PROJECT FEASIBILITY REPORT ON BAGASSE BASED …€¦ · PROJECT FEASIBILITY REPORT ON BAGASSE BASED...

M/s Narmada Sugar Pvt Ltd.

PROJECT FEASIBILITY REPORT

ON

BAGASSE BASED CO-

GENERATION POWER PLANT OF

30 MW

M/s Narmada Sugar Pvt Limited

At

VILLAGE- PONDAR, TEHSIL-

SALICHOUKA

DIST-NARSINGPUR (MP )


1. Identification of project and project proponent

M/s. Narmada Sugar Private Limited (NSPL) is one of the pioneering sugar

factories of Madhya Pradesh and is in its 10th year of operation. NSPL received

its memorandum for manufacturing of vacuum pan sugar and molasses along

with other sugarcane by products from the Ministry of Commerce & Industry in

April 2005.. The factory started its crushing operations in the year of 2006-07.

The licensed crushing capacity of the plant is 4000 tonnes per day.

The Maheshwari group has initially set up its line of business activities in year

1977 from its native place Thaini, Bankhedi, Distt Hoshangabad, M.P. with its

flagship Company M/s Ramdev Sugar Pvt. Ltd., which was into manufacturing

of khandsari sugar under kind guidance and hard dedication of Shri Navneet

Lal Ji Maheshwari. With a clear vision in mind for expansion and

diversification, Shri Navneet Lal Ji Maheshwari with his brothers & sons has

worked hard with clear strategy and planned operations to grow their family

business with a streamlined pace. Being a joint family, all the family members

had put on their efforts to match up with the demand of time for achievement

of targets for the group.

Initially Maheshwari Group of Companies had started a Khandsari unit of 20 TCD

(Tonne Crushig Day) in the year 1977 and gradually its capacity has increased, its

technology has developed and at present the group is having 4 modern automated

sugar units to the tune of 11000 TCD. Maheshwari group is also into trading business

of food grains. The Group has moved into diversified business areas and has started

production of Paraboiled Rice with manufacturing unit of 8 Tonne per hour capacity,

in 2014 and has proposed to set up Baggasse Based Co generation Power Plant of 30

MW.

With a constant growth culture and dedicated efforts of about 200 employees,

the group has achieved turnover of Rs. 603.85 Crores for financial year 2014-

2015.

Most important strengths and core competencies: Having long experience in

the existing business activities, Maheshwari group is well equipped with

suitable infrastructure and business locations, human resource,

infrastructural amenities transportation & logistic facilities, good market

reputation and financial capacity. With a zeal to grow in a diversified sector,

Maheshwari group has always focused upon the better utilization of available

resources and continual up-gradation in the systems and strategies.

Group Concern & Activities:-

Currently Maheshwari group is working with its below mentioned core

activities:-

1. M/s Ramdev Sugar Pvt. Ltd., Thaini, Bankhedi, Dist. Hoshangabad, M.P.:-


Area of Business : Manufacturing of white Crystal Sugar & Captive Power

Generation of 3 MW

Turnover : Rs. 12427.25 Lacs

2. M/s Narmada Sugar Pvt. Ltd, Salichouka, Dist. Narsinghpur, M.P.:-


Generation of 3.5 MW

Turnover : Rs.12326.19 Lacs

3. M/s Shakti Sugar Mill Pvt. Ltd., Kodiya, Dist. Narsinghpur, M.P.:-




4. M/s Shrijee Sugar & Power Pvt. Ltd., Sohagpur, Dist. Betul, M.P. :-




5. Shrinath Traders Bankhedi, Dist. Hoshangabad, M.P.:-

Area of Business : Trading of Various Food Grains like wheat, Gram,

Soyabean, Dhan, Tuar etc.


6. Shrijee Traders, Pipariya, Dist. Hoshangabad, M.P.:-

Area of Business : Trading of Various Food Grains like wheat, Gram,

Soyabean, Dhan, Tuar etc.


7. Jai Giriraj Rice & Agro Mills Pvt. Ltd. Khaparkeda, Pipariya, Dist.

Hoshangabad, M.P:-

Area of Business : Manufacturing of High quality Parboiled Rice


2. Brief Description of Nature of The Project

The proposed Bagasse bassed Cogen Project of 30 MW to be set up at NSPL,

will operate round the year at estimated average 80% PLF for the first year,

90% for second year, 100% for third year and thereon, covering 160 season

days of the sugar factory and 42 off season days. The proposed Cogen Project


will be designed for average crushing rate of 4000 TCD (227.27 TCH). All the

equipment for the proposed Cogen Project will be designed for a minimum of

4152 hours of operation in a year, on a continuous basis. The Cogen Project

will operate on bagasse during season and saved & procured bagasse from

group sugar mills, in off-season period. The proposed Cogen Project will be

designed to produce surplus power after meeting the entire requirements of

steam of the sugar mill, both during season and off season periods. Steam

requirement for the sugar crushing of upto 150 TPH will be supplied by the

proposed 30 MW cogen plant.

3. Need for the project and its importance to the country and or region

Bagasse cogen power potential has been estimated in the region of 5500 MW in

the country. Existing similar cogen power plants have resulted in socio

economic benefits to the local area, growth in renewable energy and decrease in

T & D losses. Bagasse based cogeneration/ power plants are receiving benefits

under the Kyoto protocol. Cogeneration is encouraged by the Electricity Act,

2003, Ministry of New and Renewable Energies, regulatory commissions, state

governments and all stake holders. The Hon’ble Prime Ministers office has

encouraged 10% mix of renewable energies in the grid. The Central and State

governments have identified this potential and have taken various initiatives to

support this sector in many ways.

NSPL has installed crushing capacity of 4000 TCD. The command area is rich

in sugar cane cultivation and has irrigation facilities.

For sustaining the increased steam and power needs of the sugar mill, NSPL

requires to strengthen their cogen facility. Based on recent orders of MPERC

(Madhya Pradesh Electricity Regulatory Commission), NSPL has decided to opt

for a modern high pressure grid connected bagasse / biomass based co-

generation project.

The proposed project has envisaged 126 kg/cm² pressure and 5450 C

temperature parameters for steam, which will give optimum efficiency and

power generation, when extracted through a matching turbo generator set. The

capacity of the boiler and turbine will be 150 TPH and 30 MW respectively. The

design philosophy will be to generate optimum levels of power from high

pressure steam, supply steam requirements of the sugar complex and

auxiliaries, and export optimum level of power. There is Piparia – Gadarwara

132 KV transmission line passing near the plant. Power Evacuation is to be

done on this line with LILO (Line In Line Out) switchyard arrangements in

plant area, 0.5 km away.


4. Demand –Supply Gap

The potential for exportable surplus power from sugar factories through sugar

mill based cogeneration projects in India was estimated at 3,500 MW in the

year 1993, by the Task Force appointed by the Ministry of New & Renewable

Energy (MNRE), New Delhi, erstwhile known as the Ministry of Non-

Conventional Energy Sources. MNRE re-validated the potential at 5000 MW in

March 2005 based on increased number of sugar factories (to 573 from 446),

adoption of high pressure and temperature configuration i.e. above 67 kg/sq

cm and 4950C, as well as taking into account of energy conservation and

energy efficiency in sugar manufacturing process.

A total of 288 biomass power and cogeneration projects aggregating to 2665

MW capacity have been installed in the country for feeding power to the grid

consisting of 130 biomass power projects aggregating to 999.0 MW and 158

bagasse cogeneration projects in sugar mills with surplus capacity aggregating

to 1666.0 MW. In addition, around 30 biomass power projects aggregating to

about 350 MW are under various stages of implementation. Around 70

Cogeneration projects are under implementation with surplus capacity

aggregating to 800 MW. States which have taken leadership position in

implementation of bagasse cogeneration projects are Andhra Pradesh, Tamil

Nadu, Karnataka, Maharashtra and Uttar Pradesh. The leading States for

biomass power projects are Andhra Pradesh, Chattisgarh, Maharashtra,

Madhya Pradesh, Gujarat and Tamil Nadu. Cogeneration projects have now

proven techno-commercial viability in the Indian sugar sector. Integration of

sugar mill operations with value added by-products including sale of excess co-

generated power is not only well proven but essential for the industry’s

survival.

