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PRE- FEASIBILITY REPORT
For
Proposed expansion of
Sugar Plant from 3500 TCD to 7500 TCD,
Power plant from 4 MW to 24 MW
&
Distillery of 60 KLPD
Trident Sugars Limited Kothuru-B & Didgi Village,
Zaheerabad Mandal
Sangareddy District, Telangana
Trident Sugars Limited
Sugar, Co-gen & Distillery
Pre-Feasibility report
1
1.0 EXECUTIVE SUMMARY
Trident Sugars Limited is an existing Sugar plant operating at Kothur – B & Didgi Villages,
Zaheerabad mandal, Sangareddy District, Telangana.
The following is the capacity of the existing Integrated Sugar Complex
Sr. No Unit Capacity
1. Sugar 3500 TCD
2. Captive power plant 4 MW
Total area already in possession of the management is 129.1 acres.
Now the company has proposed to enhance the capacity of the Sugar plant & Power plant
and new Distillery unit. The proposed expansion and new Distillery unit will be taken up in
the existing plant premises only.
The following will be the capacities after proposed expansion
Sr. No Unit Capacity
Existing Expansion Total
1. Sugar 3500 TCD 4000TCD 7500 TCD
2. Power plant 4 MW
(captive)
20 MW
(co-gen)
24 MW
3 Distillery -- 60 KLPD 60 KLPD
The following is the summary of the proposed expansion project
S. No. Parameters Description
1. Existing Plant capacity Sugar – 3500 TCD
Co-gen power – 4 MW
2. Proposed expansion Sr.
No Unit
Capacity
Existing Expansion Total
1. Sugar 3500 TCD 4000TCD 7500 TCD
2. Power
plant
4 MW
(captive)
20 MW
(co-gen)
24 MW
3. Distillery -- 60 KLPD 60 KLPD
3. Total area already in
possession
129.1 acres
4. Sy. No. of the land survey no. of Kothuru - B Village
12, 18, 19, 20, 21, 22, 23, 24, 25, 26/1, 48 & 173
Survey no. of Didgi village
13 & 13A
5. Project cost
(expansion)
Rs. 252 Crores
Trident Sugars Limited
Sugar, Co-gen & Distillery
Pre-Feasibility report
2
S. No. Parameters Description
6. Water requirement
a. Water requirement for
existing plant
108 KLD
b. Water requirement for
the proposed
expansion
1100 KLD
c. Total water
requirement
1208 KLD
d. Source of water Ground water
Permission for drawing water from ground will be
obtained from SGWB
7. Waste water
generation
a. Effluent generation
from the existing plant
360 KLD
b. Effluent generation
from the expansion
1640 KLD
8.
Existing Effluent
treatment
Sugar Plant
Effluent generated from the Sugar plant is being treated
in specially designed ETP and treated effluent is being
utilized for greenbelt development after ensuring quality
of treated effluent with standards stipulated for onland
for irrigation by CPCB / SPCB.
9. Effluent treatment
(proposed expansion)
Sugar Plant
Effluent generated from the Sugar plant will be treated in
specially designed ETP and treated effluent will be
utilized for greenbelt development after ensuring quality
of treated effluent with standards stipulated for onland
irrigation by CPCB / SPCB.
Power Plant
Cooling tower blowdown, DM plant regeneration water
and Boiler blowdown will be treated in neutralization
tank and treated effluent will be utilized for greenbelt
development / ash conditioning / dust suppression in the
plant premises after ensuring quality of treated effluent
with standards stipulated for onland irrigation by CPCB /
SPCB
Distillery Plant
Spent wash will be concentrated through Multiple Effect
Evaporators and concentrated Spent wash thus
obtained will be bio-composted along with the
pressmud.
Trident Sugars Limited
Sugar, Co-gen & Distillery
Pre-Feasibility report
3
S. No. Parameters Description
The condensate generated during evaporation will be
treated in Sugar Plant ETP and will be utilized for
greenbelt development / ash conditioning / dust
suppression in the plant premises after ensuring quality
of treated effluent with standards stipulated for onland
for irrigation by CPCB / SPCB
10. Steam requirement
(existing)
Steam requirement existing sugar plant is being met
from existing 20 and 32 TPH boilers
11. Steam requirement
(expansion)
Steam required will be met from proposed 100 TPH
12. Air emissions (existing) Emissions from Project are Particulate matter, SO2 and
NOx
Wet scrubbers has been provided to boiler to bring down
the particulate matter to below 100 mg/Nm3.
13. Air emissions
(expansion)
Emissions from Project will be Particulate matter, SO2
and NOx
ESP will be provided to 100 TPH Boiler to bring down
the particulate matter to below 50 mg/Nm3.
The exhaust gases from the boiler will be discharged
into the atmosphere through a stack of 80 m height for
effective dispersion of gases into the atmosphere.
14. Noise levels Ambient Noise levels are within the standards
prescribed by MoE&F Notification and its amendments
and after proposed expansion also similar practice will
be followed.
15. Solid waste generation
(existing)
Sugar Plant
press mud generated from the Sugar plant is being
given as manure to farmers
Bagasse generated from the Plant is being used as
fuel for boiler
ETP sludge generated is being utilized as manure
Boiler ash is being given as manure to farmers
16. Solid waste generation
(expansion)
Sugar Plant
press mud generated from the Sugar plant will be
used as filler material for Bio-composting
Bagasse generated from the Plant will be fuel for
power generation.
ETP sludge generated will be utilized as manure
Power Plant
Ash generated form the power plant will be given to
farmers as organic manure when bagasse / biomass is
used as fuel and will be disposed off to brick/cement
manufacturers when coal is used as fuel.
Trident Sugars Limited
Sugar, Co-gen & Distillery
Pre-Feasibility report
4
S. No. Parameters Description
Distillery
Yeast sludge generated will be bio-composted along
with concentrated spent wash
17. Noise levels Ambient Noise levels are within the standards
prescribed by MoE&F Notification and its amendments
and after proposed expansion also similar practice will
be followed.
Trident Sugars Limited
Sugar, Co-gen & Distillery
Pre-Feasibility report
5
2.0 INTRODUCTION:
2.1 Identification of project and Project Proponent Trident Sugars Limited (subsidiary of Natems Sugars Pvt. Ltd.) is an existing Sugar plant
operating at Kothur – B & Didgi Village, Zaheerabad mandal, Sangareddy District,
Telangana.
The Promoters
The following is the list of promoters of the company
S.No Name Designation
1. Shri Nandakumar Ramanujalu Chairman
2. Shri Dr. R.N. Ramnath Vice Chairman
3. Shri Ramamurthy Director
4. Shri.Guruvayurappan Margabanthu Director
2.2 Brief Description of nature of Product:
2.2.1 Sugar
Sugar known as sucrose or saccharose is an anhydrous crystalline organic product of
comparatively 99.96% purity. The physical properties of sucrose are defined as follows
CRYSTALLINE NATURE:
Sucrose crystals are hard and belong to the mono-clinic system, characterized by three
axes of unequal length. Density of sucrose is equal to 1.606 gm/cu.cm. The presence of
impurities in sugar have a remarkable influence on the formation of the crystals.
SOLUBILITY:
Sucrose is very soluble in water and in dilute ordinary alcohol. The solubility in water
increases with the rise in temperature, such that for a 10% sucrose solution, the boiling point
is 100.04 Deg.C and for a 90% sucrose solution the boiling point is 130 Deg.C. It is insoluble
in chloroform, in cold absolute alcohol, either and glycerine.
SPECIFIC GRAVITY:
The specific gravity of sucrose varies from 1.033 to 1.106 according to the concentration of
the solution. The density of the sugar solution is determined in practice by brix and baume
spindles or balling saccharimeter.
Trident Sugars Limited
Sugar, Co-gen & Distillery
Pre-Feasibility report
6
OPTICAL ROTATION:
Sucrose and glucose rotate the plane of the polarised light in a `clockwise‘ direction or to the
right and is called dextro-rotatory. Fructose, rotate in a `counter clock wise‘ direction or to the
left and is known as levo-rotatory. The specific rotation of sucrose is 66.5 Deg.
CHEMICAL PROPERTIES:
Dry sugar (sucrose) melts at 160 Deg.C into a thick transparent liquid which on cooling again
becomes crystalline. If heated for a long time at 160 Deg.C sucrose splits up into glucose
and levulosane. At higher temperatures between 190 to 220 Deg.C the decomposition is
more complete and caramel is produced. On further, heating, carbondioxide, carbon
monoxide, acetic acid and acetone are produced.
In the presence of moisture, sucrose decomposes at 100 Deg.C and becomes dark in colour
liberating water. On prolonged heating of sucrose at the boiling point and at ordinary
pressures, the dissolved sucrose combines with water and breaks up into glucose and
fructose in equal parts and the phenomenon is called Hydrolysis of Inversion.
APPLICATIONS:
The principal use of sugar as explained is as the sweetening agent in foods. The
consumption of sugar is distributed in the various sectors such as for daily human
consumption in household sector for food processing industries, beverages, baking industry,
confectioneries and miscellaneous users. Sucrose serves as raw materials for manufacture
of glucose, fructose, invert sugar syrups etc.
Non-food uses of sugar constitute a small amount of total sugar consumption. They include
use of sugar as a octacetate, a denaturant in ethyl alcohol, as sucrose diacetate, Hexa-
isobutyrate, octa benzoate, as mono and difatty acid esters for surfactants, as allyl sucrose,
in plasticisers and as raw materials for manufacture of various chemicals like glycerol,
mannitol etc.
Dextran is a polysaccharide produced from sucrose by the biological process and is a very
effective plasma volume expander. Sucrose when administered by intravenous infusion
relieves shock and prevents loss of body fluids after excessive burns, wounds or infectious
diseases. Other industries wherein sucrose is finding application towards drying oil esters
for surface coating industries and sugar derived detergents.
Trident Sugars Limited
Sugar, Co-gen & Distillery
Pre-Feasibility report
7
PRODUCT SPECIFICATIONS:
The specifications required for white sugar complying with Indian sugar standards are
defined as follows:
Characteristics Requirements
Moisture (%) weight 0.05% Max.
Pol 99.5% Min.
Reducing sugars (%) by weight 0.10% max.
Conductivity x [106] 100 max.
Sulphur dioxide (ppm) 70 max.
Calcium oxide (CaO) (mg/100gm) 30 max.
Turbidity, (%) by weight 15 max.
2.2.2 Power
Power is generated by converting the thermal energy of steam into electrical energy through
Turbo-generator.
The power generated will be utilized for meeting the power requirements for sugar, Distillery
and other auxiliaries. Remaining power after meeting the power requirement for the project,
will be exported to nearest sub-station.
2.2.3 DISTILLERY PRODUCTS
Extra Neutral Alcohol
ENA IS 6613 – 1972 is an Extra Neutral Alcohol, Basic raw material for IMFL.
Produced from Molasses, Sweet Swargam, Cane Juice and Grain etc.
Rectified Spirit IS 323 – 1959 Quality is inferior to ENA.
ENA is nothing but refined Rectified Spirit.
ENA Process is a physical process in which Aldehydes, Esters and Fusel Oils impurities
are separated by virtue of their difference in Boiling Points by steam Distillation.
ENA RS ETHANOL
01 Ethanol content percent by Volume at 15 . 6O C,Min
94.68 94.68 99.50
02 Acidity gms/100 ml1 Max 0.002 0.002 0.006
03 Residue on Evaporation gms/100 ml1 Max
0.002 0.005 0.005
04 Ester content gms/100 ml Max 0.01 0.02 0.02
05 Aldehydes gms/100 ml1 Max 0.004 0.006 0.006
06 PP Times, Minutes 30 Nil Nil
Trident Sugars Limited
Sugar, Co-gen & Distillery
Pre-Feasibility report
8
2.3 Demand – Supply Gap:
The sugar industry today is facing fierce competitive situation due to fluctuations in sugar
prices in the national & international markets, higher cane prices to be paid to the cane
growers, rising input costs, etc. The survival and growth of this industry depends on energy
efficiency, cost optimization and revenue generation from bi-products and down steam
products including power, ethanol, chemicals, etc.
The implementation of co-gen power plant concurrently with the sugar modernization cum
expansion project along with other by-products, right from the beginning goes a long way to
integrate the operations and improve sustainability.
Sugar Industry Overview
The origin of Indian sugar industry dates back to 1930, when the first sugar factory was set
up in the pre-independence era. Over the last 76 years, the sugar industry has steadily
grown and has become the backbone of the agricultural and rural economy in India. Today,
sugar is the second largest agro processing industry, next to the textile industry. India is one
of the largest producers of sugar in the world, with a production of over 15 million tones.
Sugar factories are located mostly in the rural India. They act as centers of development,
provide largest direct employment in the rural areas and contribute substantially to the
Central and State exchequers. The prospects of earning foreign exchange from export of
sugar are also quite high.
Sugar factories in India have capacities ranging from 1250 TCD to 20,000 TCD. The Indian
sugar industry has developed indigenous capabilities for design, manufacture, supply,
operation and maintenance, R&D and cane development. The major stakeholders of this
industry in India are Ministry of Agriculture, Govt. of India, Ministry of Consumer Affairs,
Food and Public Distribution, federations of co-operative and private sector sugar factories
at the national and the State levels, sugarcane growing farmers, equipment and technology
suppliers, research institutions, consultants and service providers, financial institutions and
Central / State Governments.
A total of 727 sugar factories are in operation today, with additional few new sugar factories
under implementation in different parts of the nation. The area under sugar cane cultivation,
sugar cane production, sugar cane crushing in sugar factories, average season days, sugar
recovery and sugar production has increased steadily over the years. The crop yield per
hectare and recovery has improved, particularly in the last decade.
Trident Sugars Limited
Sugar, Co-gen & Distillery
Pre-Feasibility report
9
Following Table shows the distribution of sugar factories all over India.
