 TPH 15.15 TPH

Steam at 2.5 ata Steam at 8 ata Steam at 0.1 ata for

for Dist
condenser

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POWER BALANCE – NON CRUSHING SEASON

Power Generation – 11.94 MW

11.94 MW

Captive Power – 1.92 MW

10.02 MW

Exportable Power to
Grid 10.02 MW

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