detailed project report for modernization...

DETAILED PROJECT REPORT FOR MODERNIZATION OF SUGAR PLANT TO INCREASE ENERGY EFFICIENCY AND

CAPACITY FROM 2500 TCD TO 4800 TCD.

FOR

M/S GM SUGAR & ENERGY LIMITED SANGUR-581148

DISRICT: HAVERI, KARNATAKA

PREPARED BY

NATIONAL SUGAR INSTITUTE GOVT. OF INDIA

MINISTRY OF CONSUMER AFFAIRS, FOOD AND PUBLIC DISTRIBUTION DEPT OF FOOD AND PUBLIC DISTRIBUTION

KALYANPUR, KANPUR-208017 UTTAR PRADESH, INDIA.

The 28th Day of FEBRUARY-2017

Phone: 0512-2570541-3 Fax: 0512-2570247

Email : [email protected], [email protected] Web site: nsi.gov.in

CONTENTS

Sl No Particulars Page No

1.0 Project in General 1

2.0 Introduction 3

3.0 Project Promoters 7

4.0 Executive Summery 9

5.0 Project Cost 11

6.0 Means of Finance 12

7.0 Site Information 13

8.0 Project justification / Purpose of the project 14

9.0 Resource Availability 16

9.1 Land

9.2 Material

9.3 Raw Water

9.4 Power

10.0 Process Description 18

11.0 Plant and Machinery 29

12.0 Working Parameters for the Major Equipments 49

13.0 Fuel Balance 53

14.0 Steam Balance 54

15.0 Power Balance 58

16.0 VAPOUR BLEEDING SYSTEM 60

17.0 HMBD for the Plant 62

18.0 MATERIAL BALANCE 63

19.0 Technical Feasibility 72

20.0 Organizational Set-up 73

21.0 Manpower Requirement 77

22.0 Project Implementation and Schedule 79

23.0 SWOT Analysis 80

24.0 Codes and Standards 83

25.0 Abbreviations 94

26.0 Financial Workings 100

Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar

and Energy Ltd Prepared by National Sugar Institute, Kanpur.

of 118

1. Project in General

Project in General

1 Name of the

Project

M/s.G.M.Sugar and Energy Ltd.

2 Location / Site SANGUR VILLAGE, HAVERI, KARNATAKA STATE

– 581 148

3 Other Details

Phone No +91-8375-284425

Fax No +91-8375-284426

Email ID [email protected]

Web Site -

Corporate Office 22, 2nd floor, Pamadi Towers,

Gandhi Nagar, Bangalore - 9

Phone No +91-80-22203171

Fax No +91-80-22203172

Email ID [email protected]

Web Site

4 The Project Expansion cum Modernization of Sugar Factory

from 2500 TCD to 4800 TCD

5 Raw Material Sugar Cane

6 Product Sugar



of 118

Co-products Power

Byproducts Molasses and Press mud

7 Capacity

Sugar Plant

Existing (TCD)

2500

Proposed (

TCD)

4800

Cogeneration

Existing ( MW) 14 MW (Season)

Proposed (MW) 18 MW (Season)



of 118

2.0 INTRODUCTION

On the request of M/S GM Sugars and Energy Ltd., National Sugar

Institute, Kanpur took the preparation of this Detailed Project Report on

Bagasse Based Cogeneration.

National Sugar Institute, Kanpur is

An institution dedicated to Research, Training and Advisory Services.

Associated with sugar & allied industry since 1936.

Providing trained man power, newer technologies and technical

assistance.

Trained over 4800 national and international candidates.

Over 75 years of contribution to the welfare of sugar & allied industries.

The main functions of the Institute are to:

Provide technical education and training in research in all branches of

sugar chemistry, sugar technology, sugar engineering and allied fields.

Provide technical education and training in research in all branches of

sugar chemistry, sugar technology, sugar engineering and allied fields.

Undertake research on -

Problems pertaining to sugar technology, sugar and sugarcane chemistry

and sugar engineering in general and those of sugar factories in particular

Utilization of byproducts of sugar industry.

Provides technical advice and assistance to sugar factories with a view to

improve their efficiency and to assist them in their day-to-day problems.

Assistance is also provided to Central and State Governments in matters

relating to sugar and allied industries.



of 118

M/s.G.M.Sugar and Energy Ltd.

The Karnataka Sahakari Sakkare Karkhane Ltd., Sangur, Haveri District

was established during the year 1983, under the Co-Operative Sector. The

rated capacity of the factory was 1250 TCD where as it was capable of

crushing @1800 TCD. The Factory was operating under Co-op Sector. May

be for obvious reasons it was not working consistently & economically in

spite of availability of sugarcane in the area of operation resulting in

dwindling in the cane area and hence it was leased out to M/s.G.M.Sugar

and Energy Ltd.(GMSEL), for a period of 30 years on a long term lease basis.

The present management has already expanded its crushing capacity from

1800 to 2500 TCD with 16 MW Cogeneration and now intends to expand the

crushing capacity further and also proposes to enhance the cogeneration

facility.

The minimum economical size of a sugar plant is shifting towards 4800

TCD, considering mainly the cost of production and economical and self-

sufficient downstream industries. Now the Indian Sugar industries are

expanding their capacities and modernizing the plants. Further, they are also

setting up Co-generation project as an integral part to reduce the production

cost.

M/s. GMSEL is proposing to modernize its Sugar plant for increasing

efficiency and simultaneously enhance its Capacity facility at Sangur Village

and Haveri District in Karnataka State. At proposed modernization and

capacity enhancement to 4800 TCD, the plant has sufficient cane

availability, in its command area. Hence mill operations or co-gen plant



of 118

operations do not face any risk of low cane, except in adverse agro climate

conditions. Karnataka State has been at the forefront of promoting

renewable energy in the state. Several sugar mills have already expanded

their capacity and built-up the grid connected Co-gen plants in the state and

many projects are in the pipe line.

Considering the demand and potential for the sugar plant, M/s.GMSEL,

have decided to modernize its Sugar plant and enhancing crushing capacity

from 2500 TCD to4800 TCD. and prolonged operation of cogeneration of

18MW Cogeneration plant. It is proposed to Commission the Sugar Plant

modernization by 2017-18 season.

Project at M/s.GMSEL will integrate sugar mill operations with enhanced

energy efficiency measures and optimum usage of Bagasse. Greater

urbanization and rising standard of living have sparked of a rising trend in

usage of Sugar. Industrial consumption for sugar is also growing rapidly

particularly from the food processing sector and sugar based bulk

consumers such as soft drink and ice cream manufacturers. Our

consumption of sugar is significantly higher and compares favorably with

developed countries such as USA and countries of the European Union. In

fact, in urban areas of comparatively affluent Indian states like Punjab,

Haryana etc., per capita consumption of sugar is substantially high than

even in developed countries.

During season, the Co-gen Plant will operate on generated bagasse only;

no other fuels are going to be used. All excess available power is exported

to the KPTCL grid. During off-season, surplus Bagasse from the season will



of 118

be used in the Co-gen plant and power generated, less auxiliary

consumption will be pumped to the KPTCL grid. KPTCL has an attractive

policy on the guidelines of MNES, to buy power from sugar cogenerations.

Further, the integrated Sugar modernization project will improve the

overall profitability of M/s.GMSEL, through its additional revenue

generation. This will enable M/s.GMSEL to give higher dividend to

promoters & higher price per ton of cane to its cane growers. Also the

project will help to improve Karnataka State’s power situation.



of 118

3.0 PROJECT PROMOTERS

M/S G. MALLIKARJUNAPPA AND SONS, was established during the year 1999

as a registered partnership Firm under the Partnership Act. 1932, with the

object to do the business of trading in Arecanut and to act as a commission

agent and other related activities at Bheemasamudra. The firm is one of the

concern under the flagship group of “GM GROUP” founded by Late Sri. G.

Mallikarjunappa, a great visionary and nationalist. Now, the firm is

managed by Sri. G.M. Prasanna Kumar, Sri. G.M. Lingaraju and Sri. G.S.

Anithkumar. The group companies are reputed in the field of Agro,

Software, Trading, Education, Health Care like Hospitals, etc. and other

infrastructure activities. The motto of the group “Serve with Quality”

reflects the paramount importance given by the group companies in

delivering quality products to their customers.

The following are the existing Group companies under the flagship of “GM

Group”:

G. Mallikarjunappa & Sons Agro Based Industry

GEM Laboratories Pvt. Ltd. Trading and Holding

Company

GM Software Pvt. Ltd. Software Industry

GEM International (P) Ltd. Hospitality & Realty

Industry

Sri Prasanna Traders Commerce



of 118

Shrishyla Farms (P) Ltd. Trading

G.M. Institute of Technology Technical Education

G. M. H. Pu. College Education

Shrishyla Educational Trust Education

Turnover – GM Sugar & Energy Ltd., has been incorporated in the

month of November 2007, and started manufacturing operations on

18/2/2008, form the leased sugar mill at Sangur, Haveri District. The

turnover of the company for the year 2007-08 stands at over Rs. 8.00

Crores (unaudited figures)

No. of employees - 640

It may be worth mentioning that M/s. GMSEL group companies

are financially very sound and have very good support from Financial

Institutions / Banks. They can easily organize financial support to

establish a green field project of value around Rupees three hundred

crores with their own equity to the extent required.

Establishment of the Sugar Complex with Co-gen plant will contribute

much for the rural area development. After the establishment of the

factory, the standard of living of the entire area will improve and will

provide employment directly and indirectly for 2000 and 3000 persons.



of 118

4.0 Executive Summary

1. Company Name : M/s.GMSEL.

2. Owner : Sri. G. M. Lingaraju

3. Corporate office address : 22, 2nd floor, Pamadi

Towers, Gandhi

Nagar, Bangalore - 9

4. Site Location : Sangur Village, Haveri

District,

Karnataka State.

5. Project Proposed : Modernization of sugar

plant and

Enhancing crushing capacity

2500 TCD to 4800 TCD

6. Nearest Railway station : Haveri (12 Kms)

7. Nearest Airport : Hubli (85Km)

8. Nearest Sea Port : Karwar (250 KM)

9. Expanding to Capacity (22 Hrs) : 4800 TCD

10.Cane Crushing Season days : 180



of 118

11.Total Cane crushing per season : 9.0 lakh metric tone

12.Sugar Recovery : 10.5 % Cane

13.Sugar Losses : 1.8 % Cane

14.Sugar Production : 9.45 lakh quintals

15.Average bagasse % Cane : 30.88%

16.Process steam percentage on Cane : 32 %

17.Power unit per Tonne of Cane : 22 KWH

18.Cogeneration plant capacity : 18 MW

19.Cogeneration plant Operation days : 310 Days Average

20.Capacity of the Boiler (MCR) : 100 TPH

21.Boiler Outlet Steam Parameters : 86 Kg/Sq. Cm(g) , 515 + 5 Deg.C

22.Turbo-generator type and Capacity : DEC & 18 MW

23.Captive Consumption

During Cane Crushing season : 7348 KW

During Off-Season : 2070 KW



of 118

24.Power Factor (lagging) : 0.9

25.Generation Voltage (KV) : 11

26.Ambient temperature for Electrical : 55

Equipment Design (Deg.C)

27.Parallel operation : at 110 KV

28.System Frequency : 50 ± 5%

29.The economical steam rate required : 80-100

at Percentage load (%)

30.The minimum continuous load at : 15

which the TG is expected to operate

as a percentage of the ratio load (%)

31.Commissioning by : Dec. 2017-18

32.Project cost and means of finance :



of 118

PROJECT COST

S.No Particulars Rs.In.Lakhs

1 Civil Cost 400

2 P & M Cost 7030

3 Tax and Transportation 1050

4 Pre Operative Expenditure 150

5 Working Capital Margin 400

6 Interest During Construction 200

TOTAL PROJECT COST 9230

MEANS OF FINANCE

Particulars % Amount in lakh Rs 1. Promoters Contribution 10 923 2. SDF Loan 40 3692 3. TERM LOAN 50 4615 TOTAL 100 9230

33. Pay back period (Years) 5 Years

34. Average DSCR 5.53

35. IRR % 8.63



of 118

5. Site Information

1. Rain fall : 752.8 mm

2. Ambient temperature : Max 38oC & Min 24oC

3. Relative humidity : 60 - 70

4. Plant Elevation above Sea level : 552.9 M

5. Wind Direction : North West to South East

6. Soil Bearing Capacity : 15 – 20 Tons

7. Atmospheric Conditions : Dusty



of 118

6. Project justification / Purpose of the project

6.1. Last 5 Years performance of the Plant:

The plant at its rated capacity of 2500 TCD has given outstanding

performance since the year 2012-13

Season No of Season Days

Cane crushed

In Tons

Sugar Produced in quintals

Recovery %

Units of Elect. Exported

2016-

17

90 247907 205063 8.27 22092000

2015-

16

157 450671 428416 9.51 40929000

2014-

15

200 537360 513528 9.56 53005500

2013-

14

152 395252 381417 9.65 39922500

2012-

13

135 278054 266344 9.58 76225500

Considering the demand and potential for the sugar plant, M/s.GMSEL, have

decided to modernise its Sugar plant for increasing efficiency and to enhance



of 118

crushing capacity from 2500 TCD to 4800 TCD during season. The other

reasons for this expansion project are:

1. Increasing domestic consumption of sugar in India with a CAGR of about

3.5 to 4 as compared to 2.0 to 2.5 globally.

2. Increasing demand of eco friendly power in India leading to

subsidies of several types.

3. Availability of plenty of sugar cane in the vicinity of the factory

in its command area to meet out the raw material requirement

at expanded capacity.

4. More capacity will help to reduce the overhead cost of the plant

as a whole leading to reduced cost of production per unit of

finished product.

5. Attitude of Karnataka Govt. to promote nonconventional

energy.

6. Successful working of so many sugar plants in the state of

Karnataka at this rate of crush.

7. More profits from the units may help for the upliftment of the

society.



of 118

7.0 Resource Availability

7.1 Land:

GMSEL is already having sufficient land (110 Acres) in its

acquisition with the existing plant which is sufficient for the

modernization of sugar plant and enhancing its capacity from 2500 TCD

to 4800TCD.