Status of Sugar Factories in India
State Private Public Co-op Total
Assam 1 2 3
Orissa 4 4 8
Bihar 13 15 28
Uttar Pradesh 116 14 28 158
Uttarakhand 4 2 4 10
Punjab 8 16 24
Haryana 3 13 16
Andhra Pradesh 20 1 12 33
Telangana 10 1 11
Tamilnadu 27 3 16 46
Maharashtra 80 169 249
Gujarat 5 22 27
Madhya Pradesh 16 2 5 23
Kerala 1 1 2
Rajasthan 1 1 1 3
Karnataka 48 3 25 76
Pondicherry 1 1 2
Goa
1 1
Chattisgarh
1 1
Dadra Nagar & Haveli
1 1
West Bengal 2 1 3
All India Total 360 42 325 727
Source: Sugar India Year book, 2016
The Ministry of Consumer Affairs, Food & Public Distribution, and Government of India
revised the standard specifications for sugar plant & equipment, in the year 1987. The
special committee finalized specifications for economical capacity of 2500 TCD, expandable
to 3500 TCD, employing higher-pressure boiler and turbine configuration and efficient
equipment, with a potential to export incidental surplus power to the grid.
The Indian sugar industry was de licensed in the year 1998 vide press note No. 12 issued by
the Government of India, Ministry of Industry, Department of Industrial Policy and Promotion,
on August 31, 1998. The salient features of de licensing are as follows:
The sugar industry stands deleted from the list of industries requiring compulsory
licensing under the provisions of Industries Development and Regulation Act, 1951.
However, in order to avoid unhealthy competition among sugar factories to procure
sugarcane, a minimum distance of 15 km would continue to be observed between
Trident Sugars Limited
Sugar, Co-gen & Distillery
Pre-Feasibility report
10
and existing sugar factory and a new factory, by exercise of powers under the Sugar
Control Order, 1966.
The entrepreneurs, who wish to de-license their sugar factory, would require filing an
Industrial Entrepreneur Memoranda (IEM) with the secretariat of industrial assistance
in the Ministry of Industry, as laid down for all de-licensed industries, in terms of the
press note dated August 2, 1991, as amended from time to time.
Entrepreneurs who have been issued Letter of Intent (LoI) for manufacture of sugar
need not file an initial IEM. In such cases, the LoI holder shall only file Part B of the
IEM at the time of commencement of commercial production against the LoI issued
to them. It is however open to entrepreneurs to file an initial IEM (in lieu of LoI /
industrial license held by them) if they so desire, whenever any variation from the
conditions and parameters stipulated in the LoI / industrial license is contemplated.
The statistics on economic and commercial performance for the industry is quite fluctuating.
The changes in the agro climatic conditions and sugarcane crop production, as well as the
sugar markets have been mainly responsible for these fluctuations. Efficiency, quality, and
integration have become order of the day for this industry. The industry has grown till today
over the last seven decades. The strength and capacity built so far will surely help meet
these challenges. The following are major options to meet these challenges:
a. Effecting substantial improvement in cane development and management,
including cultivation practices, varietals and water management, so as to improve
yield and recovery, without affecting the average fibre content.
b. Effecting visible improvement in the operational efficiencies and reduction of sugar
losses.
c. Effecting and sustaining improvement in energy efficiency, both in steam and
power, for saving of additional bagasse, for both sugar and by-products
manufacture.
d. Effecting adequate capacity building within and without.
e. Maximizing sugar exports for value addition.
f. Effective marketing in the national and international markets.
g. Product quality and diversification.
h. Commercializing the excess power capacity by exporting to utilities or to other bulk
power consumers.
Ministry of Consumer Affairs, Food & Public Distribution Department of Food & Public
Distribution Government of India has issued a revised order dated November 10, 2006,
Trident Sugars Limited
Sugar, Co-gen & Distillery
Pre-Feasibility report
11
amending Sugarcane (Control) Order, 1966. The key provisions of this order are outlined
below:
a. No new sugar factory shall be set up within a radius of 15 km of any existing sugar
factory or another new sugar factory in a State or two or more States.
b. Before filing the Industrial Entrepreneur Memorandum (IEM) with a Central Govt., a
certificate from the Cane Commissioner or Director Sugar or specified authority of the
concerned State Govt. shall be obtained regarding the distance criteria re-defined as
above.
c. Submission of performance guarantee of Rs. 1 crore to Chief Director, Sugar, Dept.
of Food & Public Distribution, within 30 days of filing the IEM, as a surety for
implementation of the IEM within the stipulated or extended time.
d. The stipulated time for taking effective steps shall be 2 years and commercial
production shall commence within 4 years from the date of filing of the IEM, failing
which the IEM shall stand de-recognized and performance guarantee shall be
forfeited.
e. If an IEM remains un-implemented within the stipulated or extended time limits, the
performance guarantee shall be forfeited after giving a reasonable opportunity of
being heard.
f. The above clauses will be applicable for IEM already acknowledged as on the date of
this notification, but who have not taken effective steps for its implementation, duly
defined, shall furnish a performance guarantee of Rs. 1 crore to the Chief Director,
Sugar.
Ethanol Sector Overview
The use of alcohol as a drink is an age-old story. It appears that in India the technique for
fermentation and distillation was available even in the Vedic times. Alcohol is an integral part
of the Ayurvedic system of medicine also.
Carew & Co. Ltd. set up the first distillery in the country at Cownpore (Kanpur) in 1805 for
manufacture of Rum for the British army. The technique of fermentation, distillation and
blending of alcoholic beverages was developed in India on the lines of practices adopted
overseas, particularly in Europe.
The original use of alcoholic fermentation was of course for preserving fruit juices. Now the
fermentation is adapted for the preparation of fermented grain beverages and then distilled
beverages. The utilization of Ethanol, for industrial use is a recent phenomenon. It became
important towards the end of the Second World War.
Trident Sugars Limited
Sugar, Co-gen & Distillery
Pre-Feasibility report
12
When large-scale production of alcoholic beverages was taken up, various Governments
found that alcohol was a good source for increasing government revenue through collection
of tax. When synthetic organic chemistry advanced rapidly, about a century ago, alcohol
became an indispensable chemical for this industry. However extensive manufacturing of
alcohol for industrial use was hampered due to excessive taxes. The problem was to device
a means for conserving government‘s interest in tax collection on potable alcohol and at the
same time making alcohol for industrial use relatively free of tax. Thus different governments
introduced the process of denaturation of alcohol for industrial use.
During the Second World War, the demand for the industrial alcohol increased 4-5 times,
above the prewar period, due to the production of smokeless powder for weapons. The
imports of molasses were hampered due to war conditions. This leads to evolving the
process of grain fermentation for meeting the requirement of Ethanol.
In India, after the protection granted to the sugar Industry in 1932, a large number of sugar
factories were established in the country, particularly in Maharashtra and Uttar Pradesh
where irrigation facilities existed for cultivation of sugarcane. Increase in sugar production
resulted in accumulation of molasses, which resultantly, caused unmanageable
environmental problems. At that time the demand for molasses was almost insignificant and
the sugar mills had to incur considerable expenditure for disposal of molasses. For resolving
these problems a joint committee of U.P. and Bihar was constituted in 1938 to explore the
possibilities of using molasses for developing alcohol-based industries. The Committee
recommended establishment of distilleries for production of alcohol, utilizing molasses as a
substrate.
The committee also recommended that alcohol produced by the distilleries should be
admixed with petrol, to supplement motor fuel. This helped in solving the problems of
disposal of molasses. It also filled up the gap in the demand and supply of motor spirit.
As a result, after meeting alcohol requirement for manufacture of gasohol, substantial
quantity of alcohol was diverted for production of alcohol based chemicals.
Present Status
Fossil fuels are declining. Transportation sector consumes more than 50% of the fuels.
Environmental degradation from these fuels is a major problem all over the world. World oil
production is expected to last till 2125 A.D., if consumption at the present level is
Trident Sugars Limited
Sugar, Co-gen & Distillery
Pre-Feasibility report
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maintained. On this background the use of Ethanol for fuel blending should be given a top
priority.
India requires ethanol for the following three major purposes:-
For potable liquor
For industrial use
For fuel blending
Today, the distillery industry of India uses only molasses for manufacturing alcohol. There
are handful of grain distillery units (e.g. Seagram Manufacturing Ltd.) and the alcohol
produced by them is used for captive use to make value added liquors.
All other liquor (IMFL) manufacturers use alcohol produced from molasses. In advanced
countries, liquor for human consumption is made only from grain alcohol. It is known that
alcohol produced from molasses can have residues such as sulphates, sulphites, higher
aldehydes, higher alcohols, higher acids and ketones etc., which are not present in alcohol
from, grains.
However, no such above-mentioned distinction is made in India. Thus alcohol produced only
from one source i.e. molasses is used for all 3 purposes (liquor, industrial use, fuel
blending). There is an urgent need to bring in above quality consciousness in the IMFL
industry and appropriate policy measures by the Govt.
Today, Indian distillery industry broadly consists of two parts:
One is alcohol production from molasses for industrial alcohol and two alcohol production
from molasses for liquor purposes.
Ethanol demand for fuel blending is a recent phenomenon. For this purpose, alcohol from
molasses is used.
The potable distillery producing Indian Made Foreign Liquor (IMFL) has a steady but limited
demand. The alcohol produced is now being utilized in the ratio of approximately 52 per cent
for potable purpose and the balance 48 percent for industrial purpose.
Trident Sugars Limited
Sugar, Co-gen & Distillery
Pre-Feasibility report
14
Ethanol blending
Ethanol blending is the practice of blending petrol with ethanol. Many countries, including
India, have adopted ethanol blending in petrol in order to reduce vehicle exhaust emissions
and also to reduce the import burden on account of crude petroleum from which petrol is
produced. It is estimated that a 5% blending (105 crore litres) can result in replacement of
around 1.8 million Barrels of crude oil . The renewable ethanol content, which is a byproduct
of the sugar industry, is expected to result in a net reduction in the emission of carbon
dioxide, carbon monoxide (CO) and hydrocarbons (HC). Ethanol itself burns cleaner and
burns more completely than petrol it is blended into. In India, ethanol is mainly derived by
sugarcane molasses, which is a by-product in the conversion of sugar cane juice to sugar.
The practice of blending ethanol started in India in 2001. Government of India mandated
blending of 5% ethanol with petrol in 9 States and 4 Union Territories in the year 2003 and
subsequently mandated 5% blending of ethanol with petrol on an all-India basis in November
2006 (in 20 States and 8 Union Territories except a few North East states and Jammu &
Kashmir). This was also an attempt to reduce the Under-recovery of Public Sector Oil
Marketing Companies (OMCs). Ministry of Petroleum and Natural Gas, on 1 September,
2015, inter-alia has asked OMCs to target ten percent blending of ethanol in Petrol in as
many States as possible. In countries like US, blending is allowed upto 10%. Subsequent to
Brazil's bio-fuel programme, which began in 1976, close to 94% of cars sold in Brazil are
flexible fuel cars that can handle ethanol blends from 18 per cent upward .
Ethanol blending first found mention in the Auto fuel policy of 2003. It suggested developing
technologies for producing ethanol/ bio fuels from renewable energy sources and introducing
vehicles to utilise these bio fuels. Later, as per National Policy on Bio-fuels, announced in
December 2009, oil companies were required to sell petrol blended with at least 5% of
ethanol. It proposed that the blending level be increased to 20% by 2017.
Ethanol, being a by product of the sugar industry, was expected to be freely available.
However, Oil marketing companies (OMCs) were not even able to get bids for more than
50% of the amount offered for purchase . Further, the Government decided on 22.11.2012
that procurement price of ethanol will henceforth be decided between Oil Marketing
Companies (OMCs) and suppliers of ethanol. In addition, on 03.07.2013, it was decided that
ethanol would be procured only from domestic sources. This led to a rise in ethanol prices,
which to a great extent reportedly eroded the economy of the blend. At present, government
has permitted OMCs to implement the ethanol blending programme in notified 20 States and
4 Union Territories as per the availability of ethanol.
Trident Sugars Limited
Sugar, Co-gen & Distillery
Pre-Feasibility report
15
There are reportedly significant transaction barriers which impede smooth supplies of
ethanol for blending. In several States, State not only imposes levy on molasses but also
regulates the movement of non-levy molasses. Inter-state movement of ethanol requires No-
Objection-Certificates (NOCs) from the State Excise Authorities along with permits from
dispatching and receiving States. Most States impose ―Export/Import‖ duties on ethanol
leaving and entering their boundaries. There are some instances where Octroi is levied on
ethanol for entry into municipal limits. Hence States were requested by the Central
Government to liberalise restrictions on the supply of ethanol so that its blending with petrol
can be encouraged while improving the financial health of sugar sector and also liquidation
of cane dues of farmers.
As per the estimates given in Auto Fuel Vision and Policy 2025 issued in May 2014, blended
petrol is available only in 13 states and the average blend is 2%. During the sugar year
2014-15, OMCs have achieved a blending percentage of 2.3% as per the press release
dated 25 April 2016.
Hence, in order to improve the availability of ethanol, the Government, on December 10,
2014, fixed the price of Ethanol in the Range of Rs. 48.50 to Rs. 49.50, depending upon the
distance of distillery from the depot/installation of the OMCs. (The rates are inclusive of all
central and statutory levies, transportation cost etc, which would be borne by the Ethanol
suppliers). Fixation of ethanol price based on distance, has encouraged movement of
ethanol to longer distances, including States having lack of distilleries. Further, ethanol
produced from other non-food feedstocks besides molasses, like cellulosic and ligno
cellulosic materials including petrochemical route, has also been allowed to be procured
subject to meeting the relevant Bureau of Indian Standards (BIS) specifications.
2.4 Employment generation (Direct & Indirect):
The man power required for the proposed expansion will be 120 Nos. which is inclusive of
30 nos. on permanent basis and rest all will be on Temporary or contract basis.