The sugar cogen sector has matured and passed through a learning curve of

about 10 to 15 years. The earlier projects commissioned of similar capacity,

were in the pressure range of 45 to 66 kg/cm2. With increase in experience,

increasing costs and requirements of higher efficiency, the recently

commissioned projects in Uttar Pradesh, Maharashtra and Tamilnadu are at

110 kg/cm2, 540 deg C, which maximise the power generation from biomass.

NSPL is planning to opt for technology and supply chain for 126 kg/cm2, 545

deg C.

As of September, 2013, out of the total potential of 7500 MW from bagasse

based cogeneration power projects at sugar factories, the installed capacity in

India cumulates to about 2500 MW (150 projects) and additional 2000 MW


(125 projects) are under advanced stages of implementation. The cumulative

penetration is in the range of 60% in this promising yet difficult renewable

energy sector.

The balance potential is mainly from the co-operative & public sector sugar

factories from various states. The progress is not encouraging in these sub-

sectors due to specific barriers associated including high capital costs for the

cogen power plants & associated essential modernization, inability to raise

required equity & loans from financial institutions/SDF in time, poor

manpower capacity, off-season fuel linkage etc. These barriers need to be

addressed for harnessing the balance potential.

Power Sector Scenario

AS per the LGBR Report, 2014-15, it was estimated that during the year 2014-15,

there would be energy shortage of 5.1% and peak shortage of 2.0%. The annual energy

requirement and availability and peak demand and peak availability in the country are

given in the Table below.

Particulars Energy (MU) Peak (MW)

Requirement 1048672 147815

Availability 995157 144788

Surplus (+) / Shortage (-) -53513 -3027

Surplus (+) / Shortage (-)

%

-5.1 -2.0

Source – Ministry of Power / Central Electricity Authority

Sector wise Total Installed Capacity

Sector wise total installed capacity in India, as on August, 2015, is as given below:

Sector MW % age

State Sector 96,015 34.7

Central Sector 74,171 26.8

Private Sector 1,06,597 38.5

Total 2,76,783

B) Generation

India has been one of the fastest growing markets for new power generation capacity

addition since 1990s and is currently the fifth largest power generator in the world.

For the last 24 years, the country has shown a cumulative annual growth rate (CAGR)

in its annual power generation capacity; from ~66 gigawatt (GW) in 1991 to over 276

GW in 2015. The fuel wise breakup of the installed capacity as on 31st March, 1991


and 31st September, 2015 (shown below) depicts the shift from hydro to renewable,

leaving thermal sources viz. coal and gas, at the same level except for inter-se shift

between them.


Power Generation capacity addition (excluding renewables) of 20,623 MW for

FY 2012-13 surpassed the set target of 17,956 MW.

C) Electricity Generation Performance

The electricity generation target for the year 2015-2016 was fixed as 1137.5

Billion Unit (BU). i.e. growth of around 8.47% over actual generation of

1048.673 for the previous year (2014-2015). The generation during (2014-15)

was 1048.673 BU as compared to 967.150 BU generated during April- March

2014, representing a growth of about 8.43%.

Programme, actual achievement and growth in electricity generation in the

country during 2009-10 to 2015-16:-

Year Target Achievement

% of target % of growth

2009-10 789.511 771.551 97.73 6.6

2010-11 830.757 811.143 97.64 5.56

2011-12 855.000 876.887 102.56 8.11

2012-13 930.000 912.056 98.07 4.01

2013-14 975.000 967.150 99.19 6.04

2014-15 1023.000 1048.673 102.51 8.43

2015-16* (Upto August 2015) 473.731 460.034 97.11 3.14

* Provisional Source – Ministry of Power

D) Power Supply Position

The power supply position in the country during 2009-10 to 2015-16, is as given below:

Year Energy Peak

Requirement Availability Surplus (+) /

Deficits (-)

Peak

Demand

Peak

Met

Surplus (+) /

Deficits (-)

(MU) (MU) (MU) (%) (MW) (MW) (MW) (%)

2009-10 8,30,594 7,46,644 -83,950 -10.1 1,19,166 1,04,009 -

15,157

-12.7

2010-11 8,61,591 7,88,355 -73,236 -8.5 1,22,287 1,10,256 -

12,031

-9.8

2011-12 9,37,199 8,57,886 -79,313 -8.5 1,30,006 1,16,191 -

13,815

-10.6

2012-13 9,95,557 9,08,652 -86,905 -8.7 1,35,453 1,23,294 -

12.159

-9.0


2013-14 10,02,257 9,59,829 -42,428 -4.2 1,35,918 1,29,815 -6,103 -4.5

2014-15 10,68,923 10,30,785 -38,138 -3.6 1,48,166 1,41,160 -7,006 -4.7

2015-16 4,68,509 4,58,084 -10,425 -2.2 1,48,467 1,45,101 -3,366 -2.3

*Provisional Upto August, 2015 Source – Ministry of Power

E) Renewable Energy (RE)

The total installed capacity reached 27,542 MW as on 31st March, 2013 with

Wind power at 19,051 MW (69%) being the largest component and Solar Power

at 1,686 MW(6%).

Wind Power installation registered steep de-growth of 47% (from 3,197 MW in

FY 2011-12 to 1,699 MW in FY 2012-13) due to withdrawal of Accelerated

Depreciation, expiry of Generation Based Incentive (GBI) and delays associated

with project approvals. Hon’ble CERC with a view to strength the REC market,

wherein recently supply exceeded demand manifold, has extended the validity

of RECs from 365 days to 730 days from the date of its Issuance for RECs

issued on or after 1st November, 2011.

Factors such as poor financial condition of Discoms, absence of vibrant REC

market, lack of incentives, high capital investment & low returns and delays in

project approvals prevent Wind Power Projects from realizing their true

potential.

Solar Power installations registered a steep growth of 81% (from 932 MW in

March 2012 to 1,686 MW in March 2013) under various supportive central and

state policies. Under the National Solar Mission, GoI has announced the Phase

– II of Jawaharlal Nehru Solar Mission with a target of 10,000 MW installations

during the 12th Plan. Further, Ministry of New and Renewable Energy (MNRE)

released draft guidelines for setting up of 750 MW Grid Solar PV power projects

under Viability Gap Funding scheme, wherein 30% of the project cost will be

financed by MNRE. Many states have also announced various policy measures

to promote solar power generation.

In order to improve the acceptability of Wind and Solar Power in the grid, Hon’ble

CERC has issued an order directing implementation of Renewable Regulatory Fund

mechanism w.e.f. 1st July, 2013, wherein the wind and solar generators shall be

responsible for forecasting their generation.

To spur investment in the renewable energy sector, the following were

announced in the Union Budget 2013:

1. Re-introduction of the GBI for Wind Power Projects, with allocation of Rs.

800 Core; and


2. Low interest bearing funds from the National Clean Energy Fund to Indian

Renewable energy Development Agency to on-lend to viable renewable energy

projects.

F) Power Trading

An effective power market is yet to develop in India, where currently just 11%

of the total generated electricity in the country is traded in short term power

market comprising Bilateral Segment, UI & the Power Exchanges (IEX and

PXIL). Of the total generation of 912 MUs in FY 2012-13, 99 MUs of power were

traded through short term power market, the composition of which is as

follows:

Power Exchanges have shown remarkable growth of 55% rising from 14,822

MUs in FY 2011-12 to 23,024 MUs in FY 2012-13. Further, power traded

through UI Mechanism has shown a drop of 11% as compared to FY 2011-12

whereby the volume declined from 27,758 MUs in FY 2011-12 to 24,759 MUs

in FY 2012-13 due to UI frequency band reduction by Hon’ble CERC. Hon’ble

CERC is in the process of introducing the concept of ancillary services for

reducing dependence of utilities on UI.