7.2 Raw Material

Sugar cane requirement for the expanded capacity of 4800 TCD for

180 days of season operation is 8.64 lakh metric tonnes. Assuming a

yield of 85 tonnes per hectare and a drawl percentage of 80 % the cane

area requirement for this capacity shall be 12706 hectares. As per

records available with the factory, within the cultivated area allocated

for the factory, the present cane area available is 14400 hectares which

is sufficient for supply of adequate cane for the expanded capacity.



of 118

7.3 Water

The process adopted for the plant includes recycling of water in

the plant hence there is no need for extra water for the extended

capacity. The existing tube wells will be sufficient for the make up water

required for the process. It is also kept in the mind that in future, a

water softening and recovery plant shall be installed for converting the

excess of 10 % of water from the process for drinking purpose.

7.4 Power

Since there is cogeneration of power to the tune of 18 MW during the

season, the captive requirement of power shall be taken from this

unit. During Off season, the power shall be taken from Karnataka state

grid through LILO connection.



of 118

8. PROCESS DESCRIPTION

8.1 Sugar manufacturing process involves mainly seven stages as

mentioned below.

� Weighing of sugar cane

� Crushing of sugarcane

� Juice clarification (double sulphitation)

� Evaporation & boiling

� Crystallization

� Curing

� Grading and bagging

8.2 Cane weighment and unloading system

Harvested sugarcane is brought to the factory by trucks trailers and

bullock carts. The factory will purchase the sugar cane only at the

factory gate. The factory will be provided with suitable platform type

computerized electronic weigh bridges to weigh the cane.

Trucks and trailer canes will be bound by steel wire sling ropes in two

or three layers with the weight of each layer not exceeding five tones

for easy unloading at the factory onto the cane feeder tables by

means of hooks attached to the three motion crane in the cane yard.

The cane form bullocks carts will be manually dumped into the carrier,

after weighment in the appropriate computerized electronic weigh

bridges at the factory gate.



of 118

There will be three (3) unloading cranes of 15.0 T, one 10 T and one 7

T capacities. Two feeder tables of 7 m x 6m sizes and one 7 m x 8 m

size with 3 deg. negative slope are provided for unloading the cane

from the cranes.

8.3 Cane preparatory system & milling system.

The cane carrier is a slat type conveyor of 2000 mm width dragged by

three strands of roller chains of sturdy construction moving on well-

aligned flat rails. The system will be driven by suitable variable speed

drive motors to adjust the speed between 3m/min. to 10m/min.

The main cane carrier will be of 45 m horizontal length and 20 m

inclined length of 12 Deg. And 7 deg. Slope with a loading depth of 1.5

m at the horizontal length. The preparatory systems of kicker,

chopper, leveler and fibrizer will be placed on the inclined position of

the carrier with the fibrizer at the end of the carrier.

A disc type kicker rotating at 60 rpm will level the cane mat in the cane

carrier before they reach the knives for cutting.

The chopper will have 56 knives directly coupled to a 560 kW slip ring

induction, motor of 600 rpm. The clearance between the chopper

knives and the cane carrier slat will be 300 mm. A flywheel will be

provided at the outer end of the drive shaft.

There will be no cutter/ leveler and the existing one will be removed.

An equalizer shaft of toothed design will even out the cut cane level

in the carrier after the chopper.



of 118

A heavy duty swing hammer type fibrizer with 136 hammers and box

type anvils driven by 2 nos. 1000 kw HTmotor 750 rpm is considered

as a cane preparatory equipment. The fibrizer will be placed at the

head end of the carrier with a clearance of 20 mm between the

hammer tip and the carrier slat. The fibrizer provided will be capable

of giving a preparatory index of 87% to 90%. The preparatory systems

open up the juice cells in the sugarcane and make it suitable for the

mills to extract maximum juice from the cane. The fibrized cane will

be conveyed to the milling station through a RTCC and an inclined

belt conveyor at a height of minimum 3m above the mills. A suitably

sized magnetic separator will be installed to trap the ferrous foreign

materials in order to save the mills from damage.

8.4 Milling system

The prepared cane is crushed in a milling tandem. Present tandem

consisting of Four (4) mills of three rollers each of size 910 mm dia (36

inches) and 1700 mm (67inches) length with similar size grooved

under feeder roller. The mills are driven by ACVFD motors of 373 kw

connected to the rollers through planetary type speed reduction

gears to enable the rollers to run at 2 rpm to 4.5 rpm speed.

The following changes will be done in the milling tandem:

1. one zero mill of 1000 X 2000 mm with heavy duty GRPF with 5%

higher size UFR will be added.

2. All other mills' UFR to be made 100%.

3. GRPF with 105 % UFR for the last mill will be added.

4. All the donnalley chutes' height are to be increased to 3m.



of 118

The mills will be operated at a speed of 2.5 rpm to 3.5 rpm of the

rollers to achieve an RME of plus 96%, imbibitions % fibre of 250%

and bagasse moisture of 49%. All the mills will have a provision for

adding the GRPF/TRPF system during further expansion. The

fibrized cane will be fed to the crusher through a Donnelly chute

and under feed rollers and the extracted juice is screened through

a rotary screen to remove fine bagasse particles. The bagasse after

extraction of juice wills pass through successive mills through rake

type elevators and Donnelly chutes to enable maximum extraction

of juice from the cane. Imbibition water at 80 Deg. C will be added

after the penultimate mill to extract the last traces of juice in the

bagasse. The juice extracted in the last mill will be recycled to the

penultimate mill and the juice extracted in the penultimate mil will

be recycled to the third mill and the juice from the third mill will be

recycled to the second mill and the juice from the first and second

mills are passed on to the process after screening the fine bagasse

particles in a rotary screen. The water addition and juice flow are

measured by mass flow meters. The entire operation form cane

unloading to milling will be automatically controlled.

8.5 Co-generation

The bagasse coming out of the Fourth mill will be used as fuel for

generation of steam, which in turn will be used, for production of

electrical power and supply of process steam. The existing boiler of 80

TPH capacity, to produce steam at 87 ata and 510 Deg, C steam and

has been installed along with a 18 MW double extraction cum

condensing turbo-generator. From this plant, appx 10,500 kW of

power will be exported to the KPTCL grid after meeting with the



of 118

inhouse power requirement during cane crushing season. The surplus

bagasse after production of steam in boilers will be stored for use

during non-crushing season. The cogeneration of power besides

effecting energy conservation of process and reducing costs will also

help to improve the viability of the project by sale of power to the

KPTCL grid. The exhaust steam at 2.5 ata from the turbines after

production of power will be used for process in subsequent stages.

8.6 Juice clarification (double sulphitaion)

The juice extracted from the first two mills after screening through

Decanters and measured through mass flow meter is passed through

juice heaters heated by vapour from evaporator bodies where the

temperature is raised to about 70 Deg. C. The juice after

primary heating is treated with milk of lime and sulphur dioxide gas in

a simultaneous and continuous liming and sulphitation vessel to

achieve a pH level of about 7.4.

Suitable automatic continuous sulphur burners with dried

compressed air admission for pure sulphur-di-oxide production and

stable lime slacker with classifier for removal of grit from milk of lime

and milk of lime storage vessel with pumps will be provided for

producing milk of lime and sulphur-dioxide gas. Automatic juice

stabilization provision and auto pH control provisions will be installed

for precise and continuous control of clarification process to ensure

efficiency. The dissolved mineral salts in juice and the colloids will get

coagulated as precipitates thus eliminating the impurities present in

juice. The treated juice will be further heated to 102 Deg.C in another

set of juice heaters by bled vapors from evaporators and exhaust

steam, if required. This is to enable efficient coagulation of



of 118

precipitates and faster settling. The heated juice at 102 Deg.c is sent

to two parallel continuous settlers of sedimentation vessel known as

clarifier of 30 ft dia each divided into four equal compartments

superimposed one over the other. Gravity separation of the juice and

the precipitates takes place in the clarifier in a counter current

direction resulting in sparkling clear juice at the top and thick

precipitate settling at bottom of the compartments. Clear juice and

thick precipitate known as muddy juice continuously flow out of the

top and bottom respectively of all the four compartments. While the

clear juice will be taken to the evaporators through clears juice

heater, after heating to about 110 deg, c. The muddy juice will be

taken to the rotary drum vacuum filter. The muddy juice is mixed with

fine bagacillo particles obtained by screening from the bagasse

elevator to give the required porosity to the muddy juice and the

entrapped juice is filtered through screens of the vacuum filter and

the collected juice is treated separately. The solid that sticks to the

external surface of the filter drum is also washed be hot water spray

and drips to minimize the loss of sugar through the cake. The cake

sticking to the external surface of the drum will be scrapped and taken

out through a belt conveyor which will be used for the production of

bio-compost manure, which is a valuable nutrient to the soil as it

returns all the mineral salts that were taken up from the soil by the

cane during its growth.

8.7 Evaporation, Boiling &Crystallization.

Clear juice at a pH level of 7 from the clarifier passes to the first effect

of the quintuple effect evaporator at about 110 Deg.c through a juice

heater of DCH type. There will be a quintuple effect evaporator set



of 118

with all the bodies as falling film type. All the evaporator bodies will

be provided with efficient internal and external catch all designs,

automation controls with flow measurement of exhaust and

condensates. Suitable desuperheating system for exhaust steam and

pressure reducing desuperheating provision for live steam bleeding

into exhaust will also be provided. The targeted evaporation in the

quintuple effect will be about 80%. Flash evaporation recovery system

will be provided for the condensates from all the evaporator bodies.

Efficient single entry multi condensing system will be provided at the

vapour exit of the last body of the quintuple after the vapour line juice

heater for creation of vacuum in the system. All other normal

provisions like juice syphon interconnection, level indicators, and auto

flow & level controllers, juice, etc. will also be provided. The steam

consumption at the evaporator station will be 32.5% for a continuous

capacity crush of 4800 TCD and above.

The syrup coming out of the evaporator will be maintained between

55 Brix to 60. Brix. A continuous syrup sulphitation vessel of 180 HL

will be provided for sulphating the syrup fitted with an auto pH-

indicating device. The sulphited syrup will be stored in syrup storage

vessels in the pan station.

8.8 Vacuum pan boiling

The design of the critically important pan boiling operations will

follow the following concepts.

Total automation of the boiling operations.

Efficient low head calendria vacuum pans with auto control

and pneumatic discharge for a – boiling A, B& C boiling.



of 118

Totally automatic continuous pans for B&C boiling.

Molasses conditioners for A.H. (A heavy), B.H. (B Heavy), C.L.

(C Light) A L (A Light) & melt.

Vacuum crystallizer for storage of B-grain, C-grain and A-

footing.

Open seed crystallizer for dry seed and B-seed.

Conventional water-cooled crystalisers for B massecuite storage

and air-cooled for A-massecuite. B-crystallizer will be of

continuous cooling type. C-crystallizer will be of mono vertical

type.

Slurry graining for B&C.

B-seed of dry seed for A-footing as per needs.

External save all for all pans.

Automated injection and spray system to reduce power

consumption at this station to 2.0 kW /t/hr at peak crushing rates.

Sugar ICUMSA value 50-60 as per choice.

Final molasses purity around 30%

Efficient pan design will be chosen from the point of view of heat

transfer, rate of boiling, circulation, etc.

Automated operations will ensure uniformity of boiling as well as

steady steam, power and other operational conditions.

The capacities of the plant and machinery in the pan station is

given at Plant & Machineries Clause 9.

8.9 Curing, Drying, Grading and sugar bagging.

This is a very important step in sugar manufacture where the crystal

sugar developed in vacuum pans and nurtured in crystallisers is

separated as white from the A-heavy and A-light molasses will be



of 118

pumped to the pan floor for boiling with B-massecuite and A-

massecuite respectively.

The dried sugar after cooling in the hopper will be elevated by bucket

elevators to a vibrating screen assembly above the sugar bins known

as sugar graders and sieved according to sizes.

The factory proposes to make 90% and above of S-size crystals as per

ISS. M-size crystals 10%. The colour will be 31 plus which is the highest

as per ISS. The dry sugar below ISS. And part of S-sugar will be

returned to pan station as dry seed for further boiling of high quality

A-sugar.

The sieved sugar will be stored in the sugar bins according to the

grades and bagged in 50kg /100kg packing in automatic sugar net

weighing machines kept at the bottom of the sugar bins, stitched be

machines and conveyed to the warehouse through belt conveyors

where they are stacked.

The B-massecuite and C-massecuites are cured in continuous

centrifugals and with a purity of not less than 98% is taken back to the

pan station as seed for A-massecuite some times and excess will be

completely melted. When dry seed process is followed, this will be

completely melted. The B-molasses will be taken to the pans for

further boiling of C-massecuite.

The C-sugar coming out of C-continuous centrifugal machines is

magmised in a mingler beneath the machines and cured once again in

a subsequent continuous centrifugal machine know as C-after worker.

The molasses coming out of the C-centrifugal machine is known as



of 118

final molasses, which is weighted and pumped to the storage tank

outside the factory building.

The sugar from the C-after worker centrifugal, which will be of about

98% purity, is completely melted and taken to the pan floor for boiling

with A- massescuites. The molasses from the C-after worker machine

known as C-light molasses will be pumped to pan floor for boiling once

again with the C-massecuite. Thus, the desegregation of the syrup will

be continuously carried out by constant recirculation. Every stage of

operation will be automated and integrated through DCS control

system to ensure best process controls, efficient operations and

quality outputs.

9.0 Plant & Machinery

Details of plant and machinery which includes the existing and the proposed details

with their tentative cost is tabulated as below:

Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and Energy Ltd Prepared by National Sugar

Institute, Kanpur.

of 118

Machinery and Equipments Existing Proposed Final After Expansion

A

for 2500 TCD B

for 4800TCD Expansion C

4800TCD

Approx Cost (Lakhs)

S.No

Name of Machinery/Equipment DETAILS DETAILS DETAILS ©

1. CANE WEIGHING SCALE a) WEIGHING SCALE 01 No.Weighing

Scale.Capacity 100 Ton. 1 Nos.Weighing Scale.Capacity 100 Ton.

10.00

02 Nos.Weighing Scale.Capacity 60 Ton each.

02 Nos.Weighing Scale.Capacity 60 Ton each.

02 Nos.Weighing Scale.Capacity 40 Ton.

2 x 40 T bridges which are not in use now are to be upgraded by digitizing both the bridges and shall be used for tare weighment.