S.No. Particulars No. Employees
1. Technical & Administrative Staff 20
2. Skilled & Semi Skilled 60
3. Unskilled & Helpers 40
Total 120
Trident Sugars Limited
Sugar, Co-gen & Distillery
Pre-Feasibility report
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3.0 PROJECT DESCRIPTION:
3.1 Type of the Project:
The proposed Project mainly involves
Production of Sugar from Sugarcane
Power generation using Bagasse / Coal as fuel
Production of Rectified Spirit / ENA / Ethanol using Molasses as raw material
3.2 Location:
Trident Sugars Limited is an existing Sugar plant operating at Kothur – B & Didgi Village,
Zaheerabad mandal, Sangareddy District, Telangana.
Now the company has proposed to enhance the capacity of the Sugar plant, Power plant
and install new Distillery unit. The proposed expansion will be taken up in the existing plant
premises only.
3.3 Details of the Alternate sites:
No Alternate sites have been examined as existing premises has been given permission to
set up Sugar plant.
3.4 Size or Magnitude of Operation:
The following will be the capacities after proposed expansion
Sr. No Unit Capacity
Existing Expansion Total
1. Sugar 3500 TCD 4000TCD 7500 TCD
2. Power plant 4 MW (Captive)
20 MW (Co-gen)
24 MW
4. Distillery -- 60 KLPD 60 KLPD
3.5 Process details:
3.5.1 Sugar Process Description
Sugar is nothing but sucrose in its purest crystal from. While sugar is produced from
sugarcane in India, it is produced from sugar beet in the European countries, which requires
cold climatic conditions for its growth. Basically, sugarcane contains 14% to 17% Fiber, 16
to 24% Dissolved solids and the rest is all water. About 80% to 87% of the dissolved solids
in sugarcane are sucrose solids. Hot day and cold night climate (maximum difference of
temperature between day and night) is the favorable weather condition for sugarcane
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growth. The task of the sugar factory is to extract maximum sugar from sugarcane with
minimum losses and at minimum expenditure by adding value of its bye-products.
We can divide the process operations of sugar manufacture into 6 steps namely,
1. Juice Extraction
2. Juice clarification
3. Evaporation
4. Crystallization
5. Centrifugation
6. Drying, Bagging & storing
JUICE EXTRACTION:
Juice is stored in the fibrous cells of the sugarcane stalk. We have to break open these cells
and squeeze the juice out for processing. For this, sugarcane is made into small pieces by
the preparatory devices, which cut the sugarcane using knives. These pieces are further
processed at the fibrizer of shredder where they are pealed into fibrous shape. This finely
prepared sugarcane is subjected to compressions at mills where juice is extracted. The
residue from mills called bagasse has the character of re-absorption. Hence, it absorbs juice
back into it when it is released from mills. To extract this juice also, water is sprayed into the
bagasse mat at the point where it comes out from mills. This water will penetrate in to the
cells and dilute the juice remaining in them. This diluted juice is again extracted in next
compression. Like this, the prepared cane is subjected to 4 to 5 compressions to extracts
maximum juice from sugarcane. Juice from all compressions is collected, weighed and sent
to processing house for reaping out the sugar.
Bagasse leaving the last mill is sent to boilers for generating steam. This steam is used for
producing power by the turbo-generator, which is used for operating the machinery in
factory. The exhaust steam leaving the turbine is used in the boiling house for various
process operations.
JUICE CLARIFICATION:
Weighed juice from milling plant is pumped to boiling house for clarification. The juice is first
subjected to heating in a tubular heater, where juice is passed inside the tubes and steam is
applied externally, to heat it to 700C. This hot juice is sent to reaction vessel where Milk of
Lime {Ca (oH)2} and sulfur-Di-oxide gas (SO2) are mixed. These chemicals will react with
Phosphates present in juice in the form of P2O5 and produce precipitates of Ca3 (PO4)2 and
CaSO3. These precipitates (called Mud) will absorb all the impurities in juice such as
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suspended matter, waxes, gums, pectines, coloring matter, etc. This treated juice is
subjected to heating again to its boiling temperature, i.e. around 1030C. This juice is sent to
settling tank called clarifier for settling the mud through a flash tank where excess heat and
dissolved gases like Ammonia present in the juice are vented to atmosphere, which if
permitted to enter the clarifier will disturb the settling process.
Mud is settled t the bottom in the clarifier and clear juice is taken out from the top. The mud
is mixed with bagacillo, fine powder of bagasse, and subjected to filtration at vacuum filters
for recovering the juice in it. This juice called filtrate juice is mixed to the weighed juice
received from mills for subjecting it to clarification.
EVAPORATION:
Clear juice from clarifier contains around 14% solids only and the rest is all water. This juice
is sent to multiple effect evaporator station for concentrating to 60 to 65% solids. Vapor
produced in one body of the evaporator set is used as heating medium for the next body by
maintaining differential pressures in each body; thereby lot of steam economy is ached. This
thick juice called syrup is subjected to sulphitation for removing coloring matter from it.
CRYSTALIZATION:
Thick, sulphited syrup from evaporator set is boiled again in vacuum pans for further
concentration. When the syrup is continued to boil above its saturation point, sucrose in
dissolved from in the syrup will come out as crystal. This liquid –crystal state of the material
is called Massecuite. We can control the crystal growth by maintaining saturation level in
pan by feeding sulphited syrup and continuing boiling. Since the saturation state is
maintained, sucrose in syrup will keep depositing on the already formed crystal, and hence
the crystal size increase. Once the sugar crystal attains required size, the Massecuite is
forwarded into a storage vessel called crystallizer, before it is sent for liquid-crystal
separation. This first grade Massecuite is called A-Massecuite. The liquid portion of this
mass is called molasses and it still contains some sugar. The reap out that sugar also, this
molasses is taken into masse is called B-Molasses. Sugar is melted and taken to first stage
boiling. The second stage masse is called B-Massecuite. This is subjected to centrifugation
separately for separating B-sugar and B-Molasses. Sugar is melted and taken to first stage
boiling. The second molasses called B-Molasses also contains some sugar. Hence this is
again taken to pans for boiling third grade Massecuite called C-Massecuite. This
Massecuite contain more non sugar solids and recoverable sugar is less compared to first
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two stages. This Massecuite is centrifuged in continuous centrifugals to separate sugar and
molasses.
Molasses from this third grade Massecuite contain some more sugar, but cannot be
extracted due to presence of heavily concentrated non sugars. Hence this molasses called
Final molasses will be used as raw material for production of Alcohol & Motor spirit or
Ethanol.
CENTRIFUGATION:
Centrifugation is the stage where liquid and crystal portion of the Massecuite are separated.
The separation is achieved by subjecting the Massecuite to centrifugal force in a cylindrical
or conical shaped basked to which screens of micro openings (0.4 mm for cylindrical baskets
and 0.05 mm to 0.09 mm for conical shaped baskets) are fixed through which liquid portion
is separated. First grade Massecuite is less viscous and can be separated freely from a
thick cake. Hence, this is centrifuged in batch type centrifugal. This cycle contain series of
operations such as charging of Massecuite into the machine, spinning to purge out the
molasses, washing the sugar cake for removing the molasses film on crystals, drying by
spinning at high speed and automatic discharge of sugar on to hoppers for further drying to
first grade Massecuite. Hence these Massecuite are centrifuged in machines with conical
shaped basket, called continuous centrifugal machines.
DRYING, BAGGING & STORING:
Sugar, as it is discharged from centrifugal on to the hoppers contain moisture and cannot be
bagged directly. While the sugar travel forward on the hopper, hot air at around 600C is
blown through the sugar crystals to evaporate excess water on the surface. The time the
excess water is evaporated, sugar gets heated up because of the hot air. Hence cold air is
blown again through the dried sugar crystals to bring down the temperature to around 400C.
Dried and cooled sugar is passed through grader to separate lumps, powder and for size
separation. Larger size crystals are called ‗M‘ sugar and smaller size crystals are called ‗S‘
sugar. These two sugars are stored in separate bins for bagging.
Sugar is packed in 50 Kgs PP bags or 100 Kgs jute bags, depending on the market demand,
and stored in warehouse in stacks.
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PROCESS DESCRIPTION OF PRODUCING WHITE SUGAR FROM IMPORTED RAW
SUGAR.
Imported raw sugar from 2 tons jumbo bags is dumped into the 4 tons capacity storage bin
located inside the sugar godown with the help of crane. Raw sugar from this bin is fed to a
horizontal sugar melter through a feeding device called rotary valve for continuous and
uniform feeding. Hot water is added in the melter to maintain melt liquor consistency. The
sugar melt liquor is then passed on to a vibratory mesh to remove any foreign material in it.
It is then let into the pump receiving tank from where it is pumped through pipe line to
processing house.
The sugar melt liquor from here is mixed in the regular process scheme that is adopted for
making sugar from sugar cane.
At first, the sugar melt liquor is clarified to remove dissolved colour and other impurities
using chemicals such as colour precipitant, phosphoric acid and lime. Clear melt is pumped
to storage tanks at vacuum pan station from where it is taken into vacuum pans for
evaporation for re-crystallization.
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3.5.2 Co-generation Power Plant
Sugar plant will be expanded to 3500 TCD from 7500 TCD. The cogeneration capacity is so
designed that the plant will be able to feed steam and power requirements entire Sugar
Complex. The capacity of the boiler will be 100 TPH at 110 ata and 540+/- 5 deg C. The
turbine capacity would be 20 MW at 110 ata and 545 ºC steam parameters. The new turbine
will be of Extraction-cum-condensing type.
For off-season operation, we will utilize the purchased biomass fuel, saved bagasse and
imported coal. The season period will be 5 to 6 months and off-season will be 3 to 4 months
depending on the availability of fuels at economical price.
3.5.3 Manufacturing Process (Rectified Spirit/Ethanol/ENA)
Yeast propagation:
Yeast seed material is prepared in water-cooled yeast vessels by inoculating molasses with
yeast. The contents of the yeast vessel are then transferred to the Yeast activation vessel.
The purpose of aerated yeast activation in the yeast activation vessel is to allow time for the
yeast cell multiplication.
Fermentation:
The fermentation technology adopted in the industry is of continuous fermentation with yeast
recycle with this technology the total spent wash generation will be restricted to a max. of 10
kl/kl of R.S. (As per latest CPCB recommendation).
The purpose of fermentation is to convert the fermentable sugars into alcohol. During
fermentation, sugars are broken down into alcohol and carbon-di-oxide. Significant heat
release takes place during fermentation. However the fermentation temperature is
maintained at 32 – 35 0C by forced recirculation heat exchangers.
At the end of fermentation, the wash is fed through a yeast separator where the yeast cream
is separated, acidified in the yeast treatment tank and returned to the yeast activation vessel
for activation. Sludge is separated in a sludge decanter. The clear wash from both the yeast
separator and sludge separator flows to the clarified wash tank. The wash is then pumped to
distillation.
EXISTING PROCESS FLOW
DIAGRAM (SUGAR)
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Distillation:
Fermented Wash about 8% v/v alcohol is preheated in two stages i.e. in the beer heater
using the Rectifier vapours and then in the Fermented wash PHE using the effluent. The
preheated wash is then fed the Degasifying Column to remove residual CO2 and volatiles.
The wash then flows down to Analyser Column, which acts as a total stripper. The alcohol
water vapour mixture which rises upward in this column is fed to the Rectifier Column. The
spent wash, which is devoid of alcohol, flows down the Analyser Column for suitable
treatment.
The lower boiling impurities are concentrated in the Aldehyde Column where about 5% spirit
is drawn off as impure spirit with a minimum strength of 660 OP.
The alcohol vapours are concentrated in the Rectifier Column to produce Rectified Spirit of
95% v/v strength. Higher boiling impurities, which are formed during fermentation, are
removed by taking side draw purges to a decanter from the Rectifier Column. A trace stream
of spirit is drawn off as impure spirit (about 2% of plant capacity) to remove the concentrated
volatile compounds. The high grade Rectified Spirit is taken as a draw from the upper trays
of the Rectifier Column.
The Rectified spirit is fed to the purification column. Dilution water is fed on the top most tray
of the column with a dilution ratio of 1: 9. This column serves to remove the impurities based
on the principle of HYDROEXTRACTION. The water is fed to the column in such a way that
it selects the higher alcohols and other impurities to move upwards and extracts ethanol
down. The purifier bottom alcohol composition is maintained at 12 % v/v. At this
composition there is an inversion in relative volatiles of higher alcohols as compared to
ethanol and these alcohols get separated in the top distillate. Top draw for volatiles is fed to
the Fusel oil concentration column.
The purified dilute ethanol is removed from the bottom of the purification column and fed to
the rectification column, which concentrates the ethanol to 96% v/v. The high grade spirit is
drawn from one of the upper trays of the rectification column. A small heads cut is removed
from the overhead stream as technical alcohol (T.A.) cut to with draw impurities and is fed to
the heads concentration column. The lees from the exhaust column is recycled as dilution
water after a part of it is purged. The purged spentlees is used to preheat the make-up
dilution water.
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Lower side draw streams are taken from rectification column to avoid fusel oil build up in the
column. These streams are then taken to the fusel oil column. This column concentrates
the dilute streams of ethanol containing esters and fusel oils to approximately 95% v/v of
ethanol. The concentrated ethanol is removed as T.A. cut from the top of the column. T.A.
cut is removed out of the system in order to remove propanol and remaining is fed to the
heads concentration column where the heads from the purification column and rectification
are fed to the static mixer. Soft water, which has been preheated, is used for diluting the
high proof ethanol. An impure spirit cut of about 5% of the rectified spirit feed is drawn from
the top of the column. The dilute ethanol solution at the bottom of this column is pumped
back to the purification column for repurification.
Carbon Dioxide Recovery System (By Product):
Carbon dioxide produced during fermentation will be recovered by means of scrubbing
arrangement, chemical treatment drying process and finally liquefaction. The water utilized
for scrubbing will be recycled back into the fermentor.
CO2 gas will pass through scrubbing tower, where the gas is scrubbed with water. From the
scrubber after washing the gas will pass through air compressor and then the gas will pass
through a tower containing sodium dichromate to eliminate the impurities, if any and then to
drying arrangement with sulphuric acid. Subsequently it passes through a tower containing
coke coated with washing soda to eliminate odour. Finally it goes to the chilling unit to cool
the gas before passing through different cylinders, where the cooled gas will be filled into the
cylinders under pressure. The scrubber blowdown will be recycled into the fermenters.