The share of trading segment is expected to remain low owing to various constraints

including fuel deficit, fuel allocation for long term arrangements only, transmission

capacity constraints, limited implementation of open access, poor utility finances and

trading margin cap.

Sugar Industry Review

All India

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

producer of sugar in the world, with a production of over 25 million tones.

Sugar factories are located mostly in the rural India. They act as centres 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 10000 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 703 sugar factories are in operation today, with additional 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 have

increased steadily over the years. The crop yield per hectare and recovery has

improved, particularly in the last decade.

Sugar factories in India are spread over the entire country; however 92% of

them are located in 9 States viz., Uttar Pradesh, Bihar, Punjab and Haryana in

the north, Maharashtra and Gujarat in the west and Karnataka, Andhra

Pradesh & Tamil Nadu in the south. More than 80% sugar factories are below

3500 TCD capacity and balance have higher capacities. About 44% of the

Indian sugar factories are in the co-operative, 9% in Public sectors and balance

47% in the private sector.

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:

a) 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 and existing sugar factory and a new factory,

by exercise of powers under the Sugar Control Order, 1966.

b) 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.

c) 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. Expansion of capacities and diversification into absolute alcohol/ethanol and

cogeneration power projects

e. Effecting adequate capacity building within and without

f. Maximizing sugar exports for value addition

g. Effective marketing in the national and international markets

h. Product quality and diversification


i. 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, 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.

Indian Sugar Industry

The Indian sugar Industry registered a moderate growth of 7% in sugar

production during 2011-12 season in comparison to 2010-11 season. This has

been significantly lower in comparison to the previous two seasons wherein the

growth has been around 29-30%. The year also saw an increase both in the

area under cane cultivation and yield per hectare which resulted in an increase

in sugarcane production by 4% at 358 million tones. A marginal increase in

recovery and an improved drawl rate of cane to sugar mills resulted in

increased sugar production in the country to 26.3 million tones during 2011-

12 from 24.4 million tones in 2010-11.


The overall yield of sugar cane in India has shown an improvement during the

year at 70.3 tonnes per hectare. Major sugar producing states – Karnataka,

Tamil Nadu and Maharashtra have shown a decline in comparison to the

previous season whereas states such as Uttar Pradesh, Andhra Pradesh, and

Uttaranchal recorded a higher yield during 2011-12 season. Even though the

overall recovery of sugar from cane in the country has gone up to 10.25% from

10.17% during the year, the largest sugarcane producing state of Utttar

Pradesh, recorded a marginal decline in recovery at 9.07% as against 9.14%

during the previous season. The recovery of sugar in the states of Maharashtra

and Karnataka has shown improvement over the previous year.

The Government set up a committee under the Chairmanship of Dr. C.

Ragarajan, the chairman of Economic Advisory Council to the Prime Minister,

to look into all the issues of deregulation of sugar sector. The committee has

recently submitted its report and has inter-alia recommended developing a

sugarcane pricing mechanism linked with sugar prices, doing away with

controls such as levy obligation, regulated release of sugar and command area

concept by providing freedom to the farmers to supply cane to sugar mill of

their choice. The recommendations are aimed at ushering in innovations,

investments and improvements in the efficiencies of sugar mills by way of

competition among them. The panel also recommended relaxation of

regulations over the usage of by-products like molasses, bagasse, ethanol and

power co-generation to help the sugar mills enhance the viability of the sector

and reduce the cyclical nature of industry. The report advocated devising a

stable trade policy for import and export of sugar to ensure that the industry

benefits from the global market.

Policy on Bagasse based Cogeneration Power Projects

Central Policy

The Electricity Act, 2003 encourages efficient utilisation of resources. The Act

provides for the encouragement for renewable energy and cogeneration, while

determining the regulatory tariff structure.

This Act guides the regulatory commissions for fixing the tariffs for renewable

energy sources, including bagasse based cogeneration power projects. The Act

defines the functions of the SERCs in section 86 (1), a) to k).

This section directs the SERCs for promoting cogeneration & generation of

electricity through renewable energy sources by providing suitable measures

for connectivity with the grid and sale of electricity to any person. SERCs are

advised to specify, for purchase of electricity from such sources, a percentage

of total consumption of electricity in the area of a distribution licensee.


The Government of India, through the Ministry of New Renewable Energy

(MNRE), is encouraging the existing and new sugar factories to set up

cogeneration power plants.

In order to achieve the revised potential of about 5000 MW power from

cogeneration from sugar factories in India, the Ministry has been undertaking

promotional efforts under the National Program on Biomass / Cogeneration

Power since 1994-95. Apart from providing guidelines to the States for

purchase of exportable power from such projects, the Ministry has been

offering several promotional and fiscal incentives to this sector.

The specific incentives from the Ministry included capital grant and soft loan

during 1995-1999 period, interest subsidy from 1-3 % depending on the

temperature and pressure configuration during 1999-2004 period, subsidy for

preparation of detailed project reports and assistance in syndication of loans,

financial assistance for State Nodal Agencies, consultants, industry

associations for undertaking promotional efforts, etc.

The prevailing policy again encourages development of these projects in co-operative

and joint sectors, by providing capital subsidy up to maximum of Rs. 8

crore per project, depending on the pressure and temperature configuration

used. The capital incentive for the private sector is substantially lower, due to

commercialisation of these projects in this sector.

State Policy

To encourage renewable energy power projects in the State, Government of

Madhya Pradesh had taken initiative and formulated bankable Power Purchase

policies based on the source of renewable energy. The policies were mostly in

line with the guidelines issued by MNRE. Madhya Pradesh Electricity

Regulatory Commission (MPERC) has issued power purchase policy through

the public hearing process for different renewable energy sources.

MPERC Order

a) MPERC has issued an Order dated April 01, 2013 determining tariff for the

purchase of electricity by the respective transmission / distribution companies

from non-conventional energy sources including bagasse based co-generation

projects.

The main features of the MPERC order are indicated below:

i. Annual PLF of 53% for co-generation plants for the purpose of tariff

determination

ii. O & M expenses for co-generation units shall be taken at 3% with an annual

escalation of 5% per annum

iii. Interest on working capital at the rate of 13.5% on two months bills


iv. Auxiliary consumption of 8.5%

v. Overall fuel price at Rs.1583/- per MT for the purpose of tariff determination of

co-generation plants

vi. The fuel cost escalation at 5%per annum for factoring the same in tariff

computation

vii. Station heat rate of 3600 kcal/kg with bagasse GCV of 2250 kcal/kg.

viii. Levelised tariff for co-generation projects as Rs.6.28 per unit for 20 years of the

project life.

The exportable surplus power generated from the proposed project for sale to

transmission/ distribution licensees qualifies under Renewable Purchase Obligations

and the MPERC tariff order on bagasse based cogeneration projects.

5 Imports vs. Indigenous production

No imports for production have been proposed for the project.

6 Export possibility

The project is captive in nature to meet the power requirement of the Sugar Mill.

Balance power shall be given to state electricity board.

7 Domestic/export markets

The project is captive in nature to meet the power requirement of the Sugar Mill.

Balance power shall be given to state electricity board.

8 Employment generation (direct and indirect) due to the project

Total 125 number of employee are working in Sugar Mill. With the commencement of

power plant operation , 40 number of employment will be generated.

9 PROJECT DESCRIPTION

1. Types of project: Bagasse based Co-gen power plant of 30 MW associated with

Sugar Mill.

2. Location of the Project

District/State Taluka Village Khasara No Area in acres

Narsingpur

Madhya Pradesh

Salichouka

Pondar

132/1 Ga – 0.951

133 - 0.150 135/1 - 0.247

132/1Kha- 1.112

132/1Gha- 0.428

11.935 Acres


134 0.673

135- 0.247

132/1Ka 0.966 __________________Hect

area=4.774__

M/s. Narmada Sugar Private Limited, Pondar, Salichouka Dist. Nashinghpur,

Madhya Pradesh is located on State Highway No. 22 at Pondar, Salichouka

which is 195 kms from Bhopal and 70 kms from Narshinghpur. The nearest

railway station is at Salichouka which is only 4 km from the factory. The

airport situated at Bhopal and it is 195 kms from the factory. The other

accessible airport is at Jabalpur.

