pre feasibility report of sugar unit
DESCRIPTION
5000 to 8000 TCDTRANSCRIPT
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PRE-FEASIBILITY REPORT
Modernization cum Expansion of Sugar Unit from 5,000 to
8,000TCD Capacity and Cogeneration Project of 19.5 MW
Installed Capacity
M/s. Karmayogi Shankarraoji Patil Sahakari Sakhar Karkhana Limited
Mahatma Phule Nagar, Bijwadi, Taluka Indapur, District Pune, Maharashtra
Prepared By
VASANTDADA SUGAR INSTITUTE *
Manjari (Bk), Pune, Maharashtra 412 307
Telephone: (020) 26902100, 26902343/7/6, Fax (020) 26902244
Web Site: www.vsisugar.com
*Accredited by QCI/NABET (Provisional) for EIA consultancy services
Recognized R & D Center by Department of Scientific and Industrial Research (DSIR), Ministry of
Science and Technology, Government of India and P.G. and Doctoral Research Center by University
of Pune
March 2012
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Prefeasibility Report Sugar and Cogeneration Project
Karmayogi Shankarraoji Patil SSKL, Indapur 2
PRE-FEASIBILITY REPORT
KARMAYOGI SHANKARRAOJI PATIL SAHAKARI SAKHAR KARKHANA LIMITED
EXPANSION OF SUGAR UNIT FROM 5,000 TO 8,000TCD AND 19.5MW COGENERATION
UNIT
1.0 INTRODUCTION
The Karmayogi Shankarraoji Patil Sahakari Sakhar Karkhana Limited (KSPSSKL), is
located at Mahatma Phule Nagar, village Bijwadi Tal-Indapur, Dist-Pune. It is 1.5km off
Pune-Hyderabad National Highway (NH 9). Initial crushing capacity of the KSPSSKL was
1750 TCD. On account of modernization of the plant from time to time and by effective
utilizing of in-built capacity of the plant the KSPSSKL has achieved a crushing capacity of
+5,000 TCD since 1999-2000. The sugar factory also operates a molasses based
distillery of 30 KLPD capacities.
2.0 HIGHLIGHTS OF THE PROJECT
Project
Proponent
Karmayogi Shankarraoji Patil Sahakari Sakhar Karkhana Limited
(KSPSSKL)
Geographical Location 18008N;
74057E
523 MSM
Nearest City/Town Indapur is the nearest town 08 km from the site.
Road The site is located off Pune-Solapur National highway
No. 09. Distance- 1.5 km from factory site
Railway Station Baramati railway station 45 from the site.
Air Port Pune is the nearest airport 135 km from the site.
East Village Rajwadi 2.5
West Kaulthali 3.5 Km
North National Highway 9 - 1.5km
South Village Ramoshiwadi 1.5Km
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Prefeasibility Report Sugar and Cogeneration Project
Karmayogi Shankarraoji Patil SSKL, Indapur 3
Location of the
project
Mahatma Phule Nagar, village Bijwadi Tal-Indapur, Dist-Pune
Maharashtra
Email : [email protected]
Ph no: 02111-2886103/123/144/146
Fax : 02111 - 286105
Land 18 acres built up area after expansion,
6 acres provided for green belt development
Project Modernization cum expansion of sugar unit from 5,000 TCD to
8,000 TCD along with cogeneration unit of 19.5 MW installed
capacity
Product i) White Sugar: 920 MT/Day
ii) Bagasse : 2240 MT/Day
iii) Molasses ; 320 MT/Day
iv) Press mud: 320 MT / Day
v) Power: 18.585 MW electricity
Running Days 210 Days
Main Raw
Material
i) Sugar Cane: 8,000 MT/Day
ii) Lime : 9.76 MT/Day (0.15% Cane )
iii) Sulfur: 4.64 MT/Day (0.05% Cane )
iv) Bagasse : 1,690 MT/day
Water
Requirement
2,835 m3/day Ujani dam (Permission available )
Fuel Bagasse 1690 MT/day
3.0 Need of Project and its importance to the country and region:
India is the second largest producer of sugar over the globe. With more than 45
millions of sugar cane growers in the country, the bulk of the rural population in India
depends on this industry. One of the agro-based industries in India, the sugar industry is
the second largest agricultural industry followed after the textile industry. Maharashtra
Sugar Industry is one of the most notable and large-scale sugar manufacturing sectors in
the country.