Total CO2 production : 45.6 T/day
This carbon dioxide in cylinders will be sold to industries like soft drink manufacturing units,
etc.
Ethanol Production:
This plant is filled with imported 3A grade Molecular Sieve. It is operated with vaporized
Alcohol and removes water completely. Then Molecular sieves are regenerated under
vacuum of 710 mm Hg. Feed Alcohol comes to this Plant in a Day Tank continuously from
bulk storage tank. From this tank alcohol is pumped to a steam vaporizer at 4 Kg/cm2
pressure. This is vaporized in a steam heater and then vapor is super heated to 160oC in a
super heater and taken to Molecular Sieve Unit. This super heated vapor now pressure
through one Molecular Sieve column for moisture removal. There are 2 Molecular Sieve
columns. At a time one column remain in drying cycle while other columns under goes
vacuum regeneration. Each column remains in cycle for 6 minutes. Here drying process
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takes place at 3.0 Kg/cm2 pressure and dry alcohol vapor of 99.8% purity comes out as final
product. This alcohol vapor is condensed in a water cooler and then collected in another day
tank. From this tank dry alcohol is continuously pumped to bulk day storage tank through a
level controller and a control valve. In the regeneration process some left over alcohol also
comes out which is condensed in regeneration condenser. This alcohol is around 95%
strength and is re-cycled in to rectifier column continuously.
The other Molecular Sieves column under goes regeneration by a vacuum pump. In this
column vacuum pumps pulls and creates vacuum of 710 mm Hg. At this vacuum the
moisture from Molecular Sieve pores comes out and along with 30% pure alcohol from on
line Mole Sieve bed is sprayed. Thereafter during vacuum process, some left over alcohol
and water from Molecular Sieves comes out and is condensed. Concentration of this lean
alcohol is around 70% alcohol, which can be recycled to the Rectifying Column. From
Rectifier the pure water will be sent out automatically.
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3.6 Raw Materials
The following will be the raw material requirement for the for the existing and proposed expansion project
S.NO RAW MATERIAL SOURCE QUANTITY ( TPD) METHOD OF TRANSPORT
Existing Expansion Total
Sugar plant :
1 Sugar Cane Local area 3500 4000 7500 By trucks, tractors& bullock carts
2 Lime Local area 5.50 6.29 11.79 Through covered trucks by Road
3 Sulphur Local area 1.75 2.00 3.75 Through covered trucks by Road
Co-gen power plant :
1 Fuel
Bagasse From Sugar plant 200 1000 1200 Conveyor
(or)
Coal Imported 96 480 576 By Sea/ Rail/Road Covered trucks
Distillery:
Molasses From Sugar plant &
External
--- 230 230 Through Pipeline/Tanker
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3.7 Resource Optimization / recycling and reuse: Sugar Plant
Condensate from the Sugar Plant will be utilized for Cooling tower make up
Power Plant
The effluent generated from the Plant will be treated in Neutralization pits and will be utilized
for dust suppression, ash conditioning and Greenbelt development after ensuring compliance
with stipulation for on land irrigation by MoEF / CPCB
3.8 Availability of Water:
Water requirement for the existing plant is being met from Ground water resources. Water
required for the proposed expansion also will be met from the Ground water resources.
Required permissions will be obtained from SGWB before drawing water from Ground
Water required for existing plant 108 KLD
Water required for proposed expansion of Sugar,
Co-gen and Distillery unit
1100 KLD
Total 1208 KLD
3.9 Power Requirement:
The power required for the existing project and expansion project will be met from the Captive
& Co-generation Power plant.
3.10 Quantity of wastes generated:
3.10.1 Waste water generation
Waste water generation from the existing Sugar plant is 360 KLD. Waste water generation
from the proposed expansion project will be 1640 KLD.
3.10.2 Waste water Treatment: Sugar Plant & Distillery
Total wastewater generation will be 400 cum/day from sugar plant expansion. The condensate
generated from Distillery during concentration of spent wash will be 400 KLD. Effluent
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generation per ton of cane crushed will be as per CREP recommendations. The following is
the ETP description.
Design Data & Performance Projections
This Wastewater Treatment plant ( sugar + distillery) is designed for following parameters &
shall perform as under upon reaching steady state of its operation:
PARAMETER RAW WASTE WATER TREATED WASTEWATER
Flow (m3/Day) 800 810
pH 5.0 – 6.5 6.5 – 8.0
BOD (mg/l) 3000 < 100
COD (mg/l) 6000 < 250
TDS mg/L 2000 < 2100
TSS mg/L 500 < 100
Oil & Grease mg/L 100 < 10
PROCESS DESCRIPTION
The proposed wastewater treatment plant shall consist of following treatment units.
PRIMARY TREATMENT
Screen
Oil & Grease trap
pH adjustment
Equalization Tank
SECONDARY TREATMENT
UASB Anaerobic reactor
Aeration Tank
Secondary Clarifier
Sludge Drying Beds
Screen Chamber:
Screen chamber constructed in RCC shall be provided with SS 304 fabricated bar screen for
removal of free and floating material. The screen shall be inclined at 45 Deg with horizontal.
Oil & Grease Trap:
Oil and grease trap constructed in RCC shall be provided for removal of free and floating oil
from the Wastewater. The oil trap shall of gravity type and shall be provided with Belt type oil
Skimmer.
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Lime Preparation Tank:
A lime preparation tank constructed in RCC. In this tank is used for lime solution preparation
and continuous mixing of lime. Lime solution is then feed to equalization tank for pH correction
in a required proportion. 1 HP agitator shall be provided for mixing in the tank content.
Equalization:
Wastewater emanating from sugar has fluctuations in wastewater quality and quantity.
Equalization tank shall be provided for dampening these fluctuations. In equalization tank the
raw effluent is collected and equalized for adequate time. An equalization tank shall be
provided with an agitator to mix the tank content thoroughly. The equalized effluent from
equalization tank shall then be pumped to buffer tank. A stand by floating mixer shall also be
provided for equalization tank
Buffer Tank:
Buffer tank constructed in RCC shall be provided for preconditioning / pre-acidification of the
raw effluent. In buffer tank the Raw Effluent is mixed with treated effluent form UASB Reactor.
The nutrient required for the process will also be added to the effluent in Buffer tank. The
content of buffer tank shall be mixed hydraulically using UASB Reactor feed pumps. The tank
content will then be pumped to UASB Reactor for first stage biological treatment.
UASB Reactor:
Upflow Anaerobic Sludge Blanket reactor is provided for anaerobic treatment of Sugar plant
effluent. The UASB reactor shall be constructed in RCC M-25. The reactor consists of three
zones viz. Influent distribution zone, Reaction zone, Gas solid liquid separation zone.
Influent Distribution zone: The raw wastewater enters into the at the bottom through influent
distribution zone. A sophisticatedly designed piping network is provided for uniform distribution
of the effluent in the tank. The effluent then travels upward in the reactor.
Reaction Zone: In the reaction zone the anaerobic bacteria are maintained in the form of
sludge blanket. The organic matter in the wastewater comes in contact with the bacterial
population and is degraded anaerobically to methane rich biogas, the end product of
anaerobic digestion. The process of conversion of organic matter in to the biogas is a two-
stage process. In the first stage the organic matter in the raw effluent is converted in to the
volatile acids by acid forming bacteria. In the second stage the acid produced in the first stage
are converted in to methane by another group of bacteria i.e. methane formers. In UASB
process both the stages are completed in single reactor. The biogas so produced is bubbled
through the effluent and is separated out in the third section i.e. Gas-Solid-Liquid separation
zone. The suspended solids are also separated to prevent escape of solids from the reactor.
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Gas-Solid – Liquid Separation: In gas solid liquid separation a hood fabricated in M S and
duly painted with corrosion resistant paint is provided. The hood separates the solid from the
overflowing reactor content. Gas collectors are provided for collection and conveyance of gas.
The treated effluent overflows through a launder and will take to a secondary treatment.
Aeration tank:
The partially treated effluent from UASB shall then be subject to activated sludge process for
further reduction of organic matter. Aeration tanks are provided for degradation of organic
matter through biological process. Microorganism in the controlled environment carries out the
biodegradation process. The container i.e aeration tank of requisite capacity is provided for
this purpose. The tank shall be provided with an aeration mechanism to transfer the oxygen
from air to tank content for survival for microorganisms. Slow speed fixed type surface
aerators shall be provided for this purpose. The content in the aeration tank is kept under
constant aeration and mixing. The aeration thank shall be constructed in RCC.
Secondary Clarifier:
A secondary Clarifier in the form of circular tank shall be provided for settlement of fully
aerated Effluent from the aeration tank. The tank shall be provided with centrally driven fixed
bridge type clarifier mechanism. Part of the settled sludge at the bottom of the settling tank will
be pumped to the aeration tank and part of it will be discharged on sludge drying beds as per
operational requirement. This sludge being fully mineralized is suitable for sun drying on sand
drying beds.
Sludge Drying Beds: In aeration system the sludge is sufficiently mineralized and does not
need any further treatment before dewatering and disposal. Sand filtration drying beds will be
provided, where sludge will be dewatered by filtration through sand bed and sun drying of the
dewatered sludge is scraped & may be used as manure after composting.
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PROPOSED EFFLUENT TREATMENT PLANT FLOW CHART
(1000 KLD)
Pump
Recycling Pump
Bar Screen Chamber
Equalization tank
Lime Dosing Tank
Sludge Drying Bed
Raw Effluent
Oil Removal tank
Buffer Tank
Chlorine Contact Tank
Anaerobic
Reactor
Aeration Tank
Treated Tank
Primary Clarifier
Aeration Tank-II
Secondary Clarifier
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Cogeneration Power Plant
Total wastewater generation from power plant will be 500 Cum/day. The effluent generated
from the power plant will be treated and utilized as following.
Cooling tower blow down, DM plant regeneration and Boiler blow down will be neutralized and
after treatment it will be utilized for ash quenching, dust suppression and greenbelt
development.
Sanitary waste water will be treated in septic tank followed by soak pit. Hence there will not be
any adverse impact on environment due to the proposed activities.
Non Process Effluent Treatment & Disposal:
The boiler blow down and DM plant regeneration waste water will be treated in a neutralization
tank and after treatment it will be mixed with CT Blow down. All these treated effluent streams
will be stored in a Central Monitoring Basin (CMB). The treated effluent will be used for dust
suppression / ash conditioning and onland for irrigation within the premises after ensuring
compliance with CPCB / SPCB standards. The scrubbed water from CO2 Scrubber will be
consumed in the Fermentation section. The effluent will be used for greenbelt development
within the plant premises after ensuring the compliance with CPCB/SPCB standards.
Distillery
As per CPCB recommendations the spent wash quantity will be restricted to a maximum of 8
kl/kl of R.S. for Molasses by adopting continuous fermentation technology with yeast recycle.
The Maximum Spent wash input to Bio-methanation will be 480 KL/day
TREATMENT SCHEME
Spent wash generated will be treated in three stages
1. Bio-methanation
2. Evaporation
3. Bio-composting
BIO-METHANATION
"CSTR" continuous flow stirred-tank reactor process will be adopted for Bio-methanation,
which is based on the concept of conversion of organic matter into biogas. The process of
conversion of organic matter into biogas occurs through a group of bacteria.
Figure – 10.1
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In 'CSTR' process, which is a high rate process, anaerobic digestion takes place in the
Mesophillic range of temperature, the pH inside the reactor is usually kept around 7.2 while
proper ratio of volatile acid and alkalinity is maintained.
The following three stages are involved in the process of anaerobic digestion
1. Hydrolysis: In the process of hydrolysis the complex molecular compounds i.e. polymers
are converted into the simple molecular form i.e. monomers.
2. Acidogenesis: The monomers so formed at the end of hydrolysis process are converted
into volatile fatty acids. Acetic acid forms the major portion of volatile fatty acids. The
process of conversion of monomers into acids is carried out by a group of anaerobic
bacteria known acid formers.
3. Methanogenesis: Acids produced at the end of Acidogenesis process are converted into
carbon dioxide and methane gases. The process of conversion of acid into gases is
carried out by group of anaerobic bacteria known as methane formers.
In CSTR process the bacteria responsible for digestion process are kept in suspension with
the help of Lateral as well as central mixers.
Sr. No Design Basis Input Output
I. Spent wash Volume 480 TPD @ 12 %w/w solids 480 TPD @5 %w/w solids
II. BOD (mg/lit) 65000 85-90% reduction
III. COD (mg/lit) 120000 60-65% reduction
IV. pH 3 to 4 6 to 7
SR. NO TREATMENT UNIT SPECIFICATION/VOLUME MOC
1. Buffer Tank Capacity : 100 m3 RCC Lined Lagoon
2. Bio digester feed Pump +
motor
Type-Open impeller; Horizontal,
Centrifugal, Self Priming Cap-16
m3/hr Qty-1+1 3 Phase squirrel
cage induction type Motor
SINGLE MECHANICAL SEAL
SS316
3. CSTR Digester Capacity-10700 m3
Qty -1 nos
Mild Steel, with
epoxy coating
inside
4. Flare Stack Overall Ht: 10.0 m
Dia: 1.0 m
MS with epoxy
coating
5. Degasser Dia: 1.6 m
Overall Ht: 10 m
Mild Steel, with
epoxy coating
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SR. NO TREATMENT UNIT SPECIFICATION/VOLUME MOC
inside
6. Lamella Clarifier Surface Area: suitable Mild Steel, epoxy
coated inside
Provided with
FRP Packs
7. Gas Holder Suitable capacity MS Dome + RCC
Wet well
8. Bio-Methanated Spent
wash tank
Capacity : 50 m3 RCC
9. Lamella Sludge
recirculation pump
Horizontal Centrifugal Pump
having 15 m3/Hr Discharge and 25
mtrs Head. Qty-1+1 SINGLE
MECHANICAL SEAL
SS316
10. Agitators for Mixing in
Bio-digester
Quantity :4 Nos Wetted
partSS304
11. Bio Gas Blower Rotary Twin Lobe type
compressor of 600 m3/hr capacity
with pressure rating of 2500
mmHg. Provided with safety
Valve, Non Return Valve, Coupled
with flame proof motor
12. Lamella Clarifier Packs Lamella Packs in FRP Molded
sheets shall be provided. The
Lamella packs shall be inclined at
60 Deg with horizontal. Each Plate
shall have area of 2 sqm. Each
Lamella Pack Shall has Plates of
1 m x 2 m size each. Thickness of
FRP/PVC plates shall be of 3 mm
13. Liquid Flow Meter for SW
feed
Electro-magnetic flow meter
having flow range of 0-18 m3/Hr,
SS 316 material
SS316
14. Gas Flow Meter Vortex type gas Flow meter to
measure instantaneous and
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SR. NO TREATMENT UNIT SPECIFICATION/VOLUME MOC
integrated flow meter, bio gas flow
0-800 m3/Hr
15. Pressure gauges for liquid
pressure measurement
Bourdon type pressure gauges
with Vi" NPT connection, pressure
ratings 0-5.0 kg/cm2, 4" Dial Size
16. Pressure gauges for Gas
pressure measurement:
Diaphragm type pressure gauges
with V-i" NPT connection,
pressure ratings 0-700 mmwc g,
4" Dial Size.