02 Nos.Weighing Scale.Capacity 40 Ton. Each

2 MILLING PLANT A CANE HANDLING a) CANE UNLOADER

01 No. 03 motion EOT crane with sling arrangment, 7.5 ton SWL Capacity.Lift-10 mtrs

03 No. 03 motion EOT crane with hydraulic operated sling arrangment, 15 ton SWL Capacity.Lift-10 mtrs.

03 Nos. 03 motion EOT crane with sling arrangment, 15 ton SWL Capacity.Lift-10 mtrs

100.00 1 Nos. 03 motion EOT crane with sling arrangment, 10 ton SWL Capacity.Lift-10 mtrs



Institute, Kanpur.

of 118


Discarded: 01 No. 03 motion EOT crane with sling arrangment, 5.5 ton SWL Capacity.Lift-10 mtrs

1 Nos. 03 motion EOT crane with sling arrangment, 10 ton SWL Capacity.Lift-10 mtrs

Bridge span - 22 mtrs Bridge span - 22 mtrs Bridge long travel speed - 20 mtrs/min., Trolley cross travel speed- 20 mtrs/min.Hoisting speed-15 mtrs/min.

Bridge long travel speed - 20 mtrs/min., Trolley cross travel speed- 20 mtrs/min.Hoisting speed-15 mtrs/min.

Since the carrier length is to be increased the length of the bridge is also to be increased by same length.

b) FEEDER TABLE

2 Nos. Length - 7.0 mtrs, width-6 mtrs, loading capacity-15 Ton, chain pitch-152.4 mm, drive-11 kw with VFD, final rpm-1-1440 rpm.

1 No. Length - 8.0 mtrs, width-7 mtrs, loading capacity-15 Ton, chain pitch-152.4 mm, drive-15 kw with VFD, final rpm-1-1440 rpm.

2 Nos. Length - 7.0 mtrs, width-6 mtrs, loading capacity-15 Ton, chain pitch-152.4 mm, drive-11 kw with VFD, final rpm-1-1440 rpm. 1 No. Length - 8.0 mtrs, width-7 mtrs, loading capacity-15 Ton, chain pitch-152.4 mm, drive-15 kw with VFD, final rpm-1-1440 rpm.

20.00

c) CANE CARRIER Feed cane carrier-width-1700 m.m, total length-51 mtrs, No of slats - 630, chain pitch-152.4 mm

Feed cane carrier-width-2000 m.m, total length-65 mtrs, chain pitch-200 mm

Feed cane carrier-width-2000 m.m, total length-65 mtrs, chain pitch-200 mm

650.00

Drive-Planatery gear make Kavitsu with 55 kw VFD driven motor, final rpm-0-4.5 rpm

Drive-Planatery gear with 110 kw VFD driven motor, final rpm-0-4.5 rpm

Drive-Planatery gear with 110 kw VFD driven motor, final rpm-0-4.5 rpm

B CANE PREPARATION a) CANE CHOPPER No. of knives-32,Swing

Dia-1600 mm, clearance from cane carrier-700 mm, Bearing-23136cc3K,

shall be replaced by a kicker with 50 hp motor with suitable spikes A kicker with 50 hp motor with suitable spikes


Institute, Kanpur.

of 118

Gear Box(Kirloskar)- power-110 Kw, final rpm-250 rpm

b) CANE LEVELLER No. of knives-42,Swing Dia-1450 mm, clearance from cane carrier-200 mm, Bearing-22234ckw

No. of knives-56,Swing Dia-1800 mm, No. of knives-56,Swing Dia-1800 mm,

Motor-03 Phase A.C Induction Motor 02 No X 180 Kw, rpm-560

Motor-03 Phase A.C Induction Motor 02 No X 560 Kw, rpm-560

Motor-HT, 03 Phase A.C Induction Motor 02 No X 560 Kw, rpm-560

c) CANE FIBRIZOR No. of hammers-96,Swing Dia-2130 mm, hammer tip size-80x80 mm, Bearing-23152cckw

No. of hammers-136,Swing Dia-2200 mm, hammer weight 22 kg with a suitable pusher

No. of hammers-136,Swing Dia-2200 mm, hammer weight 22 kg with a suitable pusher

Motor-HT motor Motor 02 No X 560 Kw, rpm-740



d) RTCC Carrier width-1460mm, length-22 mtrs, inclination-33 deg., chain pitch- 230 mm.

2000 mm width, pitch 250 mm, Length and slope as per the space availability

2000 mm width, pitch 250 mm, Length and slope as per the space availability

Drive- Planatery gear make make Kavitsu with 45 kw motor, Final rpm - 0-9.93 rpm.

Drive-45 kw motor with Planatery gear and vfd, Final rpm - 0-10 rpm.

Drive-45 kw motor with Planatery gear and vfd, Final rpm - 0-10 rpm.

belt conveyor 2000mm width, with provision of magnetic separator and equaliser Drive hp 25 kw. Slope and length as per the space availability.

2000mm width, with provision of magnetic separator and equaliser Drive hp 25 kw. Slope and length as per the space availability.

C MILLS a) MILLS

04 Mills with 90 % UFR and Donnelley Chute in all of them. Size: 910 X 1700 mm for all

1. one zero mill of 1000 X 2000 mm with heavy duty GRPF with 5% higher size UFR. 2. All other mills' UFR to be made 100%. 3. GRPF with 105 % UFR for the last mill 4. All the donnalley chutes' height are to be increased to 3m

1. one zero mill of 1000 X 2000 mm with heavy duty GRPF with 5% higher size UFR. 2. All other mills' UFR to be made 100%. 3. GRPF with 105 % UFR for the last mill 4. All the donnalley chutes' height are to be increased to 3m

650.00


Institute, Kanpur.

of 118

b) INTER RAKE CARRIER 03 Nos, length-8 mtrs, Effective width-1910 mm inclination-36 deg. Chain pitch-230 mm

existing RTCC will be modified as 1st IRC existing RTCC will be modified as 1st IRC

Drive- Planatery gear with 22kw motor

c) DRIVE FOR MILLS AC VFD Motor ABB-CE, 373 kw, RPM-1000, Planatery gear box-ratio - 200:1, Premium Transmission Make.

1. AC VFD Motor, 250 kW, RPM-1000, Planatery gear box-ratio - 200:1, For 1st, 2nd and the 3rd mills' feed and under feed roller. 2. AC VFD Motor, 373 kW, RPM-1000, Planatery gear box-ratio - 200:1, For GRPF of Zero mill. 3. AC VFD Motor, 500 kW, RPM-1000, Planatery gear box-ratio - 200:1, For Zero mill. 4. AC VFD Motor, 250 kW, RPM-1000, Planatery gear box-ratio - 200:1, For GRPF of last mill. 3. AC VFD Motor, 500 kW, RPM-1000, Planatery gear box-ratio - 200:1, For last mill.

1. AC VFD Motor, 250 kW, RPM-1000, Planatery gear box-ratio - 200:1, For 1st, 2nd and the 3rd mills' feed and under feed roller. 2. AC VFD Motor, 373 kW, RPM-1000, Planatery gear box-ratio - 200:1, For GRPF of Zero mill. 3. AC VFD Motor, 500 kW, RPM-1000, Planatery gear box-ratio - 200:1, For Zero mill. 4. AC VFD Motor, 250 kW, RPM-1000, Planatery gear box-ratio - 200:1, For GRPF of last mill. 3. AC VFD Motor, 500 kW, RPM-1000, Planatery gear box-ratio - 200:1, For last mill.

300.00

MILL Drive Coupling Multi- mis alignment polyster sling-Saisidha Make.

Plannetary Gear Box suitable for the drives as mentioned aove

Plannetary Gear Box suitable for the drives as mentioned aove

d) ROTARY SCREEN 01 No-Cap-190 M3/Hr, Size-18x24, Aparture- 0.5 mm, Make- Suviron

01 No-Cap-190 M3/Hr, Size-18x24, Aparture- 0.5 mm, 02 No-Cap-190 M3/Hr, Size-18x24, Aparture-

0.5 mm, 100.00 e) IMBIBITION 01 No. Electro Magnetic

Flow Meter 0-75 M3/hr 01 No. Electro Magnetic Flow Meter 0-150 M3/hr in replacement to the existing one

01 No. Electro Magnetic Flow Meter 0-150 M3/hr in replacement to the existing one

f) MILL HOUSE CRANE 01 set EOT crane, 25 Ton SWL cap with independent Trolly, Building span 22 mtrs make- KBE

One additional EOT crane of 40 T and suitable upliftment of the roof top is required for the extended portion if the mill house building for Zero mill and fibrizer.

01 set EOT crane, 25 Ton SWL cap with independent Trolly, Building span 22 mtrs make- KBE

50.00


Institute, Kanpur.

of 118

One additional EOT crane of 40 T and suitable upliftment of the roof top is required for the extended portion if the mill house building for Zero mill and fibrizer.

g) MILL ROLLER LATHE Capacity suitable for 42" x 84" mill roller. No Change

h) MILL PUMPS Capacity (M3/Hr) Head (Mtr) Size Make Motor(KW) Qty

Capacity (M3/Hr) Head (Mtr) Size Make Motor(KW) Qty

50.00

i) Zero Mill (1W+ 1SB) 250 15 150/320 PSP 18.5 1 250 15

150/320 18.5 1

250 20 6 nk 125 Kirloskar 18.5 1 250 20 6

nk 125 18.5 1 ii) 1st Mill (1W+ 1SB) 150 15

150/320 PSP 18.5 1

250 15 150/320 PSP 18.5 1

250 15 150/320 18.5 1

150 20 6 nk 125 Kirloskar 18.5 1

250 20 6 nk 125 Kirloskar 18.5 1

250 20 6 nk 125 18.5 1

iii) 2nd, 3rd & 4th Mill (1W + 1SB)

60 15 100/320 PSP 11 4

150 15 100/320 PSP 11 4

150 15 100/320 11 4

iv) Imbibition Water Pump (1W + 1SB)

60 50 65/430 PSP 22 2

150 50 65/430 PSP 22 2

150 50 65/430 22 2

v) Rotary wash pump (1W + 1SB)

25 60 40/200 KSB 7.5 2

25 60 40/200 KSB 7.5 2

25 60 40/200 7.5 4

3 CLARIFICATION PLANT


Institute, Kanpur.

of 118

a) MEASURMENT OF RAW JUICE

Electronic mass flow meter cap-0-200 MT/hr. Electronic mass flow meter cap-0-300 MT/hr Electronic mass flow meter cap-0-300 MT/hr 10.00

Raw Juice Pump 01 no. PSP make pump Cap-150 M3/Hr, Head 60 mtr, Motor-45 KW

02 no. PSP make pump Cap-300 M3/Hr, Head 60 mtr, Motor-60 KW

02 no. PSP make pump Cap-300 M3/Hr, Head 60 mtr, Motor-60 KW 10.00

01 no. Gita make pump Cap-200 M3/Hr, Head 80 mtr, Motor-90 KW

b) JUICE HEATERS J.H. Nos H.S.A. No. of passes Tube/pas No. of tube Tube length Id/Od mm

DCH for all the type of juice heating suitably sized for different stages

DCH for all the type of juice heating suitably sized for different stages

125.00

VLJH. 01 200M2 22 17 374 4000mm 42/45 VLJH. 01 240M2 20 23 460 4000mm 42/45 R,J,H. 03 200M2 22 17 374 4000mm 42/45 (2 nos vapour and 1 no. cond heater) S.J.H 03 200M2 22 17 374 4000mm 42/45 Cl.J.H. 01 200M2 22 17 374 4000mm 42/45 DCH 02 nos for S.J. Heating


Institute, Kanpur.

of 118

c) JUICE SULPHITOR 01 NOs-Con. J.S having Dia 3.0 Meter & working Height 2.1 mtrs. Drive- Planatery drive with 5.5 HP,1480 rpm, Sulphited Juice Receiving Tank-18 M3.

1 X 300 HL Continuous Juice Sulphitor with suitable juice receiving tank

1 X 300 HL Continuous Juice Sulphitor with suitable juice receiving tank

Cap-150 M3/Hr, Head 60 mtr, Motor-45 KW

02 nos. pump Cap-300 M3/Hr, Head 60 mtr, Motor-60 KW

02 nos. pump Cap-300 M3/Hr, Head 60 mtr, Motor-60 KW

01 no. Gita make pump Cap-200 M3/Hr, Head 80 mtr, Motor-90 KW

d) SULPHUR GAS PLANT

25.00

i) No.of Sulphur Furnaces & Capacity

02 Nos,Film Type Furnace Cap-150 Kg/Hr 01No,Film Type Furnace Cap-150 Kg/Hr

02 Nos,Film Type Furnace Cap-150 Kg/Hr 01 Nos,Film Type Furnace Cap-150 Kg/Hr

02 Nos,Batch Type Furnace Cap-0.6 m2 tray area Port type.

ii) AIR BLOWER 01 No. Ingersol make size 9x7, RPM-650 01 No. Ingersol make size 9x7, RPM-650

01 No. Ingersol make size 9.5x5, RPM-675 01 No. Ingersol make size 9.5x5, RPM-675

01 No. Ingersol make size 1/285x1/2x4, RPM-560

01 No. Ingersol make size 1/285x1/2x4, RPM-560

e) MILK OF LIME PLANT

i) LIME SLACKER

01 No, Rotary Type size- 2.0x4.0 mtr, fitted with Rake Type Classifier

01 No, Rotary Type size- 2.0x4.0 mtr, fitted with Rake Type Classifier

20.00 ii) M.O.L STORAGE TANKS

02 Nos,Dia-2.8 Mtrs,Height 2.1 Mtrs 1 x 400 hl

02 Nos,Dia-2.8 Mtrs,Height 2.1 Mtrs 1 x 400 hl

iii) M.O.L PUMPS 02 Nos,Cap-6 M3/Hr, Head-20 Mtrs 1 x 15 cub m

02 Nos,Cap-6 M3/Hr, Head-20 Mtrs 02 Nos,Cap- 15M3/Hr, Head-20 Mtrs

f) R.V.F

02 No, R.V.Filter, Size-8' X 16',UHEC make with all assessories 1 set of Decanter suitable for 4800 TCD 1 set of Decanter suitable for 4800 TCD

600.00

50.00 Sulp. Juice Pump 01 no. PSP make pump


Institute, Kanpur.

of 118

g) CLARIFIER 01 No, Make- 444 type Make- KBE Dia- 30' 01 No, Make- 444 type Make- KBE Dia- 30' 01 No, Make- 444 type Make- KBE Dia- 30' 150.00

B EVAPORATOR SECTION

i)

EVAPORATOR 1st SET Evaporator Body No. Type Heating Surface (m2) No. of tubes Tube length Tube ID/OD

Quintuple FFE set suitable for 4800 TCD with stand by arrangement for all the bodies

Quintuple FFE set suitable for 4800 TCD with stand by arrangement for all the bodies