3. Details of alternate site: The Co generation power plant is associated with Sugar

Unit and hence deliberation of alternative sites is not applicable.

4. Size or magnitude of operation:

Details Capacity

Bagasse based co Gen power plant of 30 MW

5 Project description with process details:

Design Philosophy

The proposed Cogen Project of 30 MW to be set up at NSPL, will operate round

the year at estimated average 80% PLF for the first year, 90% for second year,

100% for third year and thereon, covering 160 season days of the sugar factory

and 42 off season days. The proposed Cogen Project will be designed for

average crushing rate of 4000 TCD (227.27 TCH). All the equipment for the

proposed Cogen Project will be designed for a minimum of 4152 hours of

operation in a year, on a continuous basis. The Cogen Project will operate on

bagasse during season and saved & procured bagasse from group sugar mills,

in off-season period. The proposed Cogen Project will be designed to produce

surplus power after meeting the entire requirements of steam of the sugar mill,

both during season and off season periods. Steam requirement for the sugar

crushing of upto 150 TPH will be supplied by the proposed 30 MW cogen plant.

The bagasse handling system shall start from the bagasse yard and excess

bagasse will be returned back to the yard. There is a separate storage yard for

bagasse, for feeding the Cogen Project boiler, with reclaiming conveyors. Direct

conveying of bagasse from last mill to cogen boiler will be provided. The ash


handling system will be submerged. Ash will be taken and stored in silo and

disposed off in trucks, to cement factories or utilized in compost.

The Cogen Project will generate a gross output of about 30000 KW around the

year. All the internal High Pressure (HP) / Medium Pressure (MP) / Low

Pressure (LP) steam and power requirements for cogeneration power plant

auxiliaries will be met. During sugar season the project will supply upto 90.91

TPH of 1.5 ata steam to the sugar process, 5.68 MW power for sugar

processing, 2.70 MW for cogen auxiliaries & 0.10 MW for colony. After meeting

these requirements, the Cogen Project will export 21520 KW. The power

supplied at 11 KV will be stepped down to 415 V AC or 110 V DC (as required

for internal consumption of the sugar complex and cogeneration plant

auxiliaries), as well as stepped up to 132 KV for connecting and paralleling

with grid.

Design Basis

The design basis for the proposed Cogen Project is outlined below:

a) The sugar mill will stabilize operations at 4000 TCD. The cogen project is

designed for crushing rate of 227.27 TCH.

b) As discussed and explained above 126 kg/cm2 pressure and 5450 C

temperature configuration will be employed

c) Steam and power consumption for sugar process, respectively at 40% on cane

and 25 KWh/TCH (excluding cogen auxiliaries).

d) Auxiliary power consumption of 9% for season & 9.5 % for off-season of

generated capacity for cogeneration power plant is considered. Variable

frequency drives for boiler fans, feed pumps, fuel feeding system, ACC fans in

order to maintain or better the above consumption figure, will be deployed.

e) Three HP heaters will be used in order to improve the efficiency of the power

cycle.

f) The average specific steam consumption during season & off-season is

respectively at 5.00 kg/kW and 3.97 kg/kW will be achieved. The heat rates

have been worked out based on heat balance diagrams for season and off-

season periods.

Steam & Power Cycle Design

Sr. No. Item Unit Value

Season Operation

1 Avg. cane crushing TCD 5000

2 Gross season days nos. 160

3 Net season days nos. 160


4 Hrs. / day nos. 22

5 Normal cane crushing TCH 227.27

6 Cane crushed Lakh MT 8.00

7 Bagasse generation % cane 29

8 Bagasse generation TPH 65.91

9 Bagasse for bagacillo / handling

loss

% cane 0.80

TPH 1.82

10 Bagasse available for new

boilers

TPH 64.09

11 Total equivalent bagasse

available for new boiler

TPH 64.09

12 Bagasse used by new boiler Kg steam /

kg

2.72

13 Bagasse used by new boiler TPH 55.15

MT 211776

14 Bagasse saved for off season MT 13824

15 Steam generation TPH 150.00

16 Steam consumption TPH

16.1 HP steam for SJAE & GSC 0.70 0.39

HP Heater III 6.50 9.75

Total 10.14

16.2 HP steam @ 28kg/cm2

HP heater III 6.50 9.75

16.3 MP steam @ 11kg/cm2

HP heater I 6.50 9.75

Sub Total 9.75

16.4 LP steam @ 1.5kg/cm2

Sugar process % cane 40.00 90.91

De – aerator 5.00 7.50

D/s water addition 2.00 1.97

Sub Total 96.44

16.4 Condensing steam 23.92

16.5 Total 150.00

17 Power generation MW 5.00 30.00

18 Power consumption MW

Sugar process kWh/TCH 25.00 5.68

Colony 0.10

Cogen auxiliaries 9.00 2.70

Total 8.48

19 Power export

MW 21.52

MUs 82.64

20 Total no. of days / year Nos. 202


Off Season Operation

21 Off seasion fuel requirement TPH 43.75

22 Total no. of aff season days Nos. 42

23 No. of hrs / day Nos. 24

24 Steam generation TPH 119.00

25 Steam consumption TPH

25.1 HP steam @ for SJAE & GSC 0..70 0.83

HP heater II 6.50 7.74

Total 8.57

25.2 HP steam @ 28kg/cm2

HP heater II 6.50 7.74

25.3 MP steam @ 11 kg/cm2

Sugar process

HP heater I 6.50 7.74

Total 7.74

25.4 LP steam @ 1.5 kg/cm2

De – aerator 5.00 5.95

D/s water 2.00 0.12

Total 5.83

25.4 Condensing steam 89.13

25.5 Total 119.00

26 Power generation MW 3.97 30.00

27 Power consumption MW

Cogen auxiliaries 9.50 2.85

Sugar process 0.10

Colony 0.10

Total 3.05

28 Power export

MW 26.95

MUs 27.17

29 Total power export MUS 109.80

30 Boiler size (126 kg/cm2 & 545

deg C)

TPH 1 150

31 TG size (121 kg/cm2 &540 deg

C)

MW 1 30

Bagasse / Fuel Balance

The bagasse and fuel balances are indicated in the following table:

Sr. No. Item Value

Season Off season

1. Crushing rate, TCH 227.27 -


2. Bagasse generation at 29.00 % on cane, TPH 65.91 -

3. Bagacillo / handling loss at 0.80 % on cane,

TPH

1.82 -

4. Bagasse available as fuel at 28.20 % on cane,

TPH

64.09 -

5. Total equivalent bagasse available, MT 225600 -

6. Bagasse required by new boiler, TPH (MT) 55.15

(211776)

43.75

(43650)

7. Bagasse saved / available for off season

operation, MT

13824

8. Days on saved bagasse 13

9. Bagasse saved / available for off season

operation, MT

30000

10. Days on procured bagasse from group sugar

Mills

29

11. Total off season days 42

Power Balance

Following table gives the power balance for the season and off-season

Sr.

No.

Item Value

Season Off season

1. Power generation, MW 30.00 30.00

2. Power consumption, MW

Sugar process ( @ 25kW/TCH after mill/

fibrizor drives electrification)

5.68 0.10

Colony 0.10 0.10

Cogeneration auxiliaries 2.70 2.85

Total 8.48 3.05

3. Power export, MW 21.52 26.95

4. Power export at design capacity level, MU 82.64 27.17

5. Total, season + off season MU at design levels 109.80

Interfacing Scheme

The proposed Cogeneration plant would be generating at a voltage of 11 kV.

The voltage will be stepped up to 132 kV and paralleled with the grid at the

same voltage level. The 132 kV transmission lines from the Cogen Projects’s

switchyard will be connected by LILO arrangement to existing EHV line by

appropriate LILO substation, about 0.5 km from site.