17. Temperature Gauges for
Panel Indication:
Dia Type temperature Indicator
with 0-100 deg C range. Qty-2 nos
—
18. Pressure switches for
flare stake
Pressure switches for High & Low
Pressure Indication and Blower
operation. Qty-2 nos
—
19. Flame Arrestor: Suitable Dia. SS Flame arrestor
suitable for biogas flow of 800
m3/Hr, Flanged connection.
—
20. Breather Valve 200 / 100 mm Dia Dead weight
type breather valve, pressure
setting 500 mm WCG and
vacuum setting 70 mmhg Qty-1 no
—
21. Level Indicator: Glass Tube level indicator with a
range of 0-1000 mmhg to
measure the water seal in flare
stack. Qty-1 no
—
EVAPORATION PROCESS
Evaporation is an operation used to remove a liquid from a solution, suspension, or emulsion
by boiling off some of the liquid. It is thus a thermal separation, or thermal concentration,
process. Evaporation process can be defined as one that starts with a liquid product and ends
up with a more concentrated liquid as the main product from the process.
In first evaporation stage,
Bio-methanated Spent wash will be subjected to heat through steam
Spent wash vaporized in first stage will give energy to second stage.
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There will be total four falling film evaporator and one forced circulation evaporator.
These Evaporators will be in forward feed arrangement.
Vapours of Second evaporator will be fed to third effect Evaporator. Vapours of Third
evaporator will be fed to fourth effect Evaporator. Then, Vapours of fourth evaporator will
be fed to fifth effect Evaporator.
Falling film evaporators will be operated at very low temperature differences between the
heating media and the boiling liquid, and they also have very short product contact times,
typically just a few seconds per pass.
These characteristics make the falling film evaporator particularly suitable for spent wash
evaporation.
This is specifically designed Spent wash distributors for the proper distribution of Spent
wash in tubes. Specific design of the liquid distribution system achieve full and even
product wetting of the tubes. Because of the low liquid holding volume in this type of unit,
the falling film Evaporator can be started up quickly and changed to cleaning mode
easily.
Falling film evaporators are highly responsive to alterations of parameters such as
energy supply, vacuum, feed rate, concentrations, etc. it will be equipped with a well-
designed automatic control system therefore it can produce a very consistent
concentrated product.
BIO METHANATED SPENT WASH EVAPORATION SECTION
Spent wash feed : 480 TPD
Feed Solid Concentration : 5%
Process Condensate Qty : 400 TPD
Final Spent Wash after evaporation : 80 TPD
Final Spent wash Solids concentration : 30%
Sr. No. DESCRIPTION SPECIFICATIONS MOC
1. Flash tank Type: Vertical/ Cylindrical-
conical bottom Capacity: 4 m3
SS304
2. Biomethanated spent
wash Pre heater
Type - Shell & tube.
Quantity- 3 No.
SS304
3. Spent wash feed tank Type: Vertical/ Cylindrical-
conical bottom Capacity : 15
m3
SS304
4. Vacuum Blower for
flash tank
Type : Water Ring Blower
Capacity: 200 Nm3/Hr. Qty:
1+1 no.
Cl/ SS 304
Internals
5. Flash vessel condenser Type - Shell & tube, SS304
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Quantity-1 No. HTA-51 M2
6. Feed Pump motor Capacity: 18 m3/hr Type -
Centrifugal Type, Quantity-1
+ 1 Nos. Single Mechanical
Seal
Wetted Parts
SS 316
7. Falling Film
Evaporators
Type : Shell and Tube Qty: 4
FF Evaporator HTA FF1: 100
m2 FF2: 150 m2 FF1: 150 m2
FF1: 150 m2
SS 304 Shell
with SS 316
tubes
8. Forced Circulation
Evaporator
Type : Shell and Tube Qty: 1
FC Evaporator HTA : 170
SS 304 Shell
with SS 316
tubes
BIO-COMPOSTING
FEATURES OF BIO COMPOSTING TECHNOLOGY
Zero discharge concept
Complete Destruction of BOD in effluent
Flies & odour free
High quality product
Dry baggable product, easy to handle and transport.
PROCESS OF BIO COMPOSTING
A Composting cycle takes 8 weeks to complete and involves the following activities.
1st week
1. Collection of raw material:
First week Filter Cake, Boiler Ash and organic residues compose one compost batch. They
are hauled from storage yard to the bioearth compost area, a level and well-drained land that
permit heavy equipment operations.
2. Formation of Windrows & Trimming
Using a pay loader the press mud is spread in piled windrows and trim to allow passage of
Aero tiller. Each windrow consists of 100-150 metric tons of press mud. Each windrow is of
1.5m width at bottom and 100m length.
2nd week
1. Aerating and mixing:
Make the first pans of the mixovator on windrows.
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2. Inoculation of bioearth:
After the first aeration pass, the material will have achieved moderate mixing and ready
for application of acitobactor and Phosphorous soluble reagent at ½ kg per ton of
waste. This will accelerate composting stabilize temperature 65-750C and enhance
beneficial microbes.
3. Aerate the pile after inoculation and retrim.
3rd to 6th week
1. Maintenance of Moisture:
The Moisture of the pile is maintained to 50% to 60% heat is evolved during process,
this built up together with solar heat and other factor increases. Temperature resulting
to evaporation. Moisture drops to a level of about 30%to35%.
2. Application of Distillery effluent after Digesters:
Excessive/ inadequate moisture slows down composting exhibited by drop in
temperature from the trend established. Windrows are watered back to desired
moisture level using distillery effluent as moisturizing agent. The total volume
applicable each week is sprayed three times during the week.
3. Aeration:
Make one to two pass of the Mixovator after each effluent application and then retrim.
Mixovator grinds, blends, spreads, aerate and disperse the growing fungi for a uniform
and thorough decomposition of the windrow.
4. Inoculation with culture
During the 5th week, culture is again applied at 0.5 kg/ton in order to restimulate
microbial activity and to stop the development of odour.
5. Curing, Aging and Drying
7th week:
Effluent application is stopped at the end of the 6th week and the compost is allowed to cure
and age. Water is applied during the 7th week while mixing is continued twice in a week until
moisture stabilizes at 20%to 30%.
8th week:
Disposal of Bio earth to End –user Farms:
Transport the bio earth to end-user farm or a suitable storage in order to vacate the area
occupied by the compost and accommodate another batch Otherwise, a large bio-earth
composting area may be needed to process the annual production of waste.
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LAND REQUIREMENT FOR BIOCOMPOSTING
Quantity of Bio-methanated evaporated spent wash 80 KLD
No. of operating days 270 days
Annual Quantity of Bio-methanated evaporated spent wash 21,600 KL
Off seasonal run-off from compost yard 400 KL
Total effluent to be sent to compost yard 22,000 KL
Pressmud to effluent ratio 1:1.5
Filler material requirement per Annum 14,667
Composting cycle 60 days
No. of cycles 4
Filler material required per cycle 3667 T
Filler material that can be processed in 1 Acre: 1000 Tons/cycle
Land required for composting 3.7 acres
Total land requirement
Land required for composting 3.7 acres
Land required for storage of filler material 1.1 acre
Land required for storage of finished product 0.8 acre
Total land required for composting 5.7 acres
Quantity of organic compost 7,920 T
Availability of Pressmud
Total Pressmud generation from sugar plant 45,000 TPA against the requirement 14,667 TPA.
The above Bio-compost will be given to farmers to be used as manure in the agricultural fields.
Hence availability of pressmud will not be a problem.
Leachate collection system
A leachate collection system will be provided will be constructed with RCC M20 grade
concrete along with 250 micron HDPE lining to make it leak proof as per CPCB/BIS
specifications.
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Specifications for compost plant
Specification of floor of compost yard will be as under (with arrangement of leachate collection
& surface runoff and its pumping to holding lagoon and laying of pipe network for automatic
spraying of spent wash)
I. Compaction of soil
II. 5 cm local sand cushion (bottom)
III. 250 micron HDPE sheet (as per BIS specification)
IV. 5 cm sand cushion (top)
V. Brick / stone soling (not less than 6 cm in case of brick & 3 cm in case of stone
soling)
In case the coefficient of permeability is less than 10-8 cm/sec (as in black cotton soil), 30 cm
depth of impervious soil, compacted with 30 cm depth of murum at the top may also be used.
The bio-compost yard will be kept dry before starting of the monsoon period. The compost
yard is surrounded by garland canal to divert storm water from outside entering inside and
bund to prevent the surface run off from going outside the compost yard during rainy days.
Outside the garland canal greenbelt will be prepared for aesthetic reason and for avoiding
erosion. 10 acres of land will be prepared for Bio composting as per CPCB guidelines.
Specification for storage of filler material
Press mud will be transferred to compost yard before on set of monsoon and covered with
HDPE / PVC sheet / tarpaulin.
Specification for storage of finished product (compost)
Land area is raised by about 30 cm above ground level. The maximum height of storage is
restricted to 4m. Finished compost will be kept. Covered with PVC / HDPE sheet / Tarpaulin to
prevent soaking from rain water.
Compost quality
Moisture content : < 35%
Organic carbon : 20 -25%
Phosphorous : 1.5 - 2.0%
Nitrogen : 1.5 - 2.0%
Potassium : 2.0 - 3.5%
C: N ratio : <17
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Equipment & Machinery available for composting in the plant (as per CPCB protocol)
1. Tractor for transportation of press mud from storage site to compost area - 1 No.
2. Homogenising machine along with auto spraying system with 70 HP tractor
(for churning up to the bottom) - 1 No.
3. Front end loader with tractor or JCB of bucket capacity of 600 -1000 kg -1 No.
4. Automatic windrow forming mechanism – 1 No
5. Sieving Machine - 1 No.
6. Sewing machine for bagging of compost (finished product) - 1 No.
Organic compost produced in the treatment of spent wash with pressmud will be supplied to
the farmers at subsidized prices. With this the usage of compost chemical fertilizers
consumption will come down. With compost the sugar cane yield will increase by about 25%.
Storage of Pressmud
Pressmud will be transferred to compost yard before on set of rainy season and shall be
covered with tarpaulin.
Biomethanated Evaporated Spent wash storage lagoon
During the monsoon period bio-composting cannot be carried out. Hence distillery will be not
be operated during monsoon season and will be operated for only 270 days in a year.
Biomethanated Evaporated Spent wash storage lagoon size will be restricted to 5 days instead
of 30 days.
The storage lagoon will be made impervious constructed with RCC M20 grade concrete along
with 250 micron HDPE lining. The storage capacity of the lagoon will be for 5 days. The
capacity of the Bio-methanated Evaporated Spent wash storage tank will be 12.5 m x 8 m x
4.3 m.
Leachate collection Tank
Leachate Collection tank will be made impervious with 250 micron HDPE lining as per CPCB
specifications.
Spent wash storage lagoon
Spent wash storage lagoon having storage capacity for 3 days, which is far below the CPCB
norm of 30 days. This storage lagoon will be made impervious by providing 500 micron HDPE
lining as per CPCB specifications. The size of the lagoon will be 21.5 m x 17 m x 4.3 m
(including a freeboard of 0.3m).
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Treatment of Non-process effluent
Total Non-process effluent from project (excluding sanitary wastewater) : 236 KLD.
Back wash from DM plant and Softener, Boiler blowdown will be neutralized in a neutralization
tank and will be mixed with Cooling tower blowdown in the CMB and will be utilized for
greenbelt development, dust suppression and ash conditioning after ensuring compliance with
treated effluent quality as per MoEF / SPCB Standards.
3.11 Solid Waste:
The following are the solid waste generation & disposal.
S.No Solid waste Quantity (TPD)
Disposal Existing Expansion Total
Sugar Plant
1. 1. Bagasse (27%)
945 1080 2025 Will be used as fuel in boilers
2. 2. Molasses (4.5%)
158 180 338 Will be used in the Distillery
3. 2.
Filter cake
140 160 300
As mud is recycled to diffusor, No Filter cake generation presently, for expansion , it will be given to farmers as manure
4. ETP Sludge 0.14 0.16 0.3 Will be used as manure Cogeneration Power plant
5.
Ash generated when Bagasse used as fuel in Boiler
3.5 17.45 20.95
Ash generated Will be disposed to farmers to use as manure in Agricultural lands
Ash generated when Coal used as fuel in Boiler
7.6 38 45.6 Will be given to cement plants/brick manufactures
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4.0 SITE ANALYSIS
4.1 Connectivity:
Component Description
Road The site can be well approached by a SH # 4 (Zaheerabad – Bidar)
Rail Nearest Railway station located at 5.8 Km (Mettalkunta)
Air port Nearest Airport located at Hyderabad which is at distance of 100 Kms
from the Plant site
Sea Port Krishnapatnam port is at a distance of 450 Kms from the Plant site
4.2 Land form, Land use and Land ownership:
The present use of the land is Industrial as existing sugar & power plant is under operation.