There are few major reasons for the expansion of the sugar factory and
increasing availability of cane and pressing demand of the local share holder farmers to
crush all the cane they grow is the foremost reason. Since, the Karkhana is located
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Prefeasibility Report Sugar and Cogeneration Project
Karmayogi Shankarraoji Patil SSKL, Indapur 4
towards east of the Pune district, where an excellent network of canals exist. The
command area of the KSPSSKL comprises 112 villages from Indapur and Daund talukas
of Pune district and Karmala, Malshiras & Madha talukas of Solapur district. Out of total
command area of the KSPSSKL, 70% area is irrigated by Ujani and 30% area is under
well irrigation. Nira right bank canal project also covers some area under irrigation.
Hence the availability of water is ample in the area; and thus the area under cultivation
of sugar cane is going on increasing every year. Increase in the cane production can also
trace though the figures of cane crushed by the KSPSSKL during previous 10 years.
Table 1: Production of Sugar cane and cane crushing for last 10 Years
Sr. No. Year Total Cane crushed
(MT)
Total Cane production in area
(MT)
1 2000-01 5,91,560 87,000
2 2001-02 8,08,516 3,53,000
3 2002-03 7,49,863 8,00,000
4 2003-04 4,16,597 5,00,000
5 2004-05 3,98,077 5,00,000
6 2005-06 8,76,907 10,46,000
7 2006-07 12,34,935 13,50,000
8 2007-08 12,11,128 13,25,000
9 2008-09 9,89,976 11,00,000
10 2009-10 12,83,800 14,00,000
In season 2010-11 the expected crushing will 13, 59,500 where as the production or
availability is about 16, 00,000 MT. The above table infers that there is ample sugarcane
available in the command area of the KSPSSKL. However, the crushing capacity is a
limiting factor to fulfill the demand of the local farmers. The sugar cane cultivation is
anticipated to grow at least for next few seasons. Thus, the KSPSSKL has to develop its
infrastructure to crush all available cane in the command area. Hence, the management
has decided to modernize the existing 5,000 TCD sugar factory and install a 3,000 TCD
unit so as to increase the cane crushing capacity of the KSPSSKL to 8,000 TCD.
The present peak demand of power is more than 16,000 MW and only 13,000 MW is met
thorugh various sources. Considering the immediate requirements of energy and till the
end of the present period, about 5,737 MW shall be installed during the next four years,
hence the government of Maharashtra permitted such an sugar factory to utilize the
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Prefeasibility Report Sugar and Cogeneration Project
Karmayogi Shankarraoji Patil SSKL, Indapur 5
resource-able energy fuel and to make a power which will helps to decrease the energy
deficit.
While doing this, optimum utilization of the available resource is strived by the
management, by using a renewable energy source of bagasse. Bagasse is a by-product of
sugar factory, used as a fuel for boilers that produces process steam. Bagasse-based
cogeneration project is an effort for efficient use of available bagasse and steam to
generate the power for to fulfill the captive need and export the surplus to the state grid.
Hence, the KSPSSKL is installing a new 15MW capacity steam turbine, in addition to
existing 1.5 and 3MW. Thus, it will have an installed capacity of 19.5MW and it will
produce an electricity of 18.585MW.
4.0 Demand- Supply Gap
The present peak demand of power is 15,988 MW and only 11,800 MW is met during the
period 2009. Including the present deficit and projected growth rate, about 18,759 MW
shall be added till the end of 12th plan period. Considering the immediate requirements
of energy, another 5,600MW shall be added during 11th plan period ending 2012; hence
the Government of Maharashtra permitted such an sugar factory to utilize the resource-
able energy fuel and to made a power which will helps to decrease the energy deficit.
Table 2: Data on Monthly Demand~ Supply gap in MW in the state for Year 2009
2009
Month Demand Availability Short fall*
Jan-09 14,926 10,151 4,775
Feb-09 15,272 11,010 4,262
Mar-09 15,332 11,536 3,796
Apr-09 15,195 11,325 3,870
May-09 15,304 11,179 4,125
Jun-09 14,387 11,175 3,212
Jul-09 13,044 10,317 2,727
Aug-09 15,171 11,384 3,787
Sep-09 14,800 11,598 3,202
Oct-09 15,572 11,714 3,858
Nov-09 15,988 11,883 4,105
Dec-09 15,386 11,713 3,673
*Peak shortfall on a particular day of the month
V. Import vs. Indigenous production
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Prefeasibility Report Sugar and Cogeneration Project
Karmayogi Shankarraoji Patil SSKL, Indapur 6
The process is straight line and the technology even for the pollution control/disposal is
available indigenously
VI. Export Possibility
The finished products viz. Sugar, have export possibility and the surplus power
generated form cogeneration will be export to the local grid.