1st body Semikestner 1400 4300 4100 mm 35/38

2nd body Robert 1600 4840 2500 mm 42/45

3rd body Robert 750 2820 2000 mm 42/45

4th body Robert 560 2122 2000 mm 42/45

5th body Robert 440 1661 2000 mm 42/45

ii) Evaporatoe Spare Bodies Spare for 1st & 2nd body

Spare for 4th body

spare body Robert 440 1658 2000 mm 42/45

800.00


Institute, Kanpur.

of 118

Spare for 5th body

spare body Robert 440 1658 2000 mm 42/45

iii) CLEAR JUICE BUFFER TANK

01 No,Cylidrical Tank, Cap-100HL, 01 No,Cylidrical Tank, Cap-500HL 01 No,Cylidrical Tank, Cap-500HL, 10.00

C SYRUP TREATMENT PLANT

a) SYRUP SULPHITOR

02 Nos, Cap-6 M3, Dia-2.5 Mtr,Working Height-1.5 Mtr 40.00

b) Unsulphired & sulphited Syrup pumps

04 nos, cap-80m3/hr, head-30mtr, motor-18kw

2 nos, cap-150m3/hr, head-30mtr, motor-40 kw

2 nos, cap-150m3/hr, head-30mtr, motor-40 kw

4 PAN SECTION

a) SYRUP & MOL STORAGE TANK

11 Nos ractangular Type Tanks for Syrup & Molasses Storage, Cap-200 HL each



500.00

Syrup-03 NoS,Melt-01 No,A.L-01 No,A.H-02 Nos,B.H-02 Nos,Cl-02 Nos

b) MOLASSES CONDITIONER

On line molasses conditioners 3 Nos No change No Change AH- 25 Ton/Hr, BH-15 Ton/Hr, CL- 10 Ton/Hr

c) SUGAR MELTER 01 No, Cap-25T/Hr No change No change d) RORI MELTER 01 No, Cap-10T/Hr No change No change e) VACCUM PANS f) State number of Pans,Cap

of each Pan 08 Nos Total Pans,06 Nos Batch Pans and 2 nos Cont. Pans

08 Nos Total Pans,06 Nos Batch Pans and 2 nos Cont. Pans

Pan No. Cap.(ton) H.S.A. m2 Tube length(mm) Id/Od mm Use for

Pan No. Cap.(ton) H.S.A. m2 Tube length(mm) Id/Od mm Use for


Institute, Kanpur.

of 118

02 100 420 750 98/102 A- boiling

02 100 420 750 98/102 A- boiling

02 60 280 900 98/102 A- graining

02 60 280 900 98/102 A- graining

03 40 200 900 98/102 A-boiling

03 40 200 900 98/102 A-boiling

04 40 200 900 98/102 A-boiling

04 40 200 900 98/102 A-boiling

05 45 231 900 98/102 B-graining

05 45 231 900 98/102 B-graining

06 45 231 900 98/102 C-graining

06 45 231 900 98/102 C-graining

07 20ton/hr 900&1200 98/102 B-boiling Existing 15 TPH will be used for B

07 20ton/hr 900&1200 98/102 B-boiling

Existing 15 TPH will be used for B


Institute, Kanpur.

of 118

08 15ton/hr 900&1200 98/102 C-boiling 1 x 20 TPH new for C

1 x 20 TPH new for C

g) CONDENSERS

100.00 i)

Pan No-1 Pan No-2 Pan No-3 Pan No-4 Pan No-5 Pan No6 CVP for B M/C CVP for C M/C Evaporator 1&2

As per requirement of Pans with complete automation

As per requirement of Pans with complete automation

Condensor Dia.(mm)

1350 1100 1100 1100 1100 1100 1100 1100 1050 x 2 nos.

ii)

INJECTION WATER PUMPS

02 Nos Injection Pumps (For Pan), Cap-2000 M3/Hr,Head-20 Mtr, VFD Drive-132 Kw 1 x 4000 cub m per hr

02 Nos Injection Pumps (For Pan), Cap-2000 M3/Hr,Head-20 Mtr, VFD Drive-132 Kw 1 x 4000 cub m per hr to be added

100.00

02 Nos Injection Pumps (For Pan), Cap-700 M3/Hr,Head-22 Mtr, Drive-60 Kw

02 Nos Injection Pumps (For Evaporator), Cap-450 M3/Hr,Head-20 Mtr, Drive-45 Kw

iii) SPRAY POND Mist Creating Spray pond having 360 Nos. Nozzles.

Mist Creating Spray pond having 500 Nos. additional Nozzles.

Mist Creating Spray pond having 360 Nos. Nozzles. Mist Creating Spray pond having 360 Nos. additional Nozzles.


Institute, Kanpur.

of 118

iv) SPRAY PUMPS

02 Nos Pumps Cap-2500 M3/Hr, Head-15 mtr, Drive-150kw. 1 x 4000 cub m per hr

02 Nos Pumps Cap-2500 M3/Hr, Head-15 mtr, Drive-150kw. 1 x 4000 cub m per hr additional

h) CRYSTALLIZERS

150.00

10 Nos. air cooled, 02 Nos receiving, 02 nos mono vertical, 01 nos seed and 02 nos vavuum crystallizers

Apart from the existing crystallizers, the following are to be added

Type Nos Capacity Application 2X120 T for new A pans 2X120 T for new A pans

Horizontal air cooled 02 65 MT A- Massecuite

Existing Horizontal air cooled 01 45 MT A- Massecuite shall be used for new C cont receiving

Existing Horizontal air cooled 01 45 MT A- Massecuite shall be used for new C cont receiving

Horizontal air cooled 04 45 MT A- Massecuite

Horizontal air cooled 02 45 MT C- Grain

Horizontal air cooled 02 45 MT B- Massecuite

Horizontal air cooled 02 45 MT B&C cont pan receiver

Mono Vertical water cooled 01 200 MT B- Massecuite


Institute, Kanpur.

of 118

Mono Vertical water cooled 01 300 MT C- Massecuite



Horizontal 01 20 MT Dry Seed

Horizontal Vaccum 01 70 MT A Grain

Horizontal Vaccum 01 70 MT A Grain

Horizontal Vaccum 02 30 MT A&B- Grain

Existing Horizontal Vaccum 01 30 MT shall be used for C grain

Existing Horizontal Vaccum 01 30 MT shall be used for C grain

5 CENTRIFUGAL SECTION A a) CENTRIFUGAL MACHINE

i) BATCH C/F MACHINE

03 Nos KB-1250, Cap-1.25 Ton/Charge Machines for A-M/C,, Make- Thyssen Krupp

01 No. KB-2250, Cap-2.25 Ton/Charge Flat bottom C/F

01 No. KB-2250, Cap-2.25 Ton/Charge Flat bottom C/F additional

100.00

ii) CONTINUOUS C/F MACHINE

7 Nos - Continuous Machines.

200.00 02 Nos. KC-1500 & 01 no. SC-1100 Continuous Machines For CFW M/C, , 02 No NK-1100 for CAW

04 No KC-1500 For B M/C new and discard SC 1100 02 No KC-1500 For CFW M/C new

04 No KC-1500 For B M/C new and discard SC 1100 additional 02 No KC-1500 For CFW M/C new additional

b) MAGMA MIXTURE 02 Nos, Semi Open Double Stirrer Drive

c) MOLASSES RUN OF TANKS 06 Nos, Cap-5 M3

d) AIR COMPRESSOR

02 Nos, Size-EH-200, Cap-250 m3/Hr, RPM- 375, KW-30, Make-Kirloskar.

B SUGAR DRIER


Institute, Kanpur.

of 118

a) HOPPER

Grass Hopper - before FBD,Width- 1.5 Mtr,Length-11.5 Mtr

Grass Hopper - before FBD,Width- 2.0 Mtr,Length-11.5 Mtr

Grass Hopper - before FBD,Width- 2.0 Mtr,Length-11.5 Mtr 20.00

Grass Hopper -after FBD,Width-1.2 Mtr,Length-12 Mtr



b) FLUIDISED BED DRIER (FBD) Cap-25 T/H, Cap-40 T/H, Cap-40 T/H, 80.00

c) SUGAR ELEVATOR

02 Nos, Cap-25 T/Hr each ,Type- Vertical rubber belt type

02 Nos Cap-40 T/Hr each,Type- Vertical rubber belt type

02 Nos Cap-40 T/Hr each,Type- Vertical rubber belt type

20.00

d) SUGAR GRADER

01 Nos, Cap-25 T/Hr, Make I.C. Type-Vibrating Sizer with 6 decks.

01 Nos, Cap-40 T/Hr, Type-Vibrating Sizer with 6 decks.

01 Nos, Cap-40 T/Hr, Type-Vibrating Sizer with 6 decks

40.00

e) SUGAR DISTRIBUTION BELTS

01 no. for Dry Seed-600x10000 mm

6 SUGAR BAGGING & HANDLING

a) SUGAR BINS 03 Nos,Cylendrical & Conical Type.

01 No-For M-Grade, Cap-100 T

01 Nos-For S1-Grade,Cap-150 T

01 No-For S2-Grade, Cap-150 T

b)

SUGAR WEIGHING & BAG FILLING

03 Nos Automatic weighing & bagging machines, Weighing Capacity-50 kg & 100 Kg, Bagging Capacity-300 Bags/Hr, Make- Prayas.

SYSTEM

c) SUGAR BAG HANDLING SYSTEM mannual

Under ground belt conveyor system from Drier House to Sugar Godown.

Under ground belt conveyor system from Drier House to Sugar Godown.

50.00


Institute, Kanpur.

of 118

d) CHECK WEIGHMENT SYSTEM

02 Nos Electronic weighing scale, Capacity-100 +/- 0.02 Kg

e) SLAT CONVEYOR

03 Nos Stich Well Make, Capacity-600 Bags/Hr, Width-550 Speed-7.5 to 9.0 Mtr/Min.

f) STICHING MACHINE

03 Nos Stich Well Make, Capacity-100 Bags/Hr(Minimum), Type-Twin Head

7 GENERAL a) SUGAR GODOWN 03 nos, 02 nos x 74800

bags each and 01 no x 100000 bags stacking capacity. 1 X 248000 bags staking cap 1 X 248000 bags staking cap additional

500.00

b) MOLASSES STORAGE TANK

02 Nos Steel Tanks 3000 m3 capacity (4000 MT) for Final Molasses. 2 x 10000 MT

01 Nos Steel Tanks capacity 10000 MT for Final Molasses. 400.00

c) E.T.P 01 No Effluent Treatment Plant, Cap-1000 M3 /Day Make- Pure Water.

d) C.P.U.

01 No Condensate Polishing Unit, Cap-780 m3/Day, Make-Pure Water.

e) SERVICE WATER PUMP

2Nos, Cap. 250 m3/hr, Head-30 mtr, Drive- 37KW, 1450 rpm

f) SERVICE WATER PUMP (C.W.)

02Nos KPD 150/32 , Cap.-400 m3/hr, Head- 30 mtr , Drive- 45 KW , 1450 rpm

g) JACK WELL PUMP 02 nos VT pumps, Cap-317 m3/Hr, Head-52 mtrs

h) BORE WELL 04 nos KSB make pumps, drive- 7.5 HP


Institute, Kanpur.

of 118

8 STEAM POWER PLANT

A BOILER i) BOILER 01 No. Boiler MAKE-IJT-

Yamunanagar,Cap-80 Ton/Hr. Working Pressure- 87 Kg/cm2, Total Heating Surface Area of Boiler-4312 M2- Type-Water Tube,Super Heater HS Area-894 ,Economiser HS Area-1230 , Air Heater HS Area-258 ,

Modification in Boiler to enhance the capacity by 20 TPH

Modification in Boiler to enhance the capacity by 20 TPH

400.00

ii) FURNACE Type-Spreader Stroke,Grate Area of Furance-1930.

iii) FD FAN 02 Nos. FD Fan Cap.-53388 M3/h,Make-Power build Ltd,Motor-55KW,RPM-984

iv) ID FAN 02 Nos. ID Fan,Make-Power build Ltd,Motor-180KW,RPM-730

v) S.A.FAN 02 Nos,Cap-35280 M3/h,Make-Power build Ltd,Motor-110 KW,RPM-984

vi) BOILER FEED PUMPS 03 Nos. Make-KSB, Capacity - 57.1 m3/h, RPM-2980,Head-1190m,power-280KW

vii) FEED TRANSFER PUMP 02 Nos. Make-KSB, Capacity - 95 m3/h, RPM-2950,Head-85m,power-37KW


Institute, Kanpur.

of 118

viii) LP DOSING SYSTEMS Make-Reliance Industries,Tank Cap. 225 Liter,Pump Cap.-20LPH,Pump Dis. Pressure - 6.5 Kg/cm2, 37 KW

ix) 02 Nos. Make-Sri Rajeshwari Engg, LPH-20,SMP-200

x) HP DOSING SYSTEMS Make-Reliance Industries,Tank Cap. 225 Liter,Pump Cap.-20LPH,Pump Dis. Pressure 120 Kg/cm2 , 37 KW

02 Nos. Make-Sri Rajeshwari Engg, LPH-20,SMP-200, Pump Dis.Pressure - 120 Kg/cm2

xi) FEED WATER TANK 01 Nos. Cap.-60 m3,Design Pressure-2Kg/cm2,Design Temp.-105*C

xii) DEARATOR TANK 01 Nos. Cap.-102TPH,Operating pressure-1.0245Kg/cm2,Temp.-120*C

xiii) HP HEATER 01 Nos. Make-C.Doctor India,Feed water Qty-80 TPH,Tube side Pressure- 140 Kg/cm2

xiv) ELECTRO STATIC PRECIPITATOR Design Dust-Emission

xv) MAIN COOLING WATER PUMPS

04 Nos. Make-Mather+Platt,Cap.-1800


Institute, Kanpur.

of 118

m3/h, Head-30 mtr,RPM-1490,200 KW

xvi) COOLING TOWER FAN'S 03 Nos. Make-Premium Transmission,RPM-1480,55 KW

xvii)

AUXILLARY COOLING WATER PUMPS

02 Nos. Make-KSB,Discharge-300 m3/h,RPM-1480,Head-35 mtr

B COAL HANDLING SYSTEMS

a) MAGNETIC SEPERATOR 01 Nos. Make-Magnetics Corporation of India,Model No. CBM-CP-25RF-2.5TR,RPM-1420,2.2 KW

b) CBC-1 01 Nos.Make-Top Gear Transmission,Gear box,RPM-1450,9.3KW

c) TRAMP METAL DETECTOR

01 Nos.Make-Electromag,Model No.-MS/08.85/SQTA

d) VIBRO SCEENER 01 Nos.Make-Ecoman,Circular type

e) BUCKET ELEVATOR 01 Nos.Make-Top Gear Transmission,Model No.-2260X

f) CRUSHER 01 Nos. Make-Ecoman,Size-800x600,Impactor type

g) BLOWER 01 Nos. Make-Ecoman,Capacity-16500 m3/h

h) CBC-2 01 Nos.Make-Top Gear Transmission,Gear box,RPM-1450,5.5 KW


Institute, Kanpur.