Now the proposed expansion integrated sugar complex activities will be taken in the existing
plant premises only.
4.3 Topography:
The topography of the land is more or less flat without undulations.
4.4 Existing land use pattern:
The present use of the land is Industrial
4.5 Existing Infrastructure:
The infrastructure required for operating the integrated sugar complex exists at the site
4.6 Soil classification:
The soil at the site is Sandy loam
4.7 Climatologically data:
District climate is classified as tropical. The summers here have a good deal of rainfall, while
the winters have very little. The climate here is classified as AW by the Köppen-Geiger
system. The average temperature in Sangareddy is 26.3 °C. The average annual rainfall is
861 mm.
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4.8 Social Infrastructure Available:
Education
An IIT was established in 2008 near to Sangareddy at Kandi. And also JNTUH College of
Engineering Sultanpur at Sultanpur which is near by the city has been established recently.
Road:
Since Sangareddy is near Hyderabad, it is well connected to other areas like Hitech city, DLF
Gachibowli (appx 35 km away), Panjagutta and Secunderabad. The NH-9 passes through the
city. Sangareddy has two Bus Stations, the Old for Ordinary service and the new for luxury
and other services.
About 15 km Away from Sangareddy there is an outer ring road which connects to
Shamshabad airport- Rajiv Gandhi International Airport Hyderabad and to Gachibowli and
Medchal.
Rail
The nearest railway stations are Lingampally which is about 30 km, Secunderabad about 50
km and Nampally Station around 55 km. In coming years it is expected that there will be Metro
rail/ MMTS track to connect the city to Lingampally.
Air
Nearest Airport is Hyderabad International Airport which is 70 km from Sangareddy.
5.0 PLANNING BRIEF
5.1 Planning Concept:
The integrated complex will be of Sugar, Co-gen. & Distillery Project at Trident will integrate
sugar mill operations with enhanced energy efficiency measures and optimum usage of
Molasses and Bagasse. During season, the Co-gen Plant will be operated on bagasse
generated in the Plant and coal when necessary.
All excess available power will be exported to the grid. During off-season based on the
availability of Bagasse / biomass from nearby sugar mills power will be generated.
Further, the integrated Sugar & Co-gen projects will improve the overall profitability of TSL,
through its additional revenue generation. This will enable TSL to give higher dividend to
promoters & higher price per ton of cane to its cane growers. Also the project will help to
improve Telangana State‘s power situation.
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5.2 Population Projection:
Unskilled Man Power required for the proposed expansion Project will be met from the local
villages completely. Qualified semi-skilled man power required will be met from local villages if
available. Hence there will not be much population increase in the area.
5.3 Land use Planning:
The following is the Land use Planning of the area
ITEM EXTENT OF LAND (ACRES)
Existing Expansion After expansion
Built up area of Sugar plant 10 5 15
Built up area of Co-Gen Power
plant
4 6 10
Built up area of Distillery plant -- 4 4
Internal roads 4.00 2.50 6.50
Green belt area 45 45
Bio-composting 10 10
Vacant area 38.6 38.6
Total 129.1 129.1
5.4 Amenities / Facilities:
Facilities like canteen, rest rooms and recreation facilities will be provided in the proposed
expansion project.
6.0 PROPOSED INFRASTRUCTURE:
6.1 Industrial area
The following Plant and machinery will be installed in the Industrial processing area
List of Plant and Machinery for proposed expansion
Sugar Plant
Item Description Nos. Type/Capacity
Cane Weighment
Cane weighbridges 2 1 # 60 T capacity
1 # 10 T capacity
Cane Unloading
Cane unloader 2
Sling Type cane unloaders 7.5T SWL
Capacity,
Gantry and structure 1
Feeder table 2 1 # 7 m X 7 m
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Item Description Nos. Type/Capacity
Cane handling & Preparation
Feed Cane Carrier 1
Head end shall be suitable to 2200 mm
swing dia. Fibrazor.
Chain strength should be 60 T breaking
load. Head end
Sprocket is 16 teeth.
Prepared cane carrier 1
Chopper 1
2 #250 HP HP motor will run in reverse
direction at 300 rpm
through gear box having 1.95:1 ratio
Leveler 1
2 #350 HP HP motor will run in forward
direction at 585 rpm
Fibrazor 1
2200 mm swing dia, 144 nos. hammers of
23kg with new
Pocketed type anvil.
Cane pusher 1
1400 mm dia pusher driven by 30
HP/1440 rpm through
speed reducer and open spur gear
Auto cane feed control Lot
Juice Extraction Plant
Donnelly chute 2
Mills 2
2 # Mills 42" x 84" with pressure feeding
system.
First and last mill s to be provided with
GRPF
Under feed roller 2 UFR of 1100 mm PCD
Mill drive 2
2# 1250 HP AC /Planetary drives
Inter carrier 2
Rake carrier with 50 HP drive carrier
speed shall be
25m/min
JUICE HANDLING EQUIPMENT
Juice Screen 1 Rotary screen with 0.35 slit opening.
Cush - Cush conveyor 1
Double scroll type 410 mm dia x 7000.
The screw
conveyor is driven by 10 HP / 1440 rpm
Mass flow meter for imbibition water 1 150 cu.m/hr capacity, 50 m head
JUICE PUMPS
Unscreened juice pump 2 350 cu.m/hr, 12 m head 960 rpm
Screened Juice pump 3 400 cu.m/hr, 12 m head 960 rpm
Imbibition juice pump 2
350 cu.m/hr, 12 m head, 30 HP/960 rpm -
2 nos.
Imbibition water pump 2 200 cu.m/hr, 50 m head, 50 HP/1440 rpm
Mill house crane 1 Install 1# 40 t EOT crane
Mill house gantry Lot
Millhouse lathe 1 Install 1# lathe to be procured to suit
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Item Description Nos. Type/Capacity
1200 x 5000 mm rollers grooving
JUICE TREATMENT
Water flow meter 1 0-200 t/h, volumetric flow meter
Water weighing scale 1
Juice flow meter 1
Install 1 # volumetric flow meter with
density compensation
in parallel with the flow meter. Capacity
200 t/h
Juice weighing scale 1
Driver trough 1
Check weighing scale
Weighed juice receiving tank
Weighed juice pumps
Phosphate addition system
Preparation tank
Install 1 # phosphoric acid preparation
tank.
Capacity 1 cu.m
Storage tank
Dosing pump
Install 1 # dosing pump of capacity 100
lph
Juice flow stabilization system 1
Install common control system suitable for
400 t/h
for both the flow meters.
Juice sulphitor 1 250 HL capacity
Prelimer 1
pH control system for juice sulphitor 1 pH control system
Sulphured juice receiving tank 1 Cylindrical tank, Cap : 12.5 cu.m
Sulphured juice pumps 3 Install 2 # 400 cu.m/h, 60 m head pumps.
CLARIFIER & FILTERATION
Flash tank 1 Install 1# flash tank suitable for clarifier
Install 1# volumetric flow meter & control
valve to control flow to the clarifier
Clarifier 1
Install 1 # clarifier of 36' dia or Install 1#
short retention time
Clarifier suitable for 2750 TCD.
Polyelectrolyte preparation tank 1 Install along SRT clarifier
Polyelectrolyte storage / dosing tank 1 Install along SRT clarifier
Polyelectrolyte dosing tank 1 Install along SRT clarifier
Rotary vacuum filters 2 2 # Dia 3600 x Long 7200 mm (12' x 24')
Vacuum filtrate Pick-up receivers 3 2 # Dia 600 x Long 1200 mm MS
1 # Dia 900 x Long 1500 mm MS
Vacuum filtrate wash receivers 3 2 # Dia 600 x Long 1200 mm MS
1 # Dia 900 x Long 1500 mm MS
Filtrate collection tank 1 SS make dia 1100 x 2490 long
Filtrate pumps 2 Cap : 70 cu.m/h, 21.5 m head
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Item Description Nos. Type/Capacity
Filter condenser 3 2 # Dia 600 x Long 2400 mm MS
1 # Dia 750 x Long 1500 mm MS
Entrainment separator 3 2 # Dia 450 x Long 900 mm MS
1 # Dia 600 x Long 1200 mm MS
Vacuum pump 2
2# 1200 cu.m/hr with 30 hp motor, motor
rpm 1460
pump rpm 1250
1# 300 mm size water jet air extractor for
both filters
Mud overflow circulation tank 1 Dia 2235 x 1500 long
Mud recirculation pump 3 Cap : 70 cum/hr, 21.5 m head
Cake wash water pump 1 Install 1# pump Cap : 10 cum/h, 55.6m
head.
Feed mixer 1
1 # Dia 1000 x 3500 mm long for both
filters, U shaped.
Bagacillo blower and chute 2 Connected with 20 hp motor
Bagacillo piping 2 1 # pipe of 500 mm dia
1 # pipe of 350 mm dia
Cyclone separator 2 1 # MS make dia 1500 x 3150
1 # MS make dia 1340 x 2700
Mud belt conveyor 1 650 mm width troughed, 36000 mm long
Cake collection bin 1 MS make 2500 x 2500 x 1100
Vibratory screen or filtrate
1
80 mesh screen vibratory type with
rectangular
screen of 1075 x 1000 x 30
Filtrate Clarification System
Filtrate buffer tank 1
Cap : 20 cu.m, dia 2.5 m x 4.0 m height,
steam coil
is installed inside to maintain temperature
of filtrate
Untreated filtrate pumps 2 Cap : 45 cu.m/h, 15 m head
Flow meter 1 Cap : 0-50 cum/h, Magnetic type
Lime sucrate preparation tank 1 Cap : 4 cu.m, dia 1.5 m x 2.25 m Ht
Lime sucrate dosing tank 1 Cap : 4 cu.m, dia 1.5 m x 2.25 m Ht
Lime sucrate dosing pump 2 Cap : 800 lph, 1.5 bar discharge pressure
Phosphoric acid storage tank 1 Cap : 1 cum
Phosphoric acid dosage pumps 2 Cap : 100 lph, 1.5 bar discharge pressure
Flocculent preparation tank 1 Cap : 4 cum, dia 1.5 m x 2.25 m Ht
Flocculent dosing tank 1 Cap : 4 cu.m, dia 1.5 m x 2.25 m Ht
Flocculent dosing pumps 2 Cap : 800 lph, 1.5 bar discharge pressure
Reaction tank 1
Cap : 2 cum, Dia 1.1 m x 2.25 m Ht.,
Impeller
speed 48 rpm
Aeration pumps 2 Cap : 20 cu.m/h, 15 m head
Filtrate floatation clarifier 1 Cap : 13 cu.m, Dia 3.0 m x 1.8 m Ht.
Automation Set Total system is automated
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Item Description Nos. Type/Capacity
Milk of Lime and SO2 Preparation
Quick lime elevators 1
Electric hoist for bag lifting with 0.5 hp
motor
Lime slaker 1 Cap : 1200 Kg/h, 5.5 KW, 12 final rpm
Lime clarifier 1 Koran, 3.7 KW, perforation dia 0.5 mm
Vibratory screen 1 Circular, 60 mesh size, 3.7 KW, 1.5 m dia
Milk of lime storage tanks 2
Dia 3000 x 3150 mm height, 20 cum
each, 5 KW
Milk of lime pumps 2
Install 1 # new pump cap: 10 cu.m/h, 20
M head.
Sulphur burners for juice,
Continuous type 2 200 kg./h. Film Type Burners
Sulphur burner for syrup, continuous 2 Cap. 70 kg/h one working
Air compressor 4 Install 1# 1000 cum/h air compressor
Air receiver 1
air receiver for compressor suitable for
two compressors
Juice heating and Evaporation
Raw Juice Heater (Tubular type) 2 300 sq. m heating surface
Condensate Receiver for JH 2
Collect juice condensate to common
receiver for both
juice heaters
Condensate pump 2
Use both pumps for common receiver.
One working and
one stand by
Sulphured Juice heater (Tubular
type) 3 300 sq. m heating surfaces.
Condensate Receiver for JH 3
Use only 2# condensate receivers one
each for each effect bleeding
Condensate Pump 3
20 cum/h capacity, 30 m head
condensate
pumps for SJ1 & SJ2
Clear juice Heater 2 2 # Direct contact Heaters
Condensate Receiver for JH
Condensate pump
Clear juice column 1 Dia 3000 x 5000 height
Clear juice filters
Install 2 # leaf filter for clear juice filtering
suitable for 4000
TCD with all accessories
Clear juice pump 2
Capacity 250 cum/h and 60 m head to
CJ pumping
Intermediate juice receiving tank
Evaporator Set Quintuple
Quint I 1 2500 sq. m body as Quintuple 1st effect.
Quint II 1 2700 sq. m body as Quintuple 2nd effect.
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Item Description Nos. Type/Capacity
Quint III 1 1250 sq. m body as Quintuple 3rd effect
Quint IV 1 600 sq. m body as quintuple 4th effect.
Quint V 1 600 sq. m body as quintuple 4th effect.