VII. Domestic / export markets
Local as well as international market is available for sugar and molasses. Electricity will
be exported to the local grid of MSEDCL.
VIII. Employment Generation:
The KSPSSKL requires educated and skilled staff at expanded sugar factory as well as
cogeneration unit. This requirement is furnished table 3. The indirect employment is
anticipated to be plenty, since the project is going to produce surplus power. This power
may be used to run various businesses and agricultural activities
Table 3: Employment Potential of Sugar & Cogeneration Project
Engineer Department Manufacturing
department
Additional Manpower
Designation Number Designation Number Designation Number
Assistance Engineer 04 Manufacturing
Chemist
04 Instrument engineer 01
Electrical engineer 01 Juice Supervisor
04 Mechanical Engineer 01
Electrical supervisor 04 Pan In charge 04 Electrical Engineer 01
Mill & Boiling House
Fitter (A grade)
08 Pan man 04 Instruments
Technician
04
Mill & Boiling house
Fitter (B grade)
04 Quadruple
met
04 Electrical
Supervisor
01
Turbine attendant 04 Centrifugal Met
04 Mechanical Supervisor
01
Electrician 04 Sugar house
Clerk
04 Switch board
attendant
03
Wireman 07 -------- ------ ------ -----
Total Staff 40 Total 28 Total 12
Total man power for sugar expansion along with
Cogeneration (Engineer + Manufacturing + Additional )
80
Expected indirect man power Plenty
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Prefeasibility Report Sugar and Cogeneration Project
Karmayogi Shankarraoji Patil SSKL, Indapur 7
2.0 Project Description
I. Type of project
The project is modernization cum expansion of sugar unit from 5,000 TCD to
8,000 TCD along with cogeneration unit of 19.500MW installed capacity. Bagasse is a
byproduct of sugar unit has tremendous potential as a renewable source of energy.
Hence, cogeneration unit is interlinked with sugar unit.
II. Location with coordinate
project boundary :
Project coordinate : 18008N; 74057E 523 MSM
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Prefeasibility Report Sugar and Cogeneration Project
Karmayogi Shankarraoji Patil SSKL, Indapur 8
III. Details of alternative site consider and basis of selecting the proposed site:
The proposed project is actually modernization cum expansion of sugar factory and
installation of 15MW turbine. KSPSSKL already possess adequate land i.e. more than 200
acres, for the new set up as well as its ancillary units such as pollution control system,
greenbelt, etc. Considering these facts, the point of alternative site search becomes
irrelevant.
IV. Size or magnitude of operation
Modernization cum expansion of sugar unit from 5,000 TCD to 8,000 TCD along with
cogeneration unit of 19.500 MW installed capacity
V. Project description with process details
Proposed Sugar Unit
Proposed
mill house
Proposed
Cogeneration house
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Prefeasibility Report Sugar and Cogeneration Project
Karmayogi Shankarraoji Patil SSKL, Indapur 9
a) The Process Sugar
Figure1: Flowchart of sugar manufacturing process
Cane Supply
Milling
Sulphitation
Clarification
Evaporation
Pan boiling
Crystallizer
Centrifugals
Sugar
Packing
Boiler
Lime & Sulphur House
Rotary vacuum filter
Bagasse
Press mud
Juice
SUGAR MANUFACTURING
PROCESS Steam
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Prefeasibility Report Sugar and Cogeneration Project
Karmayogi Shankarraoji Patil SSKL, Indapur 10
Extraction of Juice
The sugarcane is passed through preparatory devices like knives for cutting the stalks
into fine chips before being subjected to crushing in a milling tandem comprising 4 to 6
roller mills. In the best milling practice, more than 95% of the sugar in the cane goes into
the juice
Clarification
The treated juice on boiling fed to continuous clarifier from which the clear juice is
decanted while the settled impurities known as mud is sent to rotary drum vacuum
filter for removal of unwanted stuff called filter cake is discarded or returned to the field
as fertilizer.