Capacity Utilization & Power Export

The installed capacities, expected capacity utilization levels and exportable

surplus for first 5 years of operation, are indicated in the following Table 3.7:


Capacity Utilization & Power Export

Item Year

1 2 3 4 5

Season

No. of days 160 160 160 160 160

No. of hrs. 24 24 24 24 24

Export capacity, MW 21.52 21.52 21.52 21.52 21.52

Export capacity, MU 82.64 82.64 82.64 82.64 82.64

Off-Season

No. of days 42 42 42 42 42

No. of hrs. 24 24 24 24 24

Export capacity, MW 26.95 26.95 26.95 26.95 26.95

Export capacity, MU 27.17 27.17 27.17 27.17 27.17

Capacity utilization, % 80 90 100 100 100

Exportable surplus, MU’s

Season 66.11 74.37 82.64 82.64 82.64

Off Season 21.73 24.45 27.17 27.17 27.17

Total, excluding losses 87.40 98.33 109.25 109.25 109.25

Main Plant & Machinery

Boiler

a) The steam generating system for the proposed Cogen Project will consist of one

multi-fuel fired boiler with a Maximum Continuous Rating (MCR) of 150 TPH,

with the outlet steam parameters at 126 kg/cm2 and 5450 C. The tolerance on

the super-heater outlet temperature shall be ±5°C. The combustion system of

the boiler shall be travelling grate, continuous ash discharge. The boiler

efficiency, firing 100% bagasse, shall be 70% on the Gross Calorific Value

(GCV) basis. The dust concentration in the flue gases leaving the boiler shall be

a maximum of 150 mg/Nm3.

b) The design of boiler shall be of single drum, natural circulation, radiant furnace

with water cooled membrane walls, super-heater with inter-stage de-super

heater and balanced draft. Boiler shall have all its other accessories like

economizer and air pre-heater.

c) The boiler shall be top supported and shall be of outdoor type. The boiler shall

be capable of a peak generation of 110% of the MCR generation for a period of

one hour in a shift. The operating excess air percentage at the outlet of the

boiler shall be less than 30%.

d) Boiler shall be essentially provided with high pressure heater for improved

efficiency.

e) Boiler feed water


The boiler shall be capable of operating with the following feed water quality

requirements.

Feed Water Quality Requirements

pH : 8.8 – 9.2

Oxygen : 0.007 ppm

Hardness : 0

Total Iron : 0.01 ppm

Total Copper : 0.01 ppm

Total Silica : 0.02 ppm

Hydrazine : 0.01 – 0.02 ppm

Specific electrical conductivity at 25C measured

after cation exchanger in the H + form and after

CO2 removal (max)

: 0.5 micro-ohms / cm

Sodium + Potassium (max) : 0.01 ppm

f) Steam Purity

The boiler shall be capable of supplying uninterrupted steam at the MCR rating

with the following steam purity levels.

Total dissolved solids : 0.1 ppm (max)

Total Silica (max) : 0.02 ppm

Boiler Auxiliary Equipment

a) Fuel handling

The fuel for the cogeneration power plant operation during the season will be

bagasse. The bagasse from the storage area and last mill will be conveyed to

the boiler by a combination of belt and chain slat conveyors. The system shall

have provision for returning the excess bagasse to the storage yard. The

bagasse handling system shall be designed for a capacity of about 90 TPH.

b) Ash handling

Dense phase ash handling system shall be used for fly ash collection. This ash

may be utilized for brick manufacturing activity/ spreading at agricultural

field/ for composting.

Turbine & Generator

a) There will be one no. 30 MW turbo generator. The turbo generator shall

be extraction cum condensing machine. The following shall be the salient

design parameters for the machine.

Turbine Characteristics


Item Season Off season

Steam flow at the turbine stop valve at boiler MCR, TPH 150 119

Steam pressure at the turbine stop valve, kg/cm2 121 121

Steam temperature at the turbine stop valve, 0C 540 540

Power factor (lagging) 0.8 0.8

Generation voltage, KV 11 11

Ambient temperature for electrical equipment design, °C 50 50

Parallel operation with grid As required, with grid

Grid voltage 132KV

Duty requirements Continuous 8000 hrs.

System frequency 50 +5%

Auxiliaries

Cooling System

To conserve water, decrease project lead time, decrease O&M costs associated

with large cooling towers especially with this site having high TDS of above

2000 ppm in raw water, it is decided to opt for air cooled condenser. The ACC

will be typical A-frame construction with 5/6 modules & 1 street. Air cooled

steam condenser is required to condense the exhaust steam from the turbine

into the condenser at constant pressure and temperature and required

maintain the backpressure at the turbine exhaust flange.

Air cooled condenser shall be used for exhaust stem & auxiliary cooling tower shall be

used for cooling water requirements of cogen power plant.

Pumps

The head / flow characteristics of all pumps required in the proposed

cogeneration power plant viz., boiler feed pump, condensate extraction pumps,

cooling tower pumps, etc. will be such that the head continuously rises with

decreasing capacity, until a maximum head is reached at zero flow. Maximum

run-out flow should at least 130% of duty point flow.

The shut off head should be at least 1.1 times the duty point head and should

not be more than 1.2 times the duty point head.

The power consumption curves should be of non-overloading type with the

maximum power occurring at or near duty point or towards maximum run out

flow.

Net Positive Suction Head (NPSH) curve should be a continuously rising one in

the range of operation, from the minimum flow in the range to the maximum

flow in the range. Required NPSH values shall not exceed available values over

the entire range from minimum to rated flow.


The efficiency curve should be fairly flat in the range of +1% of the BEP flow.

The duty point of the equipment should preferably lie in this flat region, but

not at a flow higher than the BEP flow.

Condensate system

The sugar factory generates more condensate than the process steam it

receives. The extractions from the turbines are taken to the sugar process, and

a substantial part of this returns as condensate, which is called as the exhaust

condensate. The exhaust condensate along with the condensate from the

turbine surface condenser will be used to meet the complete feed water

requirements of the high-pressure cogeneration plant boiler, during the season.

The exhaust condensate from condensate storage tank will be available at the battery

limits, at a minimum temperature of about 900 C. Minimum 90% of the steam

supplied for sugar process will be returned to the boiler circuit i.e. to the de-aerator.

No vapour condensate shall be used as boiler feed water.

Water Requirement, Supply & Treatment

The water requirement for the proposed Cogen Project operation will be for

boiler blow down losses and make up, auxiliary cooling tower blow down and

evaporation losses and water required for washing / cleaning, as well as for

potable purposes. Average water requirement has been worked out at peak of

554 m3/day.

With process condensate recovery, the DM water requirement is 15.35 TPH in

season. However, considering exigencies and start up requirements a DM plant

of 30 m3/hr is proposed. The borewell water is clear with low silica levels of

below 0.5 ppm and hardness of about 300 ppm.

The quality of the treated water at the outlet of the DM plant is as follows:

Quality Requirement for the DM water Plant

Hardness, ppm : 0

pH @ 250C : 8.8 – 9.2

Conductivity @ 250C (μS/cm) : 0.5

Oxygen (maximum), ppm : 0.007

Total Iron (maximum), ppm : 0.01

Total Copper (maximum), ppm : 0.01

Total Silica (maximum), ppm : 0.02

Residual hydrazine, ppm : 0.01 –

0.02

Vessels & heat exchangers


The design shall be as per ASME Sec. VIII, HEI & TEMA. All heat exchangers and

vessels for steam application like HP heater, de-aerator, etc. shall be designed for full

vacuum conditions. The heat exchangers shall be provided with start up vent

connections. The design shall have provision for complete drainage on both shell and

tube sides. The heat exchangers shall be provided with emergency drains, shell side

safety valves, and individual by passes, with manual valves. A minimum corrosion

allowance of 1.6 mm shall be provided. The tube bundle shall be of removable type.

The tube material shall be stainless steel, unless otherwise specified in the

specifications.