Condensate receiver for Quint -1st
effect 1
Install 1# 1.2 mtr dia and 2.0 mtr height
mound
Condensate pump for Quint-1st
effect 2
Install 1# 130 cu.m/hr, 30 m head
condensing pump as
common standby for quintuple 1 & 2
bodies
Condensate receiver for Quint-2nd
effect 1
Install 1# 1.2 mtr dia and 2.0 mtr height
mound
Condensate pump for Quint -2nd
effet 1
100 cum/h, 30 M head pump for this duty
pump
Condensate receiver for Quint -3rd
effect 1 Quintuple 3rd effect condensate receiver
Condensate pump for Quint -3rd
effect 1 Cap : 50 cum/h, 30 m head
Condensate receiver for Quint -4th
effect 1 Quintuple 5th effect condensate receiver
Condensate pump for Quint -4th
effect 1 Cap : 20 cum/h, 30 m head
Condensate receiver for Quint -5th
effect 1 Quintuple 5th effect condensate receiver
Condensate pump for Quint -5th
effect 1 Cap : 20 cum/h, 30 m head
Common condensate flash tank for
2nd Condensate 1
2.5 meter dia and 5.0 meter length
receiver
Common condensate flash tank for
pan and JH Condensate 1
2.5 meter dia and 5.0 meter length
receiver
Syrup receiving tank 1 Dia 1000 x 1500 mm height
Syrup Extraction Pump 2 Cap : 70 cu.m/hr, 30 m head
Syrup Clarification System
Buffer tank 1 Cap : 32 cum, Dia 3.89 m x 2.5 m Ht
Untreated syrup pumps 2 Cap : 70 cum/h, 30 m head
Syrup heaters 2
HAS 77.5 sq. m, 144 tubes, 45 OD/18
SWG/4 m length, 9
tubes / pass, 16 passes
Color precipitant preparation tank 1 Cap : 1 cum
Color precipitant dosing tank 1 Cap : 1 cum
Color precipitant dosing pumps 2 Cap : 100 lph, 1.5 bar discharge pressure
Phosphoric acid storage tank 1 Cap : 1 cum
Phosphoric acid dosage pumps 2 Cap : 100 lph, 1.5 bar discharge pressure
Flocculent preparation tank 1 Cap : 4 cum, dia 1.5 m x 2.25 m Ht
Flocculent dosing tank 1 Cap : 4 cum, dia 1.5 m x 2.25 m Ht
Flocculent dosing pumps 2 Cap : 800 lph, 1.5 bar discharge pressure
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Item Description Nos. Type/Capacity
Reaction tank 1 Cap : 32 cum, Dia 1.465 m x 1.72 m
Aeration tank 1 Dia 0.45 m x 2.0 m Ht.
Syrup floatation clarifier 1 Cap : 32 cum, Dia 4.5 x 1.8 m Ht
Clear syrup tank 1 Cap : 14 cum, Dia 2.1 x 4.0 m Ht
Clear syrup pumps 2 Cap : 50 cum/hr, 35 m head
Automation Set Total system is automated
Leaf filters for syrup filtration
Install 2 # leaf filters to filter syrup before
going to pan floor
Syrup sulphitor 1 Sulphitor of 15 cum working capacity
Caustic Soda Tank 1
Cap : 19.4 cum, Rectangular type, 2900 x
2200 x 3000 mm
Caustic Soda pumps 1 Cap : 100 cum/h, 20 m head
Pressure reducing valve no.1 (PRV-
1) P1 to P2 1
kg/sq.cm (g)
Pressure reducing valve no.2 (PRV-
2) P2 to P3 1
Cap : NA, 150 mm size from 7 kg/sq.cm
to 1.5 kg/sq.cm
kg/sq.cm (g)
Pressure reducing valve no.3 (PRV-
3) P2 to P3 1
kg/sq.cm (g)
Pressure reducing valve no.4 (PRV-
3) P4 to P2 1
Cap : 5 t/h, from 13 kg/sq.cm to 7
kg/sq.cm
kg/sq.cm (g)
Overflow surplus valve for exhaust
(OSV-1)
One exhaust over flow surplus valve of
capacity 30t/hr
Overflow surplus valve (OSV-2)
2# OSV's on two Quntiple two bodies,
Cap : 1# 20 t/h
and 1# 40 t/h
Overflow surplus valve (OSV-3) 1#OSV as relief valve. Cap : 20 t/h
Desuperheater No.1 Dia 1500 x 3000 mm height
Desuperheater No.2 Install desuperheater for PRV
Graining and Crystallization
Syrup & Molasses storage tanks 17 Each capacity 20 cum
5 # syrup, 2 # Melt, 1 # AL, 4 # AH, 3 #
BH & 2 # CL
Molasses conditioner 3
Continuous type, between runoff storage
tank and pan
supply tank
1 # Cap : 2.58 cum for AH
1 # Cap : 2.0 cum for BH
1 # Cap : 1.3 cum for CL
A Vacuum Pan - Batch 4
80 t with mechanical circulator. With Pan
automation.
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Item Description Nos. Type/Capacity
Graining vacuum pans - Batch 1
60 Ton with Mechanical circulator with
automation
B' Vacuum Pan - Continuous 1
Install 1 # 30 t/h continuous pan for B
massecuite
C' Vacuum Pan - Continuous 1
Install 25 T /hr continuous pan for C
Boiling
Pan Condensate Receiver 2
Dia 2600 x 3800 mm for 2nd vapor, Dia
2000 x 2700 for 1st
Vapor
Pan condensate pump 3 2 # Cap : 50 cum/h, 30 m head
1 # Cap : 70 cum/h, 30 m head
Dry seed crystallizer 1 U Shaped Net Cap : 40 t
B Seed crystallizer 1 U Shaped Net Cap : 40 t
Grain Seed Crystallizer 2 U Shaped Net Cap : 90 t
A Vacuum crystallizer 1 U Shaped Net cap: 40 t
B Vacuum crystallizer 1 U Shaped Net cap: 40 t
C Vacuum crystallizer 1 U Shaped Net cap: 40 t
Crystallizer for `A' massecuite 5 U Shaped, Net Cap : 90 t
Strike receiver for `B' Massecuite 1 U Shaped, Net Cap : 90 t
B' Massecuite transfer pump 1 9 ‗‘ x 9 ― PSP pump, 30 m Head
Strike receiver for B Massecuite 1 U Shaped, Net Cap. 90 t
Vertical crystallizer for B'
Massecuite 1
Install 1 # 300 t mono vertical crystallizer
for B massecuite
Liquidation pump for Vert. Cry. 1 Rota type, 8" x 8", Cap : 35 t/h, 30 m head
Strike Receiver for `C' Massecuite 1 U Shaped, Net Cap.90 t
C' Massecuite transfer pump 1
Strike Receiver for `C' Massecuite 1 U shaped, Net Cap. 90T
Vertical crystallizer for C'
Massecuite 1 set
Install 1 # 300 t mono vertical crystallizer
for C massecuite
Liquidation pump for vert.Cry 1 Roto type, 8" x 8", Cap : 35 t/h, 30 m head
Cooler for hot water 1 Install 1# parallel heater
Cold water surge tank
Cold water circulation pumps 2 Cap : 36 cum/hr, 55 m head
Hot water surge tank by gravity
Hot water circulation pumps by gravity
Hot & Cold water overhead tank 3 1 # 7500 x 3750 x 2500 for hot water
2 # 7500 x 4500 x 2500 for cold water
Service water tank 1
Concrete 40000 x 20000 x 2500, net
capacity 2000 cum
Service water pump 3 1 # Cap : 450 cum/h, 22 m lead
2 # Cap : 300 cum/h, 40 m head
Centrifugals
A Massecuite centrifugal pug mill 2
U shaped 5600 long x 1000 wide. Each
catering to 3
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Item Description Nos. Type/Capacity
Machines
A Massecutie Centrifugals 4
Install 4 # 1750 kg/charge fully automatic
DC drive
Centrifugal machines.
AH molasses receiving tank 1 Dia 1900 x 1250 height
AH molasses pump 2
Screw type pump of 30 t/h capacity, 25 m
WC
AL Molasses receiving tank 1 Dia 1900 x 1250 height
AL Molasses pump 1 Screw type, Cap : 30 t/h, 25mWC
Superheated wash water system Set Suitable for 7 batch machines
Superheated wash water pump 2 Cap : 20 cum/h, 55m head
Air Compressor 2 Discharge pressure 6 kg/sq.cm(g)
B Centrifugal pug mill 2
1 # U Shaped, 4600 long x 1000 wide, for
batch machine
1 # U shaped, 6100 long x 1000 wide, for
continuous m/c
B Centrifugals 3 1 # Batch machines of 1250 kg/charge
2 # WK 1500, Cap : 15-18 t/h continuous
machines
B-Magma mixer 2
1 # U shaped, 6000 long x 1000 wide for
batch machine
1 # U shaped, 4900 long x 1000 wide for
continuous m/c
B Magma pump 2 1# Rota type, Cap : 20 t/h, 30 m head
1 # Rota type, Cap : 20 t/h, 30 m head
B Molasses receiving tank 2 Dia 1500 x 1200 height, 1 # BL & 1 # BH
B Molasses pump 2
Screw type pump of 20 cum /h capacity,
25 mWC
CAW centrifugal pug mill 1 U shaped, 4600 long x 1000 wide
C after Centrifugals 2
WK 1500, Cap : 10-12 t/h. 1 # B curing
machine is common
standby for CAW
C After Magma mixer 1
U Shaped, 4900 long x 1000 wide for B &
CAW continuous
Machine
C-After magma pump 1 Common for B & CAW
CL Molasses receiving tank 1 Dia 1500 x 1200 height
CL Molasses pump 2
Screw type pump of 20 cum /h capacity,
25 mWC
CF centrifugal pug mill 1 6800+1000 long x 800 dia
C Fore worker Centrifugals 3
wk - 1500 or equivalent machine for C
Fore curing
C-Fore magma mixer 1 U Shaped
1 # 6000 long x 1000 wide, with planetary
C-Fore magma pump 3 Rota type, Cap : 20 t/h, 30 m head
FM receiving tank (below machines) 1 Dia 1500 x 1200 height
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Item Description Nos. Type/Capacity
FM Pump below machines 2
Screw type pump of 10 cum /h capacity,
25 mWC
Final Molasses weighing scale 1
Weighed FM Receiving tank 1 Rectangular type
FM Pump below weighing scale 2
Screw type pump of 20 cum /h capacity,
25 mWC
Final molasses storage tank 2 Cap : 7500 T each, 28 m dia x 9.50 m Ht
Final molasses transfer pump 2
Screw type pump of 20 cum /h capacity,
25 mWC
Sugar Melter 2 Cap :: 35 t/h vertical
Melt pump 3
2 # Centrifugal, Cap 40 cum/hr, 30 m
head
1 # screw type, Cap : 30 t/h, 25mWC
Sugar Handling & Bagging
Gross Hopper Conveyor 1 Single tray type, 2.0 m width, 12 m long
Fluidized bed dryer 1
1 # 40 t/h fluidized bed dryer along with all
accessories
Sugar elevator from FBD to grader 2 Cap : 40 t/h
Sugar grader
2
1 # Cap : 35 t/h
1 # Cap : 35 t/h
Sugar elevator from grader to bin 2 Cap : 25 t/h
Sugar Bins 3 125 t sugar bin
Slat Conveyor 2 Width 400 mm, 1.5 KW
Bag stitching machine 3 Cap : 300 bags/h
Dry seed magma mixer 1 U Shape, Cap : 5 t
Dry seed transfer pump 1
Rota type, 8" x 8", Cap : 300 t/h, 30 m
head
Dust collector system Set
Dust collector tank 2 1 # Dia 3.0m x 3.7m Ht
1 # Rectangular wet scrubber, 2.5 x 1.5 x
2.0m
Dust melt pump 2 Cap : 35 cum/h, 25 m head
Sugar bag belt conveyor 6 Width 600 mm
Sugar bags mobile belt conveyor 10 Width 600 mm
Sugar Godowns 4
2 # 100m x 40m x 10m, Cap : 400000
bags
Condensing Plant
Evaporator condenser 1
1 #Single entry Vapor inlet dia : 1100 mm
with automation
Batch Pan condensers 5
4 #Single entry Vapor inlet dia : 1300 mm
with automation
1 #Single entry Vapor inlet dia : 1100 mm
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Item Description Nos. Type/Capacity
with automation
Continuous Pan condensers 2
1 #Single entry Vapor inlet dia : 1100 mm
with automation
Ejector for pans & vacuum
crystallizer 1
Same system is to be followed for new
condensers also
Automation Set
Injection pump 4 1600 cum/h, 22 m head pumps
Priming pump 1 Cap : 25 cum/h, 3.75 KW
Cooling tower 3 Cap : 1600 cum/h, each cell
Cooling tower water pump
Priming pump 1 Cap : 25 cum/h, 3.75 KW
Electricals
Distribution transformers 3 2.5 MVA distribution transformer
Bus ducts 4 4000 Amps,
Power control centre (PCC) 3 4000 Amps,
Motor Control Center (MCC) 12
Distribution boards Lot
Push button stations Lot
Lighting Lot
Earthing LOt
APFC panel 2
LT power and control cables Lot
Miscellaneous work (cable tray,
danger baords, Lot
rail for transformer, gravel spreading
etc.)
Co-generation Plant:
Machinery Details:
Equipment name Qty. Capacity
Boiler Capacity 1 100 T
Turbine Capacity 1 20 MW
Electro Static Precipitator 3 Fields
FD Fans 2
ID Fans 2
Air heaters 1
Feed water system 2 HP heater-1 with 16 ata extraction steam
HP heater-2 with 8 ata extraction steam
Feed water pumps 3 80tph capacity,110kg discharge pressure
HP LP dosing system 2 HP dosing pumps for steam drum dosing
2 LP dosing pumps for derator dosing
Dearator 1
Bagasse Handling system 1 100 TPH
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Coal Handling System 1 45 TPH
Biomass preparatory system 1
Feed regulation station 1 Control valve station with manual by pass
station
Atemperation system 1 Spray between primary super heater and
secondary super heater
D M plants 2 each 400 OBR at 30TPH
Water clarifier 1 200 TPH
Cooling tower system
No. of cells 4 1600 Cum.Mtr/Hr
Cooling tower pumps 4 1600 Cum.Mtr/Hr, Discharge pressure -
3.25 KSC
Two pass surface condenser with
cooling water flow 4200 Cum.mtr/Hr
Condensate extraction system
Pumps 3 50TPH each at 6kg pressure
Gland steam condenser 1 100 TPH
Steam ejectors 2 Main
1 Hogging
Turbine lub oil system/control oil
system
1
package
ST switch gear- 11kv
Generator transformer - 36MVA-
11/110kv
Distribution transformers 3 2.50mva each, 11kv/415volt
1 3.15mva, 11kv/415v
Diesel generator set 1 1500 kva
PRDS system 1 75 tph,87/8 ata
1 80tph,8/2.5ata
Pumping station at Kali river & Piping
Pumps 3 100 tph each, Pressure-4kg
Priming pump 2 20 tph
Infiltration pump 3 100 tph
Electrical substation at Kali pump
hose with 11kv/415 v transformer,
MCC and 250 kva diesel set
Switch Yard
110kva breaker 2
11kv breaker 1
100kv Isolators 3
CTs and PTs as per the requirement
Double circuit 110kv line to Haliyal
substation
Fire fighting system for complete
complex
Fire water pump motor driven 1 100 TPH at 10 KSC
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Fire water pump diesel set driven 1 100 TPH at 10 KSC
Jacky pump 2 30 TPH at 10KSC
Distillery Plant:
SECTION I : FERMENTATION HOUSE :
MOLASSES WEIGHING SECTION :
1] Weighscale / Loadcell for Check : 1 No.
weighment. Capacity : 3 MT
2] Molasses feed tank : 1 No.