Evaporation
The syrup is again treated with sulphur dioxide before being sent to the pan station for
crystalization of sugar. Crystalization takes place in single-effect vacuum pans, where
the syrup is evaporated until saturated with sugar. At this point seed grain is added to
serve as a nucleus for the sugar crystals, and more syrup is added as water evaporates.
Centrifugation
The massecuite from crystallizer is drawn into revolving machines called centrifuges.
The perforated lining retains the sugar crystals, which may be washed with water, if
desired. The mother liquor molasses passes through the lining because of the
centrifugal force exerted and after the sugar is purged it is cut down leaving the
centrifuge ready for another charge of massecuite.
Gradation & Packing
The final product in the form of sugar crystal is dropped through pan section and this
sugar is graded and picked in 50 kg bags. The grade of the sugar depends on the size of
the crystal viz. Small (S) and Medium (M)
b) Process of Cogeneration
The proposed cogeneration, aims at improving the energy efficiency of the sugar factory
significantly and enabling the plant t o generate surplus power from its cane crushing
operation. This surplus power will be exported to the state electricity grid. Energy
efficiency and the export of power to the grid are made feasible due to the availability of
high pressure and high temperature steam and by the utilization of the available
bagasse. The flow chart for generation of the power in cogeneration as shown in
following figure
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Prefeasibility Report Sugar and Cogeneration Project
Karmayogi Shankarraoji Patil SSKL, Indapur 11
Figure 2: Process flow diagram of Cogeneration power plant
VI. Raw materials required along with estimated quantity, like source market
area final product, mode of transport of raw materials and finished good
products
Table 4: Availability raw materials & finish product and transport mode
Raw
materials
Estimated
quantity
MT/day
source
market
final
product
Estimated
quantity
MT/day
source
market
Transport
mode
Sugar
Cane 8,000 local Plantation
White
Sugar
920 Maharashtra
India
Truck
Tractor
Bullock card
Lime 9.76
Pune
Mumbai
Solapur
Bagasse 2,240 Pune Truck
Tractor
Sulfur 4.64
Pune
Mumbai
Solapur
Molasses 320 Maharashtra Tankers
Exhaust Steam
Boiler Bagasse
Power
Sugar factory and allied
units
Surplus to Electricity grid
PRDS
HP Heater
Captive Power
Steam
Turbo
Generator
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Prefeasibility Report Sugar and Cogeneration Project
Karmayogi Shankarraoji Patil SSKL, Indapur 12
Bagasse 2466 Own
sugar
factory
Burnt in
boiler
1690 Local Conveyor
Power
MW
18.585 Local grid By cable
VII. Resource optimization / recycle and reuse envisaged in the project
Modernize of the existing 5,000 TCD sugar factory and install a 3,000 TCD unit so as to
increase the cane crushing capacity of the KSPSSKL to 8,000 TCD. While doing this,
optimum utilization of the available resource is strived by the management, by using a
renewable energy source of bagasse. Bagasse is a by-product of sugar factory, it will be
used as a fuel for boilers that produces process steam. Bagasse-based cogeneration
project is an effort for efficient use of available bagasse and steam to generate the power
for to fulfill the captive need and export the surplus to the state grid. Hence, the
KSPSSKL is installing a new 15MW capacity steam turbine, in addition to existing 1.5
and 3MW. Thus, it will have an installed capacity of 19.5MW and it will produce an
electricity of 18.585MW.
Water and its source
Table 5: Water requirement and availability
Particular Estimated quantity Source
Water
Ujani dam
Permission is
available
Domestic Use (Drinking, Toilet, etc.)