Piping

a) All piping system shall be designed as per ASME B 31.1. In addition

statutory requirements of Indian Boiler Regulations (IBR) shall be complied

with for those lines under the purview of IBR.

Stress analysis shall be carried out for all possible operating modes and shall

be as per ASME B 31.1 requirements. Supports, guides, directional anchors

shall be selected to satisfy all the operating conditions.

b) Pipe sizing

All piping shall be sized considering the allowable velocity and allowable pressure drop

in the system.The suggested flow velocities of various mediums are,

Recommended Velocities for Water & Steam

Superheated steam :

45 – 55 m/sec

Saturated steam :

15 – 30 m/sec

Boiler feed water

- Pump suction :

< 1 m/sec

- Pump discharge :

2.5 – 4 m/sec

Water

- Pump suction :

< 1 m/sec

- Pump discharge :

2.5 m/sec

Condensate

- Pump suction :

0.6 – 0.7 m/sec

- Pump discharge :

2.5 m/sec

Compressed air : 12 – 18 m/sec


Lube oil

Pump suction :

0.3 – 0.4 m/sec

Pump discharge :

1.0 m/sec

c) Piping Materials

The piping material selection shall be based on the following recommendations:

- For temperatures above 5450 C, SA 335 Gr. P91 shall be used.

- For temperatures above 5100 C, SA 335 Gr. P22 shall be used.

- For temperature 4000 C - 5100 C, SA 335 Gr. P11/P12/P22 shall be used.

- For temperature 3990 C and below SA 106 Gr. B/C or ASTM A-53 seamless

shall be used.

- For HP / LP chemical dosing SA 312 TP 304, stainless steel shall be used.

- All pipe fittings other than those mentioned shall confirm to ASTM A 234

standard and dimension as per ANSI B 16.9 / B 16.28 / B 16.11.

- For cooling water, raw water, service water, safety / relief valve exhaust

IS:1239 / IS:3589 ERW / EFW pipes shall be used.

- For service air applications the piping shall be IS 1239 Black Medium Class.

- For instrumentation air applications: Galvanized pipe (Iron Pipe) to IS:1239

Part I shall be used.

- The fittings for ERW applications shall be as per IS 1239 Part II.

d) Piping Colour Code

As per the international colour code, all piping in the proposed Cogen Project

will be coloured viz., red for fire fighting, yellow for lube oil, light green for DM

water, dark green for treated water, etc.

Insulation

All exposed portions of the equipment and piping which operate at

temperatures of 600 C and above, shall be thermally insulated so that the

temperature on the outer surface of the cladding shall not exceed by more than

200 C above ambient temperatures indicated in site data. The specified

insulation thickness shall not include the thickness of wire netting, finishing

cement or any other finishing or weatherproofing application. Insulation shall

not fill the contours of the expansion bellows. In refractory walls suitable

expansion gaps shall be provided at regular intervals.

Electricals

a) All equipment for the proposed Cogen Project shall be designed for

satisfactory operation for a life span of minimum 40 years, under specified site


conditions. All equipment shall be suitable for rated voltage with 10%

variations and frequency of 50 Hz with +5% variation. All equipment shall

comply with the applicable provisions of relevant IS / IEC / IEEE standards.

b) The generator shall be of synchronous type with brushless excitation

system, and shall be designed for rated voltage and frequency of 11 kv and 50

Hz, with corresponding variations of +10% and +5%. The generator shall have

closed circuit air-cooled system with external water circuit and the windings

shall have class ‘F’ insulation, with temperature rise limited to class ‘B’

insulation limits, under specified cooing water and ambient air temperatures.

c) All auxiliaries of the cogeneration power plant shall be connected at 415 V

level, by providing 11 / 0.415 KV distribution transformers of required

capacities.

d) Surplus power from the proposed Cogen Project, after meeting the in-house

loads of cogen auxiliaries, shall be exported to grid by stepping up the voltage

to 132 KV, through one no. 32/40 MVA, 11/132 KV generator transformer. The

switchyard equipment at the Cogen Project substation, the tie line and

equipment at LILO substation located within factory will be designed in

accordance with the requirements specified by the grid. Due approval to power

evacuation scheme from the competent authority (Electrical Inspectorate), as

per the provisions of the electricity act, will be taken.

e) The nominal voltage of main DC system for protection and control systems,

turbine emergency oil pumps and emergency lighting shall be 110 V.

f) UPS system with rated voltage of 220 V AC shall be envisaged, for meeting

UPS power requirements of the plant DCS and other instrumentation / control

loads.

g) Breakers for various systems shall be as below:

132 kV breaker : SF6 circuit breaker

11 kV breaker : VCB / SF6 CB

415 V breaker : Air break circuit breaker

h) Connection between the turbine generator and the 11 kV switchgear shall be

through phase segregated bus duct. All other connections at 11 kV (between 11

kV switchgear and generator transformer / distribution transformers) shall be

carried out through 11 kV, UE grade, armoured, XLPE insulated cables.

Connection between secondary of the auxiliary transformers and the respective


PCC / Panels shall be through non-segregated phase bus duct, with electrolytic

grade Aluminium alloy enclosure. All other LT connections (power as well as

control) shall be with PVC insulated / XLPE, armoured, Aluminium / Copper

cables.

i) The cables shall be rated for the site ambient and ground temperatures,

grouping and soil resistivity. Cables shall be selected to limit the maximum

voltage drop at equipment terminals, during normal operation and starting

conditions, to be well within permissible values.

j) Cables in circuits controlled by circuit breakers shall be capable of

withstanding the maximum system fault currents till that breaker opens by

main protection. Fuse protected cables shall withstand maximum let through

fault current for fuse operating time. For 11 kV grade cables, screen shall be

suitable for carrying earth fault current of 1 kA for a duration of 1 sec.

k) Current ratings of the cables shall be assigned considering continuous

conductor temperature of not more than 700 C for PVC and 900 C for XLPE.

Cables should also be sized to carry system fault current for the duration

specified in above without exceeding the temperature limit of 1600 C for PVC

and 2500 C for XLPE.

l) For 415 V system, ACB shall be provided for rating 400 A and above, and

fuse switch / switch fuse units shall be provided for lesser ratings. Motor

feeders shall have fuse switch / switch fuse units, over load relays and air-

break contractors. Motors of rating above 15 KW shall be provided with star-

delta starters, depending on application, and shall be provided with static

motor protection relays.

m) Motors for auxiliaries shall be of three-phase induction squirrel cage type.

All motors shall have class ‘F’ insulation, with temperature rise limited to class

‘B’ limits under specified ambient and voltage / frequency conditions.

n) All equipment shall be designed to withstand the maximum fault levels of

31.5 kA for 3 sec in 66 kV, 40 kA for 3 sec in 11 kV systems and 50 kA for 1

sec in 415 V systems, under voltage variation of ±10%. Auxiliary transformers

and all accessories shall be capable of withstanding for two seconds without

damage during any external short circuit at the terminal.

o) All switchgears, Motor Control Cubicles (MCC) & Distribution Boards shall

be capable of withstanding the maximum fault currents that may arise. They

will be designed after due considerations for the maximum fault levels on high

voltage system, negative tolerance on transformer impedance and maximum

possible fault clearing time on ultimate back up protection (but not lower than

one second in any case).

p) Details of protection will be as indicated below:


Protection Details

11 kV switchgear : IP42

LT switchgears : IP52

Switchgears located

outdoor

: IP55

LT bus duct enclosure : IP52 (in the indoor portion)

IP55 (in the outdoor portion)

Control panels : IP42 (in air-conditioned area)

IP52 (in other areas)

Push button stations : IP54 (indoor)

IP55 (outdoor)

Synchronous generator : IP54

Induction motors : IP54 (indoor)

IP55 (outdoor)

q) Neutral grounding will be as indicated below:

i. 11 kV system neutral grounding shall be of low resistance earthed type to

limit the earth fault current to 100A, which shall be earthed by providing

neutral grounding resistor on the neutral of the generator.

ii. All 415 V transformer neutrals and 66 kV transformer neutral shall be

solidly earthed through bolted links.

r) The system shall be compatible for accepting / sending signals from / to

DCS. Winding, bearing and cooling circuit (where applicable) RTDs shall be

hooked up to DCS for signal processing and necessary trippings shall be

arranged from DCS, for tripping of the corresponding motor.

s) Signals from all transformers for winding temperatures, oil temperatures, oil

level gauges, Buchholz relay outputs for alarm and tripping shall be brought to

DCS.

t) Status (ON / OFF / TRIP) of all breakers, LT breakers in PCCs and all motor

feeders shall be brought to DCS, for plant monitoring. Control of motor feeders,

as per system requirement, shall also be arranged for control from the DCS

system.