of 118

i) CBC-3 01 Nos.Make-Top Gear Transmission,Gear box,RPM-1450,2.2 KW

j) CBC-4 01 Nos.Make-Top Gear Transmission,Gear box,RPM-1450,5.5 KW

k) SLOT CONVEYOR 01 Nos Make-Top Gear Transmission,Gear box,RPM-1450, 30 KW

C BAGASSE CONVEYOR 06 Nos Make-Top Gear Transmission,Gear box,RPM-1450, 7.5 KW

D ASH BELT CONVEYOR 01 Nos Make-Top Gear Transmission,Gear box,RPM-1450, 3.7 KW

ABC 03 Nos Make-Top Gear Transmission,Gear box,RPM-1450, 3.7 KW

E AIR COMPRESSOR 01 Nos. Kirloskar make,Model-TC50S,Pressure-7 Kg/cm2

01 Nos. Summits make,Model-SA0060DMN,Pressure-7 Kg/cm2

f) CHIMNEY RCC construction & suitable to accommondate one more Boiler, cap-125 ton/hr approx.Height-75 Meters,I.D-5.0 Meters

9 WATER TREATMENT PLANT

01 Nos.Thermax make RO cum mix bed Plant Cap.-10 m3/Hour followed by 01 No ION Exchange make DM Plant cap- 20 m3/hr.


Institute, Kanpur.

of 118

Bagasse Drying System Complete Bagasse Drying system for handling 40T bagasse per hour

Complete Bagasse Drying system for handling 40T bagasse per hour

400

10 POWER PLANT A POWER TURBINE 01 Nos- Multistage

extraction Siemens MAKE-TURBINE- 18000 KW, Steam pressure-86 Kg/cm2, 6800 RPM

Steam Temp-5150 c +/- 5 , Gear Box Triveni

ALTERNATOR 11 KV HT Voltage , 3 Phase, 18743 KW, Alternator TDPS Make

CONDENSOR -01 Nos.Surface Condensor Make-GEL of Heating Suface 1333 mtr2, No. of tube-4683

-02 Nos Condensate Pumps Make-Sulzer,Head-80 mtr,RPM-2960,24.5 KW

C SWITCH YARD 01 no. Transformer cap-25 MVA, 110 KV, Make- Crompton Greaves, 03 nos. P.T., 03 nos C.T.

D COGEN AUXILLARY TRANSFORMER

02 nos cap- 1.75 KVA, 11000 V/415V make - Crompton Greaves.

Automation at mills and boiling house 200.00

Total of Plant and Machinery 7030.00

B D.G. SET 01 No,Make- Perkins, 1500 KVA, HZ-50,Voltage-11 KV AC, AMP-70 l


Institute, Kanpur.

of 118

Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and

Energy Ltd Prepared by National Sugar Institute, Kanpur.

of 118

9. Working Parameters

PERFOFMANCE TARGETS

S. No.Parameters Unit Targets

1 Season Duration days 180.00

2 Sugarcane Yield t/hec. 75.00

3 Cane Crush Rate tch 230.00

4 Stoppages

1. Mechanical/ Electrical % available hrs. 1.00

2. Process % available hrs. 1.00

3. General Cleaning % available hrs. 1.00

4. Miscellaneous & festivals % available hrs. 1.00

5. Cane % available hrs. 1.00

Total % available hrs. 5.00

5 Sugar Loss

1. In Bagasse % cane 0.55

2. In Press Mud % cane 0.04

3. In Molasses % cane 1.15

4. Unknown % cane 0.06

Total % cane 1.80



of 118

6 Process Parameters

1. Pol in Cane 12.30

2. Fibre in Cane 14.50

3. Primary Juice

Bx % 19.00

Pol % 15.55

Purity % 81.84

4. Mixed Juice

Bx % 14.00

Pol % 11.25

Purity % 80.36

5. Last Mill Juice

Bx % 2.00

Pol % 1.40

Purity % 70.00

6. Bagasse

Quantity % Cane 29.97

Pol % Cane 1.83

Moisutre % Cane 49.00



of 118

7. Filter Cake

Quantity % Cane 3.40

Pol % Cane 1.20

8. Clear Juice

Bx % 13.52

Pol % 10.93

Purity % 80.86

7 Process Efficiency

a. Mill Extraction % 95.61

b. Reduced Mill Extraction % 96.31

c. Boiling House Recovery % 89.35

d. Reduced Boiling House recovery % 92.31

e. Virtual Putity of Molasses % 30.35

f. Purity Rise - MJ to CJ % 0.50

g. Final Molasses Purity % 29.00

h. Final Molasses Brix % 92.00

i. syrup Brix % 66.00

j. Imbibition % Fibre 250



of 118

8 Estimated Recovery % cane 10.50

9 sugar Production (Grade wise) % of toal

L- 30 0.00

M-30 10.00

S-30 90.00

10 Process Stores Consumption

1. Lime % cane 0.14

2. Sulphur % cane 0.04

11 Steam and Fuel Consumption

1. Steam consumption for process % cane 32.50

2. Steam /Fuel ratio kg/kg 2.51

3. Moisture in bagasse % 49.00

4. Bagasse consumption % cane 20.00

5. Extra fuel consumption % cane Nil

6. Bagasse consumption at vaccum filter % cane 0.50

7. Bagasse produced % cane 30.00

8. Power Export

i. During Season (180 days)



of 118

Total Power Generation MWhr 18.005

Power Consumption MWhr 7.348

Power Export MWhr 10.657

ii. During Off- Season (25 days saved bagasse)

Total Power Generation MWhr 17.996

Power Consumption MWhr 2.072

Power Export MWhr 15.924



of 118

10. Fuel Balance

BAGASSE /FUEL BALANCE (SEASON)

1 CANE CRUSH RATE TCD 4800.000

2 DAYS OF SEASON OPERATION DAYS 180.000

3 TOTAL CANE CRUSHED LMT 8.640

4 BAGASSE % CANE % 30.000

5 TOTAL BAGASSE PRODUCED LMT 2.592

6 BAGASILLO AND WINDAGE LOSSES % CANE 0.800

7 BAGASILLO AND WINDAGE LOSSES LMT 0.069

8 BAGASSE AVAILABLE FOR COGEN LMT 2.523

9 STEAM GENERATION TPH 100.000

10 STEAM FUEL RATIO 2.488

11 BAGASSE REQUIREMENT LMT 1.736

12 SURPLUS BAGASSE LMT 0.786

MT 78643.882



of 118

BAGASSE /FUEL BALANCE (OFF-SEASON)

1 CANE CRUSH RATE TCD 0.000

2 DAYS OF OPERATION DAYS 110.000

3 TOTAL CANE CRUSHED LMT 0.000

4 BAGASSE % CANE % 0.000

5 TOTAL BAGASSE PRODUCED LMT 0.000

6 BAGASILLO AND WINDAGE LOSSES % CANE

7 BAGASILLO AND WINDAGE LOSSES LMT 0.000

8 BAGASSE AVAILABLE FOR COGEN from season LMT 0.786


10 STEAM FUEL RATIO 2.488

11 BAGASSE REQUIREMENT LMT 0.764

12 EXTRA BAGASSE TO BE PURCHASED LMT -0.022

MT -

2240.47



of 118

11. Steam Balance

STAEM BALANCE (SEASON)


2 HP Steam for SJAE & GSC TPH 0.450

3 HP heater 1 TPH 0.000

4 MP Steam at 8 kg/cm2 TPH 9.800

5 Distillery/Ethanol Plant TPH 0.000

6 HP Heater 2 TPH 10.000

7 Desuperheating Water addition TPH 0.200

8 LP Steam at 2.5 kg/cm2 TPH 77.776

9 Sugar Process TPH 76.364

10 De-aerator TPH 3.000

11 Desuper heating water addition TPH 1.587

12 Condensing Steam TPH 11.974

Total Steam TPH 100.000



of 118

STAEM BALANCE (OFF-SEASON)


2 HP Steam for SJAE & GSC TPH 0.360

3 HP heater 1 TPH 0.000

4 MP Steam at 8 kg/cm2 TPH 6.350

5 Distillery/Ethanol Plant TPH 0.000

6 HP Heater 2 TPH 6.480

7 Desuperheating Water addition TPH 0.130

8 LP Steam at 2.5 kg/cm2 TPH 2.117

9 Sugar Process TPH 0.000

10 De-aerator TPH 2.160

11 Desuper heating water addition TPH 0.043

12 Condensing Steam TPH 63.173

Total Steam TPH 72.000



of 118

12. Power Balance

POWER BALANCE (SEASON)

1 POWER GENERATED MW 18.100

2 CONSUMPTION IN SUGAR PLANT MW 5.018

3 FOR LIGHTING AND COLONIES MW 0.500

4 FOR CCOGEN AUXILIARY MW 1.629

5 DISTILLERY/ENA/ETHANOL PLANT MW 0.000

6 TOTAL CAPTIVE POWER CONSUMPTION MW 7.147

7 EXPORTABLE POWER MW 10.953



of 118

POWER BALANCE (OFF-SEASON)

1 POWER GENERATED MW 17.910

2 CONSUMPTION IN SUGAR PLANT MW 0.350

3 FOR LIGHTING AND COLONIES MW 0.100

4 FOR CCOGEN AUXILIARY MW 1.612

5 DISTILLERY/ENA/ETHANOL PLANT MW 0.000

6 TOTAL CAPTIVE POWER CONSUMPTION MW 2.062

7 EXPORTABLE POWER MW 15.848


Institute, Kanpur.

of 118

Steam Balance for Boiling House Quintuple Effect FFE set 1 TCH 230 2 MJ Bx 12.61% 3 CJ Bx 11.13 4 Syrup Bx 67.9294003 5 Total Evaporation t/h 259.54 259.54 Exhaust I II III IV V Drop kPaa 32 32 32 32 35 6 Prs Cal kPaa 200 200 168 136 104 72 Vap kPaa 168 136 104 72 37 Drop oC 10.2 5 7.5 13.1 15.21 7 Temp Cal oC 125 125 114.8 109.8 102.3 89.2 Vap oC 114.8 109.8 102.3 89.2 73.99 sat oC 120.2 114.8 109.8 102.3 89.2 73.99 8 Qty t/h 30.13 69.307 64.6038 59.9147 49.29915 11.68909 9 Flash vapor t/h 0.72 1.01 2.16 3.5

10 Factor 0.9433 1.0473 1.047 1.046 1.044 11 Evaporation t/h 65.378 67.6596 62.7307 51.56691 12.20341 12 Heating surface sq m 2000 2000 2000 1800 1600 13 ER kg/sqm/hr 32.689 33.8298 31.3653 28.64828 7.627134 14 Total Heat kJ/kg 2716.6 2699.7 2691.5 2680.4 2663.4 2323.15 15 Bleeding 16 To Condenser 0 17 RJ1 t/h 12.20341 18 Rj2 t/h 7.05


Institute, Kanpur.

of 118

19 SJ1 t/h 4.153652 20 SJ2 t/h 11.77 21 CJ 1 t/h 3.82587 22 CJ 2 t/h 3.76 23 A Pan t/h 23 24 B Pan t/h 8.28 25 C Pan t/h 4.6 26 Bg Pan t/h 1.0626 27 Cg Pan t/h 0.4313 28 Molasses Cond t/h 0.897 29 B-C Melter t/h 0.391 30 Total 1.4939 8.75489 15.5915 43.37782 12.20341

31 Steam for losses and other miscllaneous uses

% Cane 1.93

32 Total Steam Consumption

% Cane 32.06


Institute, Kanpur.

of 118

13.


Institute, Kanpur.

of 118

14. HMBD for the Plant


Institute, Kanpur.

of 118


Institute, Kanpur.

of 118

15. MATERIAL BALANCE:

GM SUGAR AND ENERGY LTD. SANGUR Material Balance

1 Basic parameter SUMMARY

Milling rate -TCD 4800.

00

-TCH 230.0

0 MATERIAL %

Cane t/h cu.mt/h

Cane - Pol% 11.58 Cane 100.0 230.0

Fibre % 13.00 Bagasse 35.7 82.1

First expressed Juice - bx 19.34 Imbibition 35.1 80.7 80.7

- Purity 80.51 Mixed Juice 99.4 228.6 215.7

Mixed Juice purity 78.29 Quick Lime 0.2 0.4 Last Mill juice Purity 71.43 Milk of lime 3.2 7.3 7.0

Imbibition % fibre 300.0

0 Sulphur 0.1 0.1 Sulphur di oxide 0.1 0.3 738.0 2 Bagasse Air for sulphur burner 989.0 Pol % 1.86 Filter Cake 4.0 9.2 Moisture % 50.56 Filter Cake wash water 6.0 13.8 13.8 Fibre % 46.84 Filtrate 15.0 34.5 32.2


Institute, Kanpur.

of 118

Bagasse % cane 35.70 Raw Juice 114.4 263.1 248.2 -t/hr. 82.11 Sulphured Juice 117.6 270.5 255.2 pol in Bagasse %cane 0.66 Clear Juice to evaporator 105.9 243.5 229.7 Syrup 17.3 39.9 30.7 3 Imbibition

% cane 35.09 Pan Floor Material Soild t/h Bx Pol Pty % on Cane

t/hr. 80.71

A Massecuite 26.68 61.36 94.52 81.30

86.01 28.23

4 Mixed Juice B Massecuite 11.49 26.41

59 96.92 66.77

68.89 11.85

DMF 71.30 C Massecuite 7.58 17.44 100.1

1 51.35

51.29 7.57

% cane (nett) 99.39 Pol in MJ% cane 11.36 Total Massecuite % Cane 45.75 47.65

Mixed Juice A Heavy Molasses 11.49 26.41

59 81.6 56.38

69.09 14.07

Pol % 11.43 A Light Molasses 1.78 4.1 74.66 67.12

89.90 2.38

-Bx % 12.61 B Heavy Molasses 6.75 15.53 84.12 41.98

49.9 8.03

Bx. In Mixed Juice % cane 12.53 C Light Molasses 1.60 3.67 72.6 48.85

67.29 2.20

N-S in MJ % cane 1.17 Final Molasses 4.72 10.8 87.29 27.16

31.11 5.40

B Magma 4.73 10.9 90 86.40 96 5.26


Institute, Kanpur.

of 118

5 Extraction CAfter Magma 1.27 2.9 90 86.40 96 1.41

C Fore Cured Sugar 2.87 6.6 90 72.00 80 3.18

Recorded extraction % 98.10 Product Sugar 9.67 22.24 99.96 99.95

99.99 9.68

Reduced extraction % (mittal) 98.31

20 C – Massecuite solids balance

6 Cao & Milk of Lime

CaO -%cane 0.17 B-molasses purity 49.9

-Kg/hr 391 B molasses solids in C m/c % cane 6.75

Quick Lime (80% purity) -%cane 0.19

- Kg/hr 437 21 B – Massecuite & B- Sugar

Milk Of Lime

-Beaume 6.00

- kg/hr 7261.