10.00
Gardening* Nil
Industrial purpose
Process 1800.00
Washings 300.00
Boiler feed** 200.00
Spray pond ** 500.00
Others (Pump gland sealing) 5.00
Total 2835.00
Bagasse 1690 MT/day Own factory
Power 10.50 MW Own factory
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Prefeasibility Report Sugar and Cogeneration Project
Karmayogi Shankarraoji Patil SSKL, Indapur 13
IX) Quantity of waste to be generates & scheme for their disposal
Bagasse - Generation 2466MT/D And utilization as fuel 1690MT/D
Cogeneration unit
Bio-compost unit
Fly and bottom
ash (Max. 33.80 MT/Day) Steam
STGs
18.585 MW
Electricity
Boiler feed water
Boiler blow down 200m3/d
Cooling
treatment
Recycled to sugar
factory OR spray pond make-up
Treated water for greenbelt/irrigation
Sugar factory ETP
capacity 1700m3 Effluent 850m3
Sugar unit
Sugar
Cane
Effluent
from sugar unit
800m3/day
Boiler/furnace
Other wastewater ~50m3/day
Filter cake 320MT/day
Molasses 320MT/day
Sent to own
30KLPD distillery unit
Exhaust Steam
Sludge
Sludge drying bed
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Prefeasibility Report Sugar and Cogeneration Project
Karmayogi Shankarraoji Patil SSKL, Indapur 14
Figure 3: Quantity of waste to be generates & scheme
Table 6: Waste Management
Waste
Material
Type Quantity Upshot
Bagasse Solid 2466MT/day Used as a Fuel at sugar/Cogeneration and
distillery project
Molasses Liquid 320MT/day Used as a raw material for distillery
Pressmud solid 320MT/day Used as a raw material for making bio-
compost, final disposal system for the
spentwash i.e. distillery effluent
Ash Solid 33.80MT/day Used as a filler material for bio-compost,
final disposal system for the spentwash i.e.
distillery effluent
X) Schematic representation of the feasibility drawing which give information of
EIA purpose
4. Site Analysis
I) Connectivity
Table 7: Connectivity of the project
Nearest City/Town Indapur is the nearest town 09 km away from the site.
Sugar factory modernization
and expansion capacity
from 5,000 to 8,000TCD
Bagasse based Cogeneration
Project i.e. Thermal power
plant based on biomass energy
Capacity: 19.500MW
Categorization as per EIA notification 2006 (SO
1533), as amended on Dec. 2009 (SO 3067)
Sugar industry 5 (i)
Screening category B1
Scoping: State Expert Appraisal Committee
And State EIA Authority
Power plant 1(d)
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Prefeasibility Report Sugar and Cogeneration Project
Karmayogi Shankarraoji Patil SSKL, Indapur 15
Road The site is located off Pune-Solapur National highway No. 09.
Distance- 1.5 km from factory site
Also a network of State highways and Zilla Parishad roads
exist in the vicinity
Railway Station Baramati the nearest railway station 45 from the site.
Air Port Pune is the nearest airport 135 km from the site.
II) Land form land use and ownership
The project is proposed within existing sugar factory premises, the land is already used
for industrial purpose. It is owned by the KSPSSKL. The terrain is almost flat and
requires hardly any leveling.
III) Topography
The terrain is almost flat, no hills in the surroundings. The geographical coordinates of
the area are 18008N and 74057E. The proposed site is 523 meter above the mean sea
level.
IV) Existing land use pattern (Agriculture, non agriculture, forest, water bodies
including CRZ), shortest distance from the periphery of the project forest, national
park, wild life sanctuary, eco- sensitivity area, water bodies Distance from HFL
line, CRZ notification for notified industrial area.
Table 8: Information of reserve and notified land in area
The project is proposed within existing sugar factory premises, the land is already used
for industrial purpose. The project surrounding land is either fallow land or used for
agricultural purpose. Followed by agriculture, the land is used for residential purpose.
There are 23villages in the study area 10 km radius. The canals of river Nira is flowing in
west to East direction at a radial distance of 1.0 Km from the plant site. The Ujjani dam is
Within 10km Area Any sensitive stations are safe away
There is no tropical forest
There is no biosphere reserve
There is no national park
There is no wildlife sanctuary
There is no coral formation
Pune-Solapur National Highway (NH 9) 1.5 km
Ujani back water at a distance of 8.00 km
Nearest Railway station Baramati 45km and Bhigwan
40km from the site
Nearest airport Pune 150 km from the site
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Prefeasibility Report Sugar and Cogeneration Project
Karmayogi Shankarraoji Patil SSKL, Indapur 16
at an aerial distance of about 8 km from the site towards north and north-east. The
nearest residential area to the factory is at a distance of 1.5 km towards south. Towards
east west and north the settlement areas are beyond 3km distance. There is an
agricultural and fallow land in the surrounding area of the site. A small artificial pond is
present towards west of the site at a distance of 2.5km.