Control & Instrumentation

The instrumentation and control system will be based on Distributed Control System

(DCS) philosophy. It will be designed to provide monitoring and control capabilities to

ensure safe and reliable operation, minimize operator manual actions and alert

operators as to any conditions or situations requiring manual intervention in a timely

manner. The control functions shall be back up by interlocks and safety systems


which cause pre-planned actions in case where unsafe conditions develop faster than

controls or the operator can be expected respond. All I&C equipment will be of proven

design and will be selected to achieve highest level of plant availability and facilitate

equipment maintenance.

All field control elements for modulating controls will have actuators of

pneumatic type. Signals from various process parameters are electrical signals

generated by field mounted electronic smart type transmitters. The above

signals are processed in the DCS cabinets to produce electrical signal outputs

of 4 – 20 mA DC, which will be converted to control pneumatic signal of 0.2 –

1.0 kg/sq. cm (g), through E/P converters to operate the pneumatic actuators.

6 Raw Material Requirement : Following raw material will be required

Waste material of sugar unit i.e. Bagasse (2.55 lakh per Annum) will be used

as raw material ( fuel) for proposed co gen power plant

7 Recycling and Reuse

Bagasse is the waste material of sugar mill which is proposed to be used for co

generation of power , hence waste are being already recycled and re-used 100 %.

8 Water source:

Only 74 KLD of ground water shall be abstracted for the purposes of CPP out

of total requirement of 554 cum per day water , as 480 KLD water will be

available as condensate from sugar manufacturing unit. .

9 Electric System

Total power required is 30 MW for the sugar mill and residential area.

10 Solid waste management:

Fly ash form boiler shall be mixed with the press mud and shall be given to

farmer

11. Site analysis

i. Connectivity

M/s. Narmada Sugar Private Limited, Pondar, Salichouka Dist.

Nashinghpur, Madhya Pradesh is located on State Highway No. 22 at

Pondar, Salichouka which is 195 kms from Bhopal and 70 kms from

Narshinghpur. The nearest railway station is at Salichouka which is only 4

km from the factory. The airport situated at Bhopal and it is 195 kms from

the factory. The other accessible airport is at Jabalpur.


ii. Land form, land use & land ownership:

The proposed site of co generation power plant is located within the existing

premises of sugar manufacturing plant. The entire land is in possession of

proponent and no additional land is required for the project.

iii. Topography :-

The topography is almost plain with elevation of 350-347mRL . One local

nalla is passing adjacent to the site which meets the Umar river which is

formulate main drainage system of the area.

S. No.

Particulars Details

1 Co-ordinate 1. 22°51'12.60"N- 78°39'2.67"E 2. 22°51'16.24"N- 78°38'58.12"E 3. 22°51'22.80"N- 78°39'5.94"E 4. 22°51'18.52"N- 78°39'12.07"E 5. 22°51'12.67"N - 78°39'7.49"E

2 Height above mean sea level

350-347mRL

3 Nearest Town Gadarwara - 14.0km

4 Nearest Railway Station Sali Chouka Road - 3.50km - SE

5 Nearest Airport Jabalpur – 148km

6 Nearest Highway/Road Pipariya- Gadarwara SH 22 - Adjoining

7 Hills/Valley None within 10km radius

8 Ecological Sensitive Zone

None within 10km radius

9 Reserve Forest None within 10km radius

10 Nearest Village Salichouka - 1.0km - E

11 Nearest River/ Nalla Dudhi River - 5.0km - W Umar (Shkhi) Nadi - 3.50km - NE Local Nalla – Adjoining - E

12 Other industries in 5 km radius

None

13 Surrounding Features North : SH-22 South : Agricultural Land East : Agricultural Land

West : Agricultural Land


iv. Existing land use pattern: The land use of the area is defined by the

operational unit of sugar plant.

Sn Particular Details

1. Built up area for power house 3050 sq mt

2. Road Area 1500 sq mt

3. Water Storage 500 cum

4. Fuel Storage Area 600 sq mt

5. Sugar Fcatory Area 23.5 Acres


v. Existing infrastructure: M/s NSPL is having sugar manufacturing unit

within the existing premises. Required infrastructure like residential colony

, medical facility and other facilities have already been developed by the

group.

vi. Climate data from secondary sources:

Meteorological data month of 15th Sept., 14 to 14th Oct. 2014

Date

Temperature OC Relative Humidity %

Morning (8.00) Evening (17.00) Cloudiness %

Max Avg. Min Max Avg. Min Wind

Dir.

Wind

Speed km/h

Wind

Dir.

Wind

Speed km/h

Mor. Eve.

15 31 26 22 90 70 14 NW 3.7 C 0 20 10

16 32 28 23 89 71 41 C 0 N 9.3 20 10

17 32 28 23 89 69 44 C 0 C 0 20 10

18 33 28 23 92 70 45 C 0 N 5.6 20 10

19 33 28 24 85 66 45 C 0 NW 5.6 20 10

20 33 29 25 88 65 38 C 0 NW 5.6 20 20

21 33 28 22 91 71 46 C 0 E 11.1 20 20

22 33 28 24 88 65 38 C 0 C 0 20 20

23 33 28 24 88 59 37 NW 3.7 NW 3.7 20 20


24 32 28 24 84 59 38 C 0 W 3.7 10 10

25 33 28 23 79 58 29 C 0 C 0 10 20

26 33 28 22 79 55 26 C 0 C 0 20 20

27 33 28 23 78 55 28 S 3.7 C 0 - -

28 34 28 23 75 54 29 C 0 C 0 - -

29 34 28 22 79 54 26 C 0 C 0 20 20

30 34 28 22 75 56 30 C 0 C 0 - -

1 33 28 23 80 53 32 C 0 C 0 - -

2 34 28 21 76 58 31 C 0 NE 11.1 - 60

3 33 28 22 82 57 38 S 5.6 C 0 20 10

4 34 28 23 75 55 29 C 0 C 0 20 10

5 33 28 23 75 55 36 C 0 NE 3.7 - -

6 32 28 23 81 57 36 C 0 SE 9.3 - 20

7 32 27 22 98 80 50 C 0 E 3.7 20 60

8 31 26 21 88 68 49 C 0 E 3.7 20 40

9 32 27 22 90 66 37 C 0 C 0 40 10

10 32 27 22 85 65 43 C 0 C 0 20 40

11 32 26 21 87 54 19 C 0 C 0 20 20

12 32 25 19 76 50 16 C 0 NE 7.4 20 20

13 26 24 22 94 84 75 NE 11.1 NE 11.1 40 60

14 27 24 21 91 82 67 C 0 C 0 60 60

Meteorological data month of 15th Oct., 14 to 14th Nov., 14

Date

Temperature OC Relative Humidity % Morning (8.00) Evening (17.00) Cloudiness %

Max Avg. Min Max Avg Min Wind Dir.

Wind Speed km/h

Wind Dir.

Wind Speed km/h

Mor. Eve.