Material of construction : M.S
Capacity : 50 MT
- FERMENTATION EQUIPMENTS
1. PROCESS TANKS
A] Fermenter : 2 Nos
Material of construction : MS
Capacity : 500m3
Equipped with roof manholes, air sparger in stainless steel construction, sight and light
glass assemblies, level indicator, defoaming oil sensor, pressure relief device and
required nozzles and fittings.
All internal surface will be sand blasted and epoxy coated ( 1 primer coat followed by
2 finish coats - min. DFT (150 micron ).
B] Propagation Vessel I
Design code : ASME VIII, Div. 1
Material of construction : SS 304
Capacity : 180 L
Equipped with sight glass, air sparger, cooling jacket, relief valve and necessary
nozzles and fittings.
C] Propagation Vessel II
Design code : ASME VIII, Div. 1
Material of construction : SS 304
Capacity : 2000 L
Equipped with sight glass, manhole, air sparger, relief valve and necessary nozzle and
fittings.
D] Propagation Vessel III
Geometric Capacity : 100,000 L
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Design code : IS 803
Material of construction : MS (epoxy lined)
Equipped with shell and roof manholes, air sparger, sight and light glass assembly and
necessary nozzles and fittings.
All internal surfaces will be sand blasted and epoxy coated (1 primer coat followed by 2
finish coats - min. DFT 150 micron).
E] Defoaming Oil Day Tank.
Capacity : 1000 L
Material of construction : MS
2. PROCESS PUMPS :
A] Molasses feed pump : 1 + 1 standby.
Type : Positive displacement
Material of construction : CI with SS wetted parts.
Shaft sealing. : Gland packing.
Drive : Variable speed
-Molasses storage to feed : 1+1
-Weighing to diluter : 1+1
B] Fermenter Cooling Pump : 2 + 1 standby
Type : Centrifugal
Material of construction : SS 316
C] Fermenter Discharge Pump : 1 + 1 standby
Type : Centrifugal
Material of construction : SS 316
D] Wash Transfer Pump : 1 + 1 No.
Type : Centrifugal
Material of construction : SS 316
E] Sludge Pump : 1 + 1 No.
Type : Centrifugal
Material of construction : SS 316
F] Recycle Pump : 1 + 1 standby
Type : Centrifugal
Material of construction : SS 316
G] Propagation II Cooling Pump : 1 Nos.
Type : Centrifugal
Material of construction : SS 316
H] Defoaming oil dosing Pump : 1
Type : Positive displacement.
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Material of construction : GI
3. PLATE HEAT EXCHANGERS. [ Alfa Laval make ]
M.O.C of Qty
Plates Nos.
a] Prop II Temp. Control PHE SS 316 1
b] Fermenter Cooling PHE SS 316 2
(Min.AK 20 FMI 168 plates each with back flushing arrangement)
4. MISCELLANEOUS :
A] Positive Displacement Blowers : 1 + 1 standby
Type : Twin lobe
Material of construction : CI body, cast steel.
Braided with suction/discharge silencers, relief valve, non-return valve & suction filter.(
water cooled) OR
Alternatively Vacuum Pump may be considered for same duty.
Capacity : 1700nm3/hr+900nm3/hr
Head : 9 MWC
B] Carbon-di-oxide Scrubber : 2 Nos.
Type : Sieve plate column
Material of construction : SS 304
Plate material : SS 304
Diameter : 600mm
With water spraying arrangement in AISI 304, sight glass and packing support grid.
C] Strainers - : 3 Nos.
For : 1) Fermented wash
2) Recycle.
3) Diluted Molasses
Type : Basket
Material of construction : AISI 304
Hole size : 0.6 mm
D] Sterile Air filters : 2 Nos.
Capacity : 20 M3/Hr. & 120 M3/Hr
E] Water molasses static mixer in AISI 304 : 1 No.
F] Air Compressor for Instrumentation Air : 1No+1No (Common for entire
plant including Mol. Sieve plant)
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5. YEAST RECYCLING SYSTEM :
A] Yeast Separator [Alfa Laval make] 2 + 1 Nos.
Indigenous model DX 409
B] Chain Pulley block with travelling trolley : 1 No.
Capacity 1 MT
C] Cleaning table for separator in MS : 1 No.
D] Yeast Cream Funnel : 3 Nos.
Material of construction : SS304
E] Hydrocyclones : 1 Set.
Material of construction :
- Body : AISI 304
- Cone : Ceramic
6. CIP SYSTEM :
I CIP tank/Hot water tank : 1 No each.
Capacity : 2000 L
Material of Construction : AISI 304
II CIP Pump : 1 No.
Type : Centrifugal
Material of construction : SS 316
7. Cooling Tower : 2 Nos. 400 Cu.m./ hr.
SECTION II : Distillation
1 Analysing Column (Vacuum) Material of Construction : SS304
Type of Trays : Sieve
No. of trays : 50
Tray spacing : 750mm
Diameter : 1698mm / 2195mm
(min. diameters mentioned)
2 Rectifying Column (Under pressure) Material of Construction : SS304
Type of Trays : Sieve
No. of trays : 144
Tray spacing : 300
Diameter : 1790mm
(min. diameters mentioned)
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3 Aldehyde Column Material of Construction : SS304
Type of Trays : Sieve
No. of Trays : 60
Tray spacing : 250mm
Diameter : 710mm
(min. diameters mentioned)
7 Beer Pre-heater : Shell & Tube type
Material of Construction : SS 304
Tube length : 3000mm
Tube thickness : 1.25mm
8 Analysing coloumn Reboiler : Shell & Tube type
Material of Construction : Shell: 304Tubes: SS316
Tube length : 3000mm
Tube thickness : 1.25mm
Qty : 1+1
9 Stripper Rectifier Column Reboiler
Type: Shell & Tube
MOC: Tubes : SS304 Shell : CS, Ends : CS
Qty : 1 Nos.
10 Final Condensor : Shell & Tube type
Material of Construction : Tube and tube sheet are in
SS 304, water side in CS
Tube length : 3000mm
Tube thickness : 1.25mm
11 Aldehyde Condensor : Shell & Tube type
Material of Construction : SS 304
Tube length : 3000mm
Tube thickness : 1.25mm
12 Aldehyde Vent Condensor : Shell & Tube type
Material of Construction : SS 304
Tube length : 3000mm
Tube thickness : 1.25mm
13 Final Product Cooler : PHE
Material of Construction : SS 304 plates
Area : Suitable
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14 Fusel Oil / Heads Spirit Cooler : Vertical type
Material of Construction : SS 304
15 Fusel Oil washer decanter : Vertical type
Material of Construction : SS 304
16 Steam Chest : 1 No.
Material of Construction : MS
17 Hot water tank
Capacity : 1 M3
Material of Construction : MS
18 Reflux Tanks : 2 Nos.
19 Plate Heat Exchangers:
Sr. Description M.O.C. (Plates) Qty.
I Wash Pre-heating PHE SS316 2
II Recycle Wash Cooler (Recycle) PHE SS316 1
III Spent Wash Cooler PHE SS316 1
20 Pumps : With flame proof motors, mechanical seals & back pull out rotor design.
Sr. Description M.O.C. Qty.
IV Rectifier Reflux Pump SS316 1+1
V Weak Alcohol feed pump SS316 1+1
21. Cooling Tower : 2 Nos. 375 Cu.m. / hr.
SECTION III: Molecular Sieve Dehydration:
1 Mol Sieve Superheater
Type: Shell & Tube
MOC: Tubes: SS304 Shell: CS Bonnets: CS
Qty : 1 Nos
2 Mol Sieve Unit
Type: Dished ends; with packed bed of Molecular Sieves
MOC: SS
Qty: 2 Nos
3 Mol Sieve Condenser
Type : Shell & Tube
MOC: Tubes: SS304 Shell: CS Bonnets: CS
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Qty : 1 Nos.
4 Mol Sieve Product Cooler
Type: PHE
Qty : 1 Nos.
5 Mol Sieve Regenerant Condenser
Type: Shell & Tube
MOC: Tubes : SS304 Shell : CS Ends : CS
Qty : 1 Nos.
6 Mol Sieve Regenerant Drum
Type: Dished top & bottom
MOC : SS
Qty: 1 Nos
7 Mol Sieve Vacuum Pump Drum
Type: Dished top & bottom
MOC : SS
Qty: 1 Nos. 1
8 Mol Sieve Recirculation Cooler
Type: PHE
Qty : 1 Nos.
9 Mol Sieve Regenerant Pump
Type: Centrifugal
MOC: Impeller:SS Casing: CI
Qty: 1 + 1 No.
10 Mol Sieve Vacuum Pump
Type: Liquid Ring
Qty : 1 No+1No
11 Rectified Spirit Day Tanks: 2 Nos. MS , Capacity : 100 KL Each.
Additional Columns for ENA Production.
Extractive Distillation Column
Recovery Column
Polishing Column
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6.2 Residential Area (Non Processing area):
Facilities like canteen, rest room and indoor games facilities will be provided in the proposed
expansion project.
6.3 Green Belt:
Total 1/3rd of the total area including existing will be developed in the Plant premises.
Greenbelt development plan
Local DFO will be consulted in developing the green belt.
Greenbelt of 45 acres will be developed in the plant premises as per CPCB guidelines.
15 m wide greenbelt will be developed all around the plant.
The tree species to be selected for the plantation are pollutant tolerant, fast growing,
wind firm, deep rooted. A three tier plantation is proposed comprising of an outer most
belt of taller trees which will act as barrier, middle core acting as air cleaner and the
innermost core which may be termed as absorptive layer consisting of trees which are
known to be particularly tolerant to pollutants.
6.4 Social Infrastructure:
Social infrastructure will be developed as per need based in the nearby Villages.
6.5 Connectivity:
Component Description
Road The site can be well approached by a SH # 4 (Zaheerabad – Bidar)
Rail Nearest Railway station located at 5.8 Km (Mettalkunta)
Air port Nearest Airport located at Hyderabad which is at distance of 100 Kms
from the Plant site
Sea Port Krishnapatnam port is at a distance of 450 Kms from the Plant site
6.6 Drinking water management:
Drinking water required for the workers will be met from ground water resources.
6.7 Sewerage system:
Domestic waste water generated will be treated in septic tank followed by Sub-surface
dispersion
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6.8 Industrial waste management:
6.8.1 Waste Water Management
Waste water generated from the proposed Project will be treated in Effluent Treatment
proposed which is furnished under paragraph 3.10.2
6.8.2 Solid Waste Management
Solid wastes disposal in the existing and expansion project is discussed in paragraph 3.11
6.9 Power requirement & Supply / Source:
The power required for the project will be met from Cogen & Captive power plant during
season and Captive power plant of 4 MW during off season.
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7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN
No rehabilitation or resettlement plan is proposed as there are no habitations in the in the
Plant site.
8.0 PROJECT SCHEDULE & COST ESTIMATES
The total cost of the project has been estimated at Rs. 252 Crores.
Detailed breakup of the Cost is given below.
S.NO. DESCRIPTION RS. Crores
1. Land preparation cost 2.0
2. Civil works –Building /Foundation 15.0
3. Plant & Machinery 130.0
4. Electrical works 10.0
5. Miscellaneous works 5.0
6. Distillery 70.0
7. Working capital & I D C 20.0
Total 252.0
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9.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)
With the implementation of the proposed expansion project, the socio-economic status of the
local people will improve substantially. The land rates in the area will improve in the nearby
areas due to the proposed activity. This will help in upliftment of the social status of the people
in the area. Educational institutions will also come-up and will lead to improvement of
educational status of the people in the area. Primary health center will also come-up and the
medical facilities will certainly improve due to the proposed expansion project.
EMPLOYMENT POTENTIAL
The following will be the man power requirement for existing and expansion Project
S.No. Particulars No. Employees
1. Technical & Administrative Staff 20
2. Skilled & Semi Skilled (Contract basis) 60
3. Unskilled & Helpers (Contract basis) 40
Total 120
OTHER TANGIBLE BENEFITS
The following are the other benefits to the area due to the proposed expansion project.
Educational status will improve in the area
Medical standards will improve due to the proposed expansion project.
Overall economic up-liftment of socio-economic status of people in the area.
Ancillary developmental activities like CO2 plant, Cattle feed plants will be created due
to the establishment of the proposed unit.
SOCIO-ECONOMIC DEVELOPMENTAL ACTIVITIES
The management is committed to uplift the standards of living of the villagers by undertaking
following activities / responsibilities.
Health & hygiene
Drinking water
Education for poor
Village roads
Lighting
Helping locals to conduct sports
Training to the unskilled manpower
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HEALTH & HYGINE
1. Personal and domestic hygiene,
2. Maintaining clean neighborhood,
3. Weekly health camps offering free-check up & medicines
4. Ambulance services
5. Education & drug de-addiction, aids.
DRINKING WATER
Making drinking water available at centralized locations in the village,
SUPPORTING EDUCATION
1. Providing books to all poor children,
2. Conducting annual sports festival in the village schools,
3. Providing amenities like fans, lavatories,
4. Maintain play ground etc.