There is no sanctuary, bio-sphere reserve or national park in the 10km radius area. The
nearest sanctuary to the site is Great Indian Bustard bird sanctuary at Nanaj, district
Solapur approximately 140km from the site.
VI) Existing Infrastructure
Raw Material: Sugar Cane:
The viability of the proposed expansion of sugar unit as well as cogeneration unit
depends on the availability of sugar cane. Table 8, describes the cane production of the
operational area of the KSPSSKL and the cane crushing performance of the KSPSSKL for
last ten years.
Table 8: Production & crushing performance for last ten years
Sr. No. Year Total Cane production in area
(MT)
Total Cane crushed (MT)
1 2000-01 87,000 5,91,560
2 2001-02 3,53,000 8,08,516
3 2002-03 8,00,000 7,49,863
4 2003-04 5,00,000 4,16,597
5 2004-05 5,00,000 3,98,077
6 2005-06 10,46,000 8,76,907
7 2006-07 13,50,000 12,34,935
8 2007-08 13,25,000 12,11,128
9 2008-09 11,00,000 9,89,976
10 2009-10 14,00,000 12,83,800
Above table shows the raw materials potential in the command area
Irrigation and transportation Facilities:
The KSPSSKL is located in the vicinity of back water of Ujani reservoir (approx. 8Km
towards north). Thus more than 70% of the area of agricultural land is under irrigation,
where as remaining area found very good ground water level. Hence, farmers prefer a
cash crop such as sugar cane. Another important factor is proximity of National Highway
(NH 9) and also network of state and Zilla Parishad roads in the operating area of the
KSPSSKL
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Prefeasibility Report Sugar and Cogeneration Project
Karmayogi Shankarraoji Patil SSKL, Indapur 17
Fuel
The availability of bagasse is mainly dependent upon the crushing of cane at
sugar factory. The cane crushing data of the factory for five seasons i.e. 2005-06
up to 2009-10 has been tabulated as follows.
Table 9: Bagasse production for last five seasons (i.e. 2005-06 to 2009-10)
Year Sugarcane Crushed (MT) Bagasse produced (29%)
2005-06 3,98,077.00 1,15,442.00
2006-07 8,76,907.00 2,55,173.00
2007-08 12,34,935.00 3,58,131.00
2008-09 12,11,128.00 3,51,227.00
2009-10 9,89,976.00 2,87,093.00
Thus, from the above data it can be inferred that the sugar factory is having adequate
source of fuel i.e. bagasse.
Water:
At present sugar factory draw water from Ujani dam the permission letter attached at
the end of report as an annexure. The water requirement for proposed project will be
around 2835m3/day. Water conservation will be achieved by recycling of water. Water
from the reservoirs will be used for all plant and fire-fighting purposes diesel driven
pump (capacity as per TAC recommendation) along with one electrical pump will be
installed for supply to all fire hydrants and sprinklers
Table 11: Water consumption details
Activity Consumption (M3 /day)
1. Domestic Use (Drinking, Toilet,
etc.)
10.00
2. Gardening* Nil
3 Industrial purpose
4. Process 1800
5. Mill Washings 320
6. Boiler feed** 200
7. Spray pond ** 500
8. Others (Pump gland sealing) 5
Total 2835
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Prefeasibility Report Sugar and Cogeneration Project
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Power
Power generation and consumption of the proposed project will be as follows.
Table 12: Power generation & consumption
Power Generation
From 15 MW BP type TG set 14.085 MW
From De-aerated 1.5MW BP type TG Set 1.500 MW
From 3MW BP type TG set 3.000MW
TOTAL 18.585 MW
Power Consumption
Sugar Factory 10.500MW
ETP 0.075MW
Office, Colony, Workshop, Other 0.350MW
Total 10.925
Surplus exportable power (During season only) 7.660 MW
VI) Soil classification
These soils have less depth and course texture thereby making them less fertile than
black soils. On the other hand deep black and medium deep soils
VIII) Social Infrastructure available
Schools (Primary as well as secondary)
Colleges (Science, commerce, Arts, engineering, medical, pharmacy, education)
Health centers, dispensaries, hospitals
ST bus
Electricity
Drinking water supply
Banks (Cooperative as well as nationalized) and credit societies
Veterinary centers
The present project is proposed by one of the leading and progressive cooperative sugar
industry from western Maharashtra. During the period of establishment, the industry
received a strong leadership in the form of Late shri. Shankarraoji Patil. Presently
Honorable Minister Shri Harshavardhanji Patil is leading the KSPSSKL.