43 B massecuite purity 68.89

-Cu m /h 6.98 B- foresugar purity 96

-%cane 3.16 B-massecuite solids % cane 11.49

B- foresugar solids % cane 4.73


Institute, Kanpur.

of 118

7 Sulphur & sulphur Dioxide Pan dropping Bx. 96.92

Sulphur -%cane 0.06

Expected crystal content % Massecuite 38.33

-kg/hr 138.0

0 Expected exhaustion % 18.99 Commercial sulphur -purity 99.9

-%cane 0.06 22 A-Heavy molasses

-kg/hr 138.1

4

Sulphur di-oxide -%cane 0.12 A-H molasses purity 69.09

(60 deg C,1.0 bar(g)) -Kg/hr 276.0

0 AH molasses in B Massecuite %cane 11.49

-cu m/hr

737.968 Total 11.49

For Juice Sulphitation -Kg/hr 184.0

0 For Syrup Sulphitation -Kg/hr 92.00 23 MELT

B sugar solid for melting - % Cane 4.73

8 Compressed Air C sugar solid for melting - % Cane 1.27

Volume required -cu m/hr 989 B+C Sugar solids for melting

- % Cane 6.00

Juice Sulphitor -cu m/hr 593.4 B+C Sugar magma brix 90

Syrup Sulphitor -cu m/hr 395.6 B+C Sugar magma quantity

- % Cane 6.67


Institute, Kanpur.

of 118

Dust & Rori sugar for melting - % Cane 1.00

9 Bagacillo Dust & Rori sugar magma brix 90

Mill wet (50% moisture) - Kg/tch 12.5

Dust & Rori sugar magma quantity

- % Cane 1.11

-Kg/hr 2875 Total sugar solids for melting - % Cane 7.0

-% cane 1.25 Total Magma for melting

- % Cane 7.78

Dry basis -% cane 0.63 Avg magma brix for melting 90

Is clear juice used for melting Y/N 1/0 0

10 Filter Cake Clear Juice for melting

- % Cane 0

Mud solids % cane 0.65 Clear Juice solid in melt - % Cane 0

Total dry solids %cane 1.28 Total Melt solids - % Cane 7.0

Moisture %filter cake 70 Total Melt quantity - % Cane 10.00

filter cake %cane 4 - t/h 23.00

-t/h 9.20 - cu.m/h 17.04

Pol %filtercake 2.64 Pol in filter cake %cane 0.11 24 SYRUP SULPHITER 11 Filter wash water Syrup from Evaporator

- % Cane 17.34


Institute, Kanpur.

of 118

Qty % cane 6 - t/h 39.89 -t/h 13.80 12 Filterate 25 A LIGHT MOLASSES

Dry solids % in Sulphured juice 0.8

Dry solids % clarifier underflow 4.8 Reference purity A Sugar 99.9

Clarifier underflow -% cane 14.8 Purity A Light molasses 89.9

-t/h 34.04 A Light molasses solids % Cane 1.78

filterate -% cane 15

-t/h 34.50 26 A MASSECUITE 13 Raw Juice Input Material % Cane Sulphured syrup soilds 17.34 Mixed % cane 99.39 Melt Solids 7.0 Filterate %cane 15.00 A Light molasses soilds 1.78

Raw Juice -% Cane

114.39 Total soilds input 26.1

-t/h 263.0

97 Purity 86.01

-cu m/hr

248.20

Output material % Cane


Institute, Kanpur.

of 118

14 Sulphured Juice A Sugar 9.68

Raw juice % cane 114.3

9 AH Molasses 11.49 Milk Of Lime % Cane 3.16 AL Molasses 1.78

Sulphur dioxide % cane(55 % abs) 0.06 Total Soilds output 22.94

Sulphured Juice - % Cane

117.61

-t/h 270.5

0 27 EVAPORATION IN PANS %CANE

-cu m/hr

255.19

(a) A Massecuite Boiling

15 Clear Juice Dropping Brix 94.52 Mixed Juice % cane 99.39 Input Material : Milk of lime% Cane 3.16 Syrup @ 65 Bx 26.68 Sulphur di oxide % Cane 0.06 Seed Magma @ 70 Bx 10.00 Fresh Wash Water %cane 6 A Light Molasses @ 70 Bx 2.54 Bagacillo % Cane 1.25 Total input material 39.22 Filter cake % Cane ( less) 4

Clear Juice % Cane 105.8

6 Output Material : Pol in clear juice % Cane 9.22 A Massecuite @94 Bx 28.38 NS in clear juice % Cane 2.57 Evaporation 6.76

Clear Juice - pol% 8.7

Add Movement water @ 3% MC Soilds 0.851


Institute, Kanpur.

of 118

- Bx% 11.13 Total Evaporation 7.61

- Purity 78.22

- t/h 243.4

7 (b) B Massecuite Boiling

For Melting - t/h 0 Dropping Brix 96.92

- % Cane 0 Input Material :

AH Molasses 16.41

To evaporator - t/h 243.4

7 Total input material 16.41

-cu m/hr

234.107

- % Cane

105.86 Output Material :

16 Syrup Bx% 67.93 B Massecuite @96 Bx 11.85 Total evaporation % cane 88.51 Evaporation 4.56

Syrup -%cane 17.34

Add Movement water @ 5% MC Soilds

0.57426

- t/h 39.89 Total Evaporation 5.13

- cu m /hr 30.69

( c) C Massecuite Boiling

17 Final molasses Dropping Brix 102


Institute, Kanpur.

of 118

Purity product Sugar 99.9 Input Material : Purity final molasses 31.11 AH Molasses@80 0

Final molasses solids % cane 4.72 BH Molasses @80 8.44

Final molasses sugar % cane 1.28 CL Molasses @80 2.0

Final molasses NS % cane 3.44 Total input material 10.44 18

C-massecuite & C- foresugar Output Material :

C massecuite purity 51.29 C Massecuite @102 Bx 7.43 C- foresugar purity 80 Evaporation 1.60

C-massecuite solids % cane 7.58 Add Movement water @ 10% MC Soilds 0.74

C- foresugar solids % cane 2.87 Total Evaporation 2.35

Pan dropping Bx. 100.1

1

Expected crystal content % Massecuite 29.33

Total Pan Floor evaporation % Cane 15.09

Expected exhaustion % 20.18 Bled Vapour requirement for pans % Cane 15.09

19

C-After sugar & C-light molasses

C-after sugar purity 96 C-light molasses purity 67.29

C-after sugar solids 1.268

53 C-light molasses solids 1.60


Institute, Kanpur.

of 118

C-magma Brix 90

Expected crystal content % magma 78.99

Expected exhaustion % 28.71



of 118

16. Technical Feasibility

Modernization cum Expansion of the plant has been proposed by alteration and additions of suitable plant and machinery. The project has been prepared by Experts from National Sugar Institute, Kanpur who is considered to be the best in this field. Detailed specifications of plant and machinery are given in para-9 of the report. This DPR shows:

1. Land availability is there for the expansion. Ref Para- 7.1 2. Raw material required for the project is sufficient. Ref Para-7.2 3. There is surplus of water available for the plant operation and

maintenance. Ref Para 7.3 4. Due to co-gen plant of the plant, there is enough of power available. 5. The process to be adopted, Ref papa 8; is a well proven process and is

followed by number of factories in India and worldwide. 6. The targets fixed for the working parameters are well within the reach. Ref

para-10 7. Availability of fuel for the project is sufficient. Ref para 11 8. Availability of steam for the project is sufficient. Ref para 12 9. Man power required for the project is sufficiently available. Ref para 16/17

Keeping in view the above points, which are the requirements for any project to be technically viable, it ascertained that the project is technically feasible.



of 118

17. Organizational Set-up

The present organizational set up of the plant is as follows:

Existing Streingth for Sugar Season 2016-17

S.N. Position Shift

A Shift B Shift C Shift R General Vacant Total Engineering

1 Chief Engineer 1 1 2 Dy C E 1 1 3 Drafts Man 1 1

Mill House 4 Shift Engr 1 1 1 1 4 5 Fore Man 1 1 6 Fitter 1 1 1 1 1 5 7 Fitter Helper 2 2 2 1 1 8 8 Oil Man 1 1 1 1 4 9 RTC Operator 1 1 1 1 4

10 Pump Attdr 1 1 1 3 11 Feeder Tb opr 1 1 1 3 12 Welder 1 1 1 1 4 13 Unloader opr 4 4 4 2 14 14 Regger 2 2 2 1 1 8 15 Attdr 1 1

Boiling House 16 Fore Man 1 1 17 Fitter 2 2 2 1 7 18 Fitter Helper 1 1 1 1 4 19 Oil Man 1 1 1 1 4 20 Pump Attdr 2 2 2 1 7 21 Welder 1 1 1 1 4

Work Shop 22 Engineer 1 1 23 Turner 1 1 1 1 4 24 Machinist 1 1 25 Carpenter 1 1



of 118

26 Fitter 1 1 27 Helper 2 2 28 Jackwell opr 1 1 1 3

Manufacturing 29 Chief Chemist 1 1 30 Dy C C 1 1 31 Shift Chemist 1 1 1 1 4 32 Juice Supervisor 1 1 1 3 33 Evap Mate 1 1 1 1 4 34 Juice Sul Mate 1 1 1 1 4 35 RVF mate 1 1 1 1 4 36 Dorr mate 1 1 1 3 37 SB Attdr 1 1 1 3 38 JH Attdr 1 1 1 3 39 Pan Incharge 1 1 1 1 4 40 Pan Man / Asst. P Man 5 5 5 2 17 41 Pan Helper 2 2 2 1 7 42 Centrifugal Mate 1 1 1 1 4 43 Centrifugal Opr 4 4 4 2 14 44 Crystallizer attdr 2 2 2 1 7 45 Melter Attdr 1 1 1 1 4 46 Magma mixer Attdr 2 2 2 1 7

ETP 47 ETP Opr 1 1 1 1 4 48 LAB 49 Lab I/C 1 1 50 Lab Chemist 1 1 1 1 1 5 51 Lab Boy 2 2 2 1 1 8

Materials 52 Material Manager 1 1 53 Godown Keeper 2 2 54 Clerk 2 2 55 Attdr 2 2 56 Store I/C 1 1 57 Store Keeper 1 1 58 Clerk 1 1 59 Asst Store Keeper 1 1 1 1 4 60 Attdr 2 2

Total 230



of 118

Casual Labour Enginnering Man Power for Engineering 102 Casual lab for CC 6 Man Power for Manufacturing 112

Casual lab for Mill & W/S 12 Man power for Store & Godown 16

Manufacturing Casual Labour 49 Hopper Attdr 3 Total 279 Syp/ Mol tank mazdur 6 RVF Helper 6 ETP Mazdur 8 Store Attdr 2 Cleaning Mazdur 6 Total 49



of 118

18. Manpower Requirement

The present strength of manpower is sufficient for the expanded capacity

because;

1. There is no increase of any section or station. There is only increase in

equipment capacities.

2. Due to implementation of automation, there will be saving in manpower

as no of batch equipments will be made continuous and automated.

Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and Energy Ltd Prepared by National

Sugar Institute, Kanpur.

of 118

19. Project Implementation and Schedule



of 118

19.1 SWOT ANALYSIS

Strengths (S)

I. Excellent sugarcane availability in the area of operation to the tune

of about 12.5 lakh MT.

II. Required equity and bank loans are in place

III. Required land is in possession

IV. Professionally and efficiently managed organization by promoters

and technical team

V. Major NOCs are already secured

VI. Availability of basic infrastructure

VII. Crushing season starts from November to April, which is the

period, when the demand for the power is at peak level. Excess

power generated by the Project will help to meet peak demand of

the state utility.

VIII. Environment friendly power generation

IX. Close to demand/load centers

X. Low transmission cost



of 118

Weaknesses (W)

I. Delay in project implementation may increase capital cost

(GMSPL will take due care for commissioning of the plant within

the desired time & cost schedules)

Opportunities (O)

i. Expansion of sugar & cogen plant

ii. Levy sugar is removed

iii. Decontrol of Sugar Sector

iv. A Sugar Plant with grid connected Cogen Project is now well

proven in India, for techno - commercial viability

v. Ease in sale of sugar

vi. Keenness of Government of Karnataka to purchase power

vii. Availability of nearby KPTCL substation and grid to evacuate

exportable surplus

viii. Capital subsidies from MNRE & low cost funds from SDF

ix. Potential for trade of emission reductions in the international

market

x. Demand supply gap existing in the State. Potential for KSEDCL to

absorb the complete excess power generated due to demand

supply gap



of 118

xi. Opportunities for selling the sugar internationally owing to export

subsidy and power to any third party through a power trader as

allowed in Electricity Act 2003

xii. KERC’s Renewable Purchase Specification (RPS) to all distribution

licensees.

xiii. Most of the State Electricity Regulatory Commissions have come

up with RPS specifications. Therefore if the State utility is not in a

position to absorb the power generated, this can be sold to

utilities outside the state through open access

Threats (T)

I. Fluctuating prices of sugar

II. Over dependence on KSEDCL for revenue in the PPA.

Alternatively, third party buyers can be identified.

III. Cycle or climatic changes leading to low crushing. Cane

development in the nearby area to reduce shortage of

sugarcane

IV. Threats from diseases on sugarcane.

V. Delay in project implementation which may lead to project

overrun and cost overrun



of 118

20. Codes and Standards:

Systems and equipment will be designed in accordance with the

applicable sections of the following codes, standards and regulations

in effect at the date of the Contract. Applicable sections of codes,

standards and regulations will be defined in specifications.