15 30 25 20 87 66 38 NE 5.6 C 0 20 10

16 31 26 20 87 63 34 C 0 C 0 - -

17 32 26 20 82 58 32 C 0 C 0 20 40

18 32 26 21 80 62 38 C 0 C 0 20 20

19 32 26 20 85 66 41 C 0 C 0 20 20

20 32 26 21 83 62 38 C 0 C 0 - -

21 30 24 19 87 59 30 C 0 C 0 - -

22 30 24 18 87 55 24 C 0 C 0 20 -

23 30 24 17 74 51 24 C 0 C 0 20 -

24 31 24 17 76 46 24 C 0 C 0 20 10

25 26 24 22 79 67 61 S 3.7 C 0 20 20

26 27 23 19 75 58 35 C 0 S 3.7 20 20


27 29 24 19 82 58 26 S 3.7 C 0 20 -

28 29 23 17 86 58 26 C 0 C 0 20 10

29 31 24 17 83 52 26 S 3.7 C 0 20 -

30 31 25 19 69 52 24 C 0 C 0 20 10

31 32 24 17 83 50 18 SW 3.7 C 0 20 -

1 31 24 17 81 54 24 C 0 C 0 20 -

2 30 24 17 83 56 25 C 0 C 0 20 -

3 30 22 16 80 52 15 C 0 C 0 20 20

4 31 24 16 67 50 19 C 0 C 0 20 20

5 31 24 16 83 58 24 S 3.7 C 0 20 10

6 30 24 17 76 52 16 C 0 C 0 20 20

7 30 22 16 72 51 23 C 0 C 0 20 20

8 30 23 16 79 53 19 C 0 C 0 20 20

9 30 22 16 77 51 15 C 0 NE 3.7 20 20

10 30 22 16 72 44 19 C 0 C 0 - -

11 30 24 19 65 47 32 C 0 C 0 20 10

12 30 24 19 69 45 24 C 0 C 0 60 -

13 31 24 17 75 52 23 C 0 C 0 20 -

14 31 24 17 82 48 16 C 0 C 0 20 -

Meteorological data month of 15th Nov., 14 to 14th Dec., 2014

Date

Temperature OC Relative Humidity %

Morning (8.00) Evening (17.00) Cloudiness %

Max Avg Min Max Avg Min Wind Dir.

Wind Speed km/h

Wind Dir.

Wind Speed km/h

Mor. Eve.

15 31 24 17 62 44 25 S 3.7 C 0 20 -

16 28 24 19 60 40 20 C 0 C 0 20 20

17 29 22 14 60 40 14 C 0 C 0 - -

18 27 18 10 75 41 10 C 0 C 0 - -

19 28 19 10 78 52 13 C 0 C 0 20 20

20 28 20 12 65 46 13 C 0 C 0 20 20

21 29 20 12 75 48 17 S 3.7 C 0 20 20

22 29 20 11 72 49 15 C 0 C 0 20 -

23 28 20 11 79 49 17 C 0 C 0 20 -

24 31 23 12 67 52 15 S 3.7 C 0 20 40

25 28 20 12 79 49 15 C 0 C 0 - -

26 27 20 12 79 45 15 SE 3.7 C 0 - -

27 28 20 11 66 47 16 SE 3.7 C 0 20 -

28 30 20 11 79 48 13 C 0 C 0 - -


29 30 22 14 66 47 15 C 0 C 0 - -

30 30 22 14 83 51 16 S 5.6 C 0 20 -

1 29 22 14 66 49 24 S 3.7 C 0 20 20

2 30 21 12 94 56 14 C 0 C 0 20 -

3 28 20 11 100 66 15 S 3.7 C 0 40 60

4 28 20 11 100 65 17 C 0 C 0 20 40

5 27 18 10 92 51 20 C 0 C 0 20 -

6 26 18 10 79 54 25 C 0 C 0 - 20

7 26 18 10 84 63 25 C 0 C 0 20 -

8 26 18 10 81 53 22 C 0 C 0 20 20

9 28 19 10 82 57 30 C 0 C 0 20 20

10 31 21 11 94 61 30 C 0 C 0 20 -

11 29 20 12 95 65 23 C 0 W 5.6 20 40

12 28 20 12 89 60 23 C 0 C 0 40 40

13 22 19 16 83 74 59 SE 7.4 C 0 40 40

14 31 24 17 94 87 80 C 0 C 0 40 40

4 Planning brief:

a. Planning concept:

Detail Planning Concept has been given in the project report

.

b. Population projection: The project is small in magnitude. No influx of

population is expected as labour shall be deployed from the local villages.

c. Land use planning (breakup along with green belt etc.)

Particulars Unit Area

Water Treatment Plant Sqm 1000.00

Cooling Tower Area Sqm 155.85

Power House (Ground Floor) Sqm 1026.00

Power House (Covered Area) Sqm 2052.00

Air Cooled Condenser Area Sqm 1629.77

D.G.Set (1&2) Area Sqm 59.50

Boiler Area Sqm 2637.65

Building Near Gate Sqm 495.84

Road Area Sqm 1500.00

Total 10556.61


d. Amenities/facilities

Rest shelters, Toilets, drinking water facilities, first aid facilities , regular

medical check up facilities has already been provided for labours , staff and

their families.

5 Proposed infrastructure

a. Industrial area (processing area)

All the existing infrastructure will be used.

b. Residential area (non processing area)

Small colony has already provided within the existing premises.

c. Green belt

Till date 1500 plants has been in survival stage at colony, plant premises.

d. Social infrastructure

Company shall evaluate the need base programme under CSR and shall

execute as per the given plan.

e. Drinking water management (source & supply of water):

The Drinking water will be supplied through bore well with proper RO system.

f. Sewerage system: Proper sewerage net work has been designed for the

industrial and residential area. The Treatment Plant is proposed to take

care of the effluent generated from domestic activities.

g. Industrial waste management:

Fly ash generated as solid waste which will be mixed with press mud nd shall be

given to the farmers of the area. . As regards to liquid effluents, there would be two

effluents(i) sewerage- which is proposed to be treated in a common STP (ii) waste

water from DM, Cooling Tower etc which will treated in neutralization tank, sand

filter and treated effluent water are being re-used in the quenching and gardening

purposes.

h. Solid waste management:

As above

6 Power requirement & supply/source:

As described earlier..

7 Rehabilitation and Resettlement (R & R) Plan:

No R&R plan is required as no displacement of people is proposed for the

project.

8 Project Schedule and Cost estimates


As soon as requested EC and consent will be received , additional

generation will be taken as no additional activities are needed to be

scheduled.

a. Likely date of start of construction and likely date of completion (time

schedule for the project to be given)

After obtaining environmental clearance and water / air consent the company shall start the project. Proposed date shall be April 2016 ( subject

to clearances).

b. Estimated project cost along with analysis in terms of economic

viability of the project

Name and Address of Sugar Factory

: M/s. Narmada Sugar Private Limited, Pondar, Salichouka, District –Narsinghpur (M.P.) Ph: 07576-228788 Fax: (07576) 228899 Email: [email protected]

Installed capacity – Sugar, TCD

: 4000

Design Crushing rate, TCH : 227.27

Installed Capacity of the project Export

: 30 MW 21.52 MW in season, 26.95 MW in off season

Capacity utilization : 80% in first year, 90% in second & 100% from third year onwards

Total no. of units exported at design level, million KWh

: 109.80

Item Value, Rs. lakh

Land & Site Development : 45

Civil works & Buildings : 1132

Indigenous Plant and Machinery : 10143

Misc. Fixed Assets : 523

Preliminary & Pre-Operative Expenses : 1074

Contingencies : 253

Working Capital : 320

Total : 13490

9 Analysis of proposal

i. Financial and social benefits with special emphasis on the benefit to the

local people including tribal population, if any, in the area.


The proposal is environmental compatible and will helps to people

improving their financial status, performance and repayment capability.

From the foregoing analysis, it is observed that capacity utilization of captive

CPP is safe and helps them in improving their performance and repayment

capability. This also helps the company in venturing into production of niche

specialty products which will eventually better their profits and also their

ranking in the industry.

Need base CSR programme shall be executed by the group , through which

people of the area will be benefitted.

Date post:	03-Apr-2018
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