Indian Standards (IS)

IS : 6 : Moderate heat duty fire clay refractories

Group-A

IS : 8 : High heat duty fire clay refractories

IS : 325 : Three phase induction motors

IS : 456 : RCC Structures

IS : 498 : Grading for Vacuum Pan Sugar

IS: 800 : Code of practice for Constructions in steel

IS: 807 : Code of practice for Design, Manufacture,

Erection and Testing (Structural Portion of

Cranes & Hoists)

IS : 875 : Code of practice for Design loads for

building

Structures

IS : 1162 : Cane Molasses

IS : 1554 : PVC insulated (heavy duty) electrical cables

IS : 1651 : Stationary cells and batteries, lead-acid type

(with Tubular positive plates)



of 118

IS : 1893 : Criteria for earthquake Resistant-Design of

Structures

IS : 1973 : Sugarcane Crushers

IS : 2026 : Power Transformer

IS : 1893 : Criteria for earthquake Resistant-Design of

Structures

IS :2309 : Practice for the protection of the buildings

and Allied Structures against lighting – code

of Practice

IS : 2429 : Round Steel Short link chain electric butt

welded Gr.30

IS : 2544 : Porcelain post-insulators for system with

Nominal voltage Greater than 1000V.

IS :2705 : Current Transformers

IS : 2825 : Code for unfired pressure vessels

IS : 3043 : Code for practice for earthing

IS : 3144 : “Methods of test for Mineral Wool Thermal

Insulation Material”

IS : 3156 : Voltage Transformer

IS : 3177 : Code practice for design of Electrical

OverheadTraveling Crane and Gantry Crane

IS : 3427 : Metal-enclosed switchgear and control gear

for Rated Voltages above 1kv and including

52 kv



of 118

IS : 3646 : Code of practice for interior illumination

IS : 3832 : Hand Operated Chain pulley blocks

IS : 3938 : Specification for Electric Wire Rope Hoists

IS : 4503 : Shell and Tube Heat Exchangers

IS : 4772 : Code of practice for Construction of Sugar

Godowns

IS : 4776 : Toughed Belt Conveyors

IS : 4903 : Guide for Treatment and disposal of

Effluents of cane Sugar Industry

IS : 5422 : Turbine type generators

IS : 5521 : Steel Tanks for Storage of Molasses

IS : 5527 : layout plant for Sugar Factory Laboratories

IS : 5982 : Plantation White Sugar for

Identification

IS : 6547 : Specification for Electrical Chain Hoists

IS : 6983 : Rollers and Axis for Sugarcane Crushers

IS : 6997 : Test code for sugar cane crushers

IS :7098 : Cross linked polyethylene insulated

PVC Sheathed cables

IS : 7155 : Code of recommended practice for Conveyor

Safety



of 118

IS : 7424 : Photoelectric Reflectance method

for Measurement of Whiteness of

Plantation White Sugar in Solid State

IS : 8183 : “specification for Bonded Mineral Wool”

IS : 8466 : Bagasse Carrier Chains

IS : 8531 : Pulleys for Belt Conveyors

IS : 8598 : Idlers and Idler Sets for Belt

Conveyors

IS 8623 : Low voltage switchgear and control Gear

assemblies

IS 9069 : Inter-Carrier Chains

IS 9921 : Alternating current disconnectors

(isolators) &

earthing switchers for voltage above 1000V

IS 9952 : Batch type Centrifugal Liners for Final

Massecuite for sugar industry

IS 10556 : Code of practice for storage and handling of

insulating Materials

IS 11102 : Glass Bottles for sugar standards

IS 11592 : Code of Practice for Selecting and Design of

Belt Conveyors



of 118

IS 12198 : Sprockets for Sugar Factories

IS 13118 : High voltage alternating current circuit

beakers

IS 13947 : LV switchgears and control gear

IS 13770 : Static wait hour meters, class 1 and 2

IS 14164 : Industrial application and finishing of

Thermal

insulating materials at Temperatures above

80OC and upto 700OC

IS 14350 : Code of Hygienic Conditions for Sugar

Factories

American Society of Mechanical Engineers ( ASME)

ASME Section I : Rules for construction of power boilers

ASME Section IX : Welding & Brazing Qualifications

ASME Section VIII : Unfired Pressure Vessels Code

ASME Section IX : Welding Qualification

ASME Performance Test Code

ASME PTC 4.1 : steam Generating Units

ASME PTC 4.3 : Air Heaters



of 118

ASME PTC 3.0 : Guide for evaluation of Measurement

Uncertainty in performance test of steam Turbine

ASMW PTC 10.11 : Water and Steam in the Power Cycle (Purity

and Quality , Leak detection and Measurement).

ASMW PTC 25.3 : Safety and Relief Valves

American National Standards Institute

ASME B 13.5 : Pipe flanges and flanged fittings

ASME B 13.9 : Butt welding fittings

ASME B 13.11 : Socket Welding and Threaded fittings

ASME B 31.1 : Code for Power piping

IEEE STANDARDS

IEEE :80 : Guide for safety in AC substation Grounding

IEEE: 141 : Recommended Practice for Electric Power

Distribution of Industrial and Commercial

Power Systems

IEEE: 142 : Recommended Practice for Grounding of

Industrial

and Commercial Power Systems

IEEE:241 : Recommended Practice for Electric Power

Systems.

in Commercial buildings

IEEE:242 : Recommended Practice for Protection and



of 118

Coordination of Industrial and Commercial

Power Systems

IEEE:399 : Recommended Practice for

Industrial and Commercial Power Systems

IEEE:446 : Recommended Practice for Emergency

And Standby Power for Industrial and

Commercial Power Systems

IEEE :493 : Recommended Practice for the Design of

Industrialand Commercial Power Systems

IEC Standards

IEC :34 : Rotating Electric machines

IEC :44 : Instrument Transformers

IEC : 56 : HVAC circuit breakers

IEC : 71 : Coordination of insulation

IEC : 76 : Power Transformers

IEC : 85 : Thermal evaluation and classification of

Electrical Insulations

IEC: 99 : Lighting Arrestors

IEC: 129 : Alternating current disconnectors

(Isolators) and Earthing Switches



of 118

IEC : 144 : Degrees of protection of enclosures for low

Voltage switchgear & control gear

IEC : 137 :Bushings for Alternating Voltages Above 1000 V

IEC : 183 : Guide for selection of HV cables

IEC : 185 : Current Transformers

IEC : 186 : Potential Transformers

IEC : 214 : On loan tap changers

IEC : 227 : PVC insulated electric cables

IEC : 255 : electrical relays

IEC : 269 : LV fuses

IEC : 270 : Partial discharge requirements

IEC : 296 : Insulating oils

IEC : 298 : AC metal enclosed switch gear and control gear for

rated voltages above 1 kV and upto and Including 52

kV.

IEC : 354 : Loading guide for oil immersed Power

Transformers

IEC : 376 : Specification and acceptance of new

sulphur

hexafluoride

IEC : 439 : LV switchgears and control gear assembly



of 118

IEC : 502 : Extruded solid dielectric insulated power for

Rated voltages from 1 kV upto 30 kV

IEC : 529 : Classification of degree of protection

IEC : 542 : Application guide for on load tap changers

IEC : 606 : Application guide for power transformers

IEC : 694 : Degrees of protection provided by enclosure

(IP code)

IEC : 885 : Electric test methods for electric cables

IEC : 909 : Short circuit current calculation in Three

phase AC systems

IEC : 947 : LV switchgears and control gear

IEC : 1036 : Static meters

Industry Standards (As determined to be applicable by Contractor)

Indian Boiler Regulations (IBR)

American Gear Manufacturers Association (AGMA)

American Petroleum Institute (AP1)

American Society for Heating, Refrigeration and Air-conditioning

Engineers (ASHRAE) Handbook

American Society for Testing and Materials (ASTM)

American Water works Association (AWWA)

American welding society (AWS) Structural Welding Code (AWS D1.1)

Conveyor Equipment Manufacturers Association (CEMA)



of 118

Cooling Tower Institute (CTI)

Heat Exchange Institute (HEI)

Hydraulic Institute (HI)

Institute of Electrical and Electronics Engineers (IEEE)

Instrument Society of America (ISA)

Manufacturers Standardization Society (MSS) of the Valve and Fitting

Industry

National Fire Protection Association (NFPA)

Pipe Fabrication Institute (PFI)

Tubular Exchanger Manufacturers Association (TEMA)

Turbine:

IEC Recommendation Publication No : 45CSN 080030DIN 1943

British Standards

BS 4592 : Industrial type metal floors, walkways and

Stair Treads

BS 5395 : Stairs, ladders and walkways

BS 2573 : Permissible Stresses in Cranes

BS:460 : EOT Cranes for general use in factories,

workshops & Warehouses

BS: 5316 : Performance Testing of Pumps Part-I Class C



of 118

RECOMMENDED MINIMUM THICKNESS FORTHERMAL INSULATION (MINERAL

WOOL)

NOMINAL

DIA IN MM OPERATING TEMPERATURE (Dec.C)

Below 101 - 151 - 201 - 251 - 301 - 351 - 401 - 451 -

100 150 200 250 300 350 400 450 500

65 & Below 25 30 30 35 40 45 45 50 60

80 30 35 40 40 45 50 55 60 70

100 35 35 50 45 50 60 65 70 75

125 35 40 45 50 55 65 70 75 80

150 35 40 50 55 60 70 75 80 90

200 35 45 66 60 65 70 80 95 100

250 40 50 60 65 70 80 85 100 110

300 40 55 60 75 80 90 100 110 120

350 45 55 60 75 80 90 100 110 120

400 45 60 70 75 80 80 8 90 105

450 50 60 75 90 - - - - -

500 50 60 75 90 90 105 115 125

135

550 55 60 80 90 95 105 115 125 135

600 55 65 80 95 95 110 120 130 140

Above 600



of 118

& Flat 55 65 80 95 100 110 120 130 140

Surfaces

Note The table is given only as a guideline and the thickness shall be

selected as per the calculations using IS Standard for conductivity.



of 118

21. ABBREVIATIONS

AC : Alternating Current

AGMA : American Gear Manufacturer’s Association

API : American Petroleum Institute

ASHRAE : American Society of Heating, Refrigeration and AC Engineers

ASME : American Society of mechanical Engineers

ASTM: American Society of Testing Materials

AWS : American Welding Society

AWWA : American Water Works Association

BC : Belt conveyor

BS : British Standards

CACW : Closed Air Circuit Water cooled

CBD : Continuous Blow Down

CEMA : Conveyor Equipment Manufacturer’s Association

CT : Current Transformer

CTI : Cooling Tower Institute

CU.M : Cubic Metre

DBT : Dry Bulb Temperature

DC : Direct Current



of 118

DCS : Distributed Control System

DG : Diesel Generating Set

DM : De-Mineralized

DPR : Detailed Project Report

DSCR : Debt Service Coverage Ratio

EL : Slat Chain Elevator/ Elevation

ENA : Extra Neutral Alcohol

EOT : Electrical Operated Overhead Trolley

ESP : Electrostatic Precipitator

ETH : Ethanol

ETP : Effluent Treatment Plant

FD : Forced Draft

GCV : Gross Calorific Value

GOI : Government of India

GOK : Government of Karnataka

GSC : Gland Steam Condenser

HEI : Heat Exchange Institute

HI : Hydraulic Institute

HP : High Pressure



of 118

HT : High Tension

HVAC : Heating, Ventilation & Air Conditioning

HYSD : High Strength Deformed Steel

IBD : Intermittent Blow Down

IBR : Indian Boiler Regulations

ID : Induced Draft

IDC : Interest during Construction

IEC : International Electro technical Commission

IEEE : Institute of Electrical and Electronics Engineers

IRR : Interest Rate on Return

ISA : Instrument society of America

KA : Kilo Ampere

KPTCL : Karnataka Power Transmission Corporation Ltd

KV : Kilo Volt

KW : Kilo Watt

LAVT : Lightning Arrestor & Voltage Transformer

LC : Letter of Credit

LP : Low pressure

LS : Lump Sum



of 118

LT : Low Tension

LV : Low Voltage

MCC : Motor Control Centre

MCR : Maximum Continuous Rating

MNES : Ministry of Non-conventional Energy sources

MSS : Manufacturer’s Standardization Society

MT : Metric Tonnes

NEMA : National Electrical Manufacturer’s Association

NFPA : National Fire Protection Association

NGR : Neutral Grounding Resistor

NPSH : Net Positive Suction Head

PCB : Pollution Control Board

PCC : Power Control Center

PFI : Pipe Fabrication Institute

PLC : Programmable Logic Controller

PLF : Plant Load Factor

PRDS : Pressure Reducing De-superheating Station

PVC : Poly Vinyl Chloride

PT : Potential Transformer



of 118

RBC : Return Belt Conveyor

RCC : Reinforced Cement Concrete

REC : Rural Electrification Corporation Limited

RM : Running Meter

RPM : Revolutions Per Minute

RO : Reverse Osmosis

RS : Rectified Spirit

RTD : Resistance Temperature Detector

SA : Secondary Air

SBC : Soil Bearing Capacity

SC : Slat Chain Conveyor

SCADA : Supervisory Control and Data Acquisition

SG : Steam Generator

SQ.M : Square Metre

TAC : Tariff Advisory Committee

TCD : Tonnes of Cane per Day

TCH : Tonnes of Cane per Hour

TEMA : Tubular Exchanger Manufacturer’s Association

TG : Turbo Generator



of 118

TPH : Tonnes Per Hour

TVM : Trivector Meter

WCM : Working Capital Margin

WBT : Wet Bulb Temperature

XLPE : Cross Linked Poly Ethylene



of 118

FINANCIAL WORKINGS



of 118

M/S GM SUGAR AND ENERGY LTD SANGUR, HAVERI DISTRICT (KARNATAKA)

FINANCIAL FORECAST OF THE ANNUAL WORKING OF THE SUGAR FACTORY

AFTER COMMENCEMENT OF THE PROJECT

S NO

. PARTICULARS UNIT 2016-

17 2017-

18 2018-

19 2019-

20 2020-

21

1 PHYSICAL PARAMETERS 1.01

Additional Installed Crushing Capacity TCD 2500 2500 2500 2500 2500

1.02 Operational Crushing Capacity TCD 2250 2375 2500 2500 2500

1.03 Capacity Utilisation % 90 95 100 100 100

1.04 Working days during Season Days 90 180 180 180 180

1.05 No. of Shift/Days No. 3 3 3 3 3

Gross Days Days 300 300 300 300 300 1.06

Cane Expected to be Crushed ( on the basis of 100% capacity)

Lakh MT Tonnes 9.45 9.45 9.45 9.45 9.45

1.07

Crushed cane in Lakh MT (on the basis of working capacity)

Lakh MT Tonnes 8.51 8.98 9.45 9.45 9.45

1.08 Average Sugar Recovery % Cane 10 10 10 10 10

1.09 Baggase Production

30 % of Cane

2.55204

2.69382

2.8356

2.8356

2.8356

1.10 Total Sugar Production M.T. 42534 89794 94520 94520 94520

1.11

Molasses Production(In lakh MT)

4.5 % of Cane

0.3828

0.4041

0.4253

0.4253

0.4253

1.12 Filter Cake Production

3 % of Cane

0.2552

0.2694

0.2836

0.2836

0.2836

1.13

Electricity Production(Peak season) in units (24 Hrs) (180

days) 20717

208 43736

328 46038

240 46038

240 46038

240

1.14

Electricity Production(Off season) in units (24 Hrs) (130

days) 44723

016 47207

628 49692

240 49692

240 49692

240 1.15 Electricity Rate (Rs Per unit) Units 5.79 5.79 5.79 5.79 5.79



of 118

1.16 Rate of Sugar Rs. / M.T. 36000 36000 36000 36000 36000

1.17 Rate of Molasses Sale Rs. / M.T. 6000 6000 6000 6000 6000

1.18 Rate of Bagasse Rs. / M.T. 1500 1500 1500 1500 1500

1.19 Rate of Filter Cake Rs. / M.T. 100 100 100 100 100

2 INCOME (SALES)

2.1 Sale of Sugar Lakh Rs. 15312

.24 32325

.84 34027

.20 34027

.20 34027

.20

2.2 Sale of Molasses Lakh Rs. 1148.

42 2424.

44 2552.

04 2552.

04 2552.

04

2.3 Sale of Surplus Bagasse Lakh Rs. 0.00 0.00 0.00 0.00 0.00

2.4 Sale of Filter Cake Lakh Rs. 12.76 26.94 28.36 28.36 28.36

2.5 Sale of Electricity (during

season) Lakh Rs. 1199.

53 2532.

33 2665.

61 2665.

61 2665.

61

2.6 Sale of Electricity (during off

season) Lakh Rs. 1294.

73 2733.

32 2877.

18 2877.

18 2877.

18

Total Sales revenue (A) Lakh Rs. 18968 40043 42150 42150 42150

3 EXPENDITURE 3.1.2 Raw Material & Consumables Lakh Rs.

11909.52

25142.32

26465.6

26465.6

26465.6

Purchase tax on Sugar Cane Lakh Rs. 357.2856

754.2696

793.968

793.968

793.968

Chemicals Consumed Lakh Rs. 850.6

8 1795.

88 1890.

40 1890.

4 1890.

4 3.1.3 Power And Fuel Lakh Rs.

861.57

1818.88

1914.61

1914.61

1914.61

3.1.4 Salaries & Wages Lakh Rs.

850.68

1795.88

1890.4

1890.4

1890.4

3.1.5 Insurance Lakh Rs. 21.09 37.15 40.15 40.15 40.15

3.1.6 Repaires & Maintenance Lakh Rs.

102.08

242.44

255.20

255.20

255.20

3.1.7 Total Conversion Cost Lakh Rs.

14952.91

31586.82

33250.33

33250.33

33250.33

3.1.8 GROSS PROFIT Lakh Rs.

4014.76

8456.05

8900.06

8900.06

8900.06

3.1.9

Selling &Adimistrative Exp.@ 2 % of sales Lakh Rs.

379.35

800.86

843.01

843.01

843.01

3.1.10 Depreciation Lakh Rs.

694.17

694.17

694.17

694.17

694.17



of 118

3.1.11 Preliminary Expenses W/off Lakh Rs. 40.00 40.00 40.00 40.00 40.00

3.2 INTEREST 3.2.1 Interest on Working Capital loan Lakh Rs. 35 70 70 70 70

3.2.2 Interest On Term Loan Lakh Rs.

283.80

387.04

290.28

193.52 96.76

3.2.3 Total Interest Lakh Rs. 318.8

457.04

360.28

263.52

166.76

4 Total Cost (B) Lakh Rs. 16385

.23 33578

.89 35187

.79 35091

.03 34994

.27

5 Profit Before Tax (A-B) Lakh Rs. 2582.

44 6463.

98 6962.

60 7059.

36 7156.

12

6 Provision For Tax * Lakh Rs. 852.2

1 2133.

11 2297.

66 2329.

59 2361.

52

Net Profit Lakh Rs. 1730.

24 4330.

87 4664.

95 4729.

77 4794.

60

Add: Depreciation Lakh Rs. 627.5

0 627.5

0 627.5

0 627.5

0 627.5

0

Add: Preliminary exp w/off 40.00 40.00 40.00 40.00 40.00

Cash accruals Lakh Rs. 2397.

74 4998.

37 5332.

45 5397.

27 5462.

10

Cumulative Cash accruals Lakh Rs. 2397.

74 7396.

11 12728

.55 18125

.83 23587

.93

* Assuming tax rate in india 33%

Working for Reserve and \Surplus

Opening 0.00 1730.

24 6061.

11 10726

.05 15455

.83

Current Year Profit 1730.

24 4330.

87 4664.

95 4729.

77 4794.

60

Closing 1730.

24 6061.

11 10726

.05 15455

.83 20250

.43



of 118


PROJECT COST FINANCING PATTERN

PARTICULARS % AMOUNT(in

lakhs)

OWN Finance 10 923

Equity 30 2769

Cash Credit from Bank 8 700 TERM LOAN from Bank 52 4838

Total 100 9230

REPAYMENT OF TERM LOAN

PARTICULARS 2016-17 2017-18

2018-19

2019-20

2020-21

Opening Balance Of Principal 4838.

00 3870.40 2902.

80 1935.

20 967.6

0

Total Installment 967.6

0 967.60 967.6

0 967.6

0 967.6

0

Balance 3870.

40 2902.80 1935.

20 967.6

0 0.00

Interest 283.8

0 387.04 290.2

8 193.5

2 96.76 Note:- Interest for Rs 200 lacs during constructions period is capitalised .



of 118


CALCULATION OF DEBTORS & CREDITORS & INTEREST ON WORKING CAPITAL.

PARICULARS UNIT 2016-

17 2017-

18 2018-

19 2019-

20 2020-

21

Sugar Production MT 42534 89794 94520 94520 94520

Rate 30000 Rs

MT

Total Lakhs 15312.

24 32325.

84 34027.

20 34027.

20 34027.

20

Average Stock Period @ 20 Days Lakhs

1276.02

1771.28

1864.50

1864.50

1864.50

Average Debtor Period @ 20

Days Lakhs 1276.0

2 1771.2

8 1864.5

0 1864.5

0 1864.5

0

Sugar Cane MT 425340 897940 945200 945200 945200

Average Creditor Period @ 20 Days Lakhs

1701.36

1795.88 1890.4 1890.4 1890.4

Interest 10% 35.00 70.00 70.00 70.00 70.00



of 118

M/S GM SUGAR AND ENERGY LTD SANGUR, HAVERI DISTRICT (KARNATAKA) CALCULATION OF BREAK EVEN POINT

PARICULARS UNIT I II III IV V

Net Sales Lakhs

18,967.68 40043 42150 42150 42150

Variable Cost

Raw Material Lakhs

11,909.52

25142.32 26465.6 26465.6 26465.6

Purchase tax on Sugar Cane Lakhs

357.29 754.27 793.97 793.97 793.97

Chemicals Consumed Lakhs

850.68 1795.88 1890.4 1890.4 1890.4

Power And Fuel Lakhs

861.57 1818.88 1914.61 1914.61 1914.61

Salaries & Wages Lakhs

850.68 1795.88 1890.4 1890.4 1890.4

Repairs & Maintainance Lakhs

102.08 242.44 255.20 255.20 255.20

Selling &Administration Expences

Lakhs

379.35 800.86 843.01 843.01 843.01

Total

15,311.18 32350.5

2995 34053.1

8942 34053.1

8942 34053.1

8942

Fixed Cost

Insurance Lakhs

21.09 37.15 40.15 40.15 40.15

Depreciation Lakhs

694.17 694.17 694.17 694.17 694.17

Preliminary Expenses W/off Lakhs

40.00 40.00 40.00 40.00 40.00

Interest On Term Loan

283.80 387.04 290.28 193.52 96.76 Interest on Working Capital

loan

35.00 70.00 70.00 70.00 70.00

Total

1,074.06 1228.36 1134.60 1037.84 941.08

Contribution Lakhs

3,656.50

7,692.34

8,097.20

8,097.20

8,097.20

Contribution Per KG Lakhs

8.60

8.57

8.57

8.57

8.57



of 118

Break Even Point(In MT Of Sugar)

M.T

12,493.89

14,338.8

1

13,244.3

4

12,114.8

4

10,985.3

5

Break Even Sales(in lacs)

5,571.54

6,394.27

5,906.20

5,402.51

4,898.82 Break Even sales in terms

of % 29.37

15.97

14.01

12.82

11.62



of 118


STATEMENT SHOWING DEBT SERVICE COVERAGE RATIO SNO. PARTICULARS UNIT

2016-17

2017-18

2018-19

2019-20

2020-21

1 Net Profit / Loss Lakh Rs.

2582.44

6463.98

6962.60

7059.36

7156.12

2 Add Back: Depreciation 627.5

0 627.5

0 627.5

0 627.5

0 627.5

0

Add Back: Preliminary Expencesw

w/off 40.00 40.00 40.00 40.00 40.00

3 Interest on Term Loan 283.8

0 387.0

4 290.2

8 193.5

2 96.76

Interest on Cash Credit 35.00 70.00 70.00 70.00 70.00

4 Cash Available for DSCR 3568.

74 7588.

52 7990.

38 7990.

38 7990.

38

5 Debt to be Serviced

Term Loan From bank 967.6

0 967.6

0 967.6

0 967.6

0 967.6

0

Interest on Term Loan 283.8

0 387.0

4 290.2

8 193.5

2 96.76

Interest on Cash Credit 35.00 70.00 70.00 70.00 70.00

Total 1286.

40 1424.

64 1327.

88 1231.

12 1134.

36

6 Debt Service Coverage ratio 2.77 5.33 6.02 6.49 7.04 7 Average DSCR 5.53



of 118


STATEMENT OF SOURCES AND APPLICATIONS OF FUNDS DURING

CONSTRUCTION AND THE YEAR THEREAFTER

SNO PARTICULARS UNIT

2016-17

2017-18

2018-19

2019-20

2020-21

SOURCES OF FUNDS A INTERNAL:

1 Profit after Depreciation but before

intt/tax 2582.

44 6463.

98 6962.

60 7059.

36 7156.

12

2 Depreciation 627.5

0 627.5

0 627.5

0 627.5

0 627.5

0 40.00 40.00 40.00 40.00 40.00 B EXTERNAL

1 Share Capital Lakh Rs. 923

Equity 2769

2 Term loan AND CASH CREDIT From

Bank 5538

TOTAL 12479

.94 7131.

48 7630.

10 7726.

86 7823.

62 APPLICATION OF FUNDS 1 Capital Expenditure On Project 8330

2 paymant of Term Loan 967.6

0 967.6

0 967.6

0 967.6

0 967.6

0

3 Working Capital Margin 566.4

1

4 preliminary expences 200.0

0

TOTAL 10064

.01 967.6 967.6 967.6 967.6

Opening Balance 0 2415.

93 8579.

82 15242

.32 22001

.59

Additions 2415.

93 6163.

88 6662.

50 6759.

26 6856.

02

Closing Balance to be utilised into further expansions

2415.93

8579.82

15242.32

22001.59

28857.61



of 118


STATEMENT OF AFFAIRS

SNO PARTICULARS

2016-17 2017-18 2018-19 2019-20 2020-21

I. Equity and liabilities 1 Shareholder's funds (i) Share capital 3692 3692 3692 3692 3692

(ii) Reserves and surplus

1730.

24 6061.11 10726.0

5 15455.8

3 20250.4

3

5422.

24 9753.11 14418.0

5 19147.8

3 23942.4

3 2 Non-current liabilities (i) Long-term borrowings

Bank Loan

3870.

40 2902.80 1935.20 967.60 0.00 (ii) Other long term liabilities Long-term provisions

3870.

40 2902.80 1935.20 967.60 0.00 3 Current liabilities (i) Short-term borrowings

(ii) Trade payables

1701.

36 1795.88 1890.4 1890.4 1890.4 (iii) Other current liabilities Working Capital Margin 700 700 700 700 700

Provision for Tax

852.2

1 2133.11 2297.66 2329.59 2361.52

3253.

57 4628.99 4888.06 4919.99 4951.92

Total

12546

.20 17284.9

0 21241.3

1 25035.4

2 28894.3

5

II. Assets



of 118

1 Non-current assets

(i) Fixed assets

7635.

83 6941.66 6247.49 5553.32 4859.15 Capital work-in-progress

CAPITAL EXPANSION

PROGRAMME 200 800 1600 2500 (ii) Non-current investments

(iii) Long-term loans and advances

(iv) Other non-current assets 160 120 80 40 0

7795.

83 7261.66 7127.49 7193.32 7359.15 2 Current assets Current investments

(i) Inventories

1276.

02 1771.27

8904 1864.50

411 1864.50

411 1864.50

411

(ii) Trade receivables

1276.

02 1771.27

8904 1864.50

411 1864.50

411 1864.50

411

(iii) Cash and bank balances

122.6

7 115.55 235.34 239.91 209.3

(iv) Short-term loans and advances

2674.

71 3658.10

7808 3964.34

8219 3968.91

8219 3938.30

8219

10470

.54 10919.7

7 11091.8

4 11162.2

4 11297.4

6

-2075.

66 -6365.13

-10149.4

7

-13873.1

8

-17596.8

9



of 118


DEPRECIATION CHART

ASSET UNIT BUILDING AND CIVIL

WORKS PLANT AND MACHINERY

MISC. FIXED ASSETS

TOTAL

Capital Cost Lakh Rs. 620 7210 500

8330

Life Of Asset years 12 12 12 12

Dep for the year 51.67 600.83 41.67 694.17



of 118


CALCULATION OF INTERNAL RATE OF RETURN

S NO. PARTICULARS UNIT CONST.

2016-17

2017-18

2018-19

2019-20

2020-21

1 Total Inflow Lakh Rs.

3568.74

7588.52

7990.38

7990.38

7990.38

2 Capital Expenditure Lakh Rs. 8330

3 Net Cash InFlow 35128.42

4 IRR 8.63%

detailed project report for modernization...

Documents