The sugar factory has already initiated several activities for the development of the
region. Some of the prime activities are as follows.
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Prefeasibility Report Sugar and Cogeneration Project
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It is providing good quality seed (Cane) material and fertilizers to member farmers.
It has established an educational facility through which academic as well as technical
education has been made available to the nearby students
It is running a cooperative consumer society.
It is operating soil testing facility and provides bio-fertilizers at very nominal price
It helps farmer to obtain loan from local credit societies and banks
5. Planning
I) Planning concept
Type of industry : Modernization cum expansion of sugar unit from 5,000 TCD
to 8,000 TCD along with cogeneration unit of 18.585 MW
total power generation capacity
Facilities for transport: KSPSSKL is situated just 1.5 Km off the National
highway 9. All the villages from the command area of KSPSSKL are accessible by
asphalted (pucca) road, operational year around. Hence, public transportation is
available. State transport (ST) buses ply on schedule and connect almost all the
villages of the command area.
Town and country planning / Development authority classification:
The project is located at village Bijawadi Grampanchyat is the local authority. The
Bijawadi panchyat has issued No Objection Certificates (NOC)for this proposed
project. This industry was established since 1984-85. Since, then the land is used for
industrial purpose and will be used for the same purpose only.
II) Population projection: No population flux is anticipated due to the project
III) Land use Planning: 18 acres for sugar and cogeneration (including expansion and
new turbine set), 6 acres provided for green belt
development
IV) Assessment of infrastructure Demand (Physical & Social)
The basic infrastructure such as roads, electricity, transportation, drinking water
supply, health centers and hospitals, school, colleges, sanitation facilities are available
in the vicinity. The proposed project is not going to exert any unbearable load on any of
these resources. In fact, the project could reduce the electricity load by generating
18.585MW of power.
V) Amenities/ Facilities
KSPSSKL is already having following facilities.
Canteen, Laboratory, Guest house, rest room, petrol pump, Hotels, medical facilities,
drinking water plant, soil & water testing laboratory etc.
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Prefeasibility Report Sugar and Cogeneration Project
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6. Proposed Infrastructure
I) Industrial Area : (Processing Area) : 18 Acres
II) Residential Area (Non processing Area): 25 Acres already exist
III) Green belt : 06 Acres (in addition to existing)
IV) Social Infrastructures : All type of infrastructure is already available in
the vicinity.
V) Connectivity : National highway 9 and state highway as well as zilla parishad
road infrastructure exist
VI) Drinking water management
KSPSSKL draws water from Ujani reservoir. It operates a special water treatment plant
to supply the drinking water to factory as well as the staff colony
VII) Industrial waste management
The sugar factory has been upgraded in previous year and installed the
additional bio-tower for reduce the organic load and enhance the treatment capacity up
to 1,700m3/day to treat the effluent coming from sugar unit along and cogeneration
unit. Wastewater from other sources such as spray pond, excess condensate, etc will be
collected cooled in the cooling pond. This effluent dont have any significance COD or
BOD or any polluting content, except high temperature, hence all collected effluent will
be cool and directly used for the irrigation purpose. The treated water shall be mainly
reused for gardening/irrigation activity. The sanitary wastewater shall be disposed
by using septic tank and soak pit system. Thus, due to proper treatment of
effluent and disposal of treated water within the factory premises, overall impact
of wastewater from the unit on the surrounding water bodies or land is
envisaged to be minor negative impact.
Road Pune-Solapur National highway No. 09. - 1.5 km from factory site
Railway Baramati the nearest railway station 45 from the site.
Air Port Pune is the nearest airport 135 km from the site.
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Prefeasibility Report Sugar and Cogeneration Project
Karmayogi Shankarraoji Patil SSKL, Indapur 21
Table 13: The ETP scheme
Preliminary Treatment Secondary treatment Disposal
Oil and grease
removal machine
screen chamber
Equalization,
Neutralization chamber
primary clarifier
Bio-tower
Activated Sludge Process
for irrigation
Figure 3: schematic structure of ETP
Table 14: Solid waste generation, treatment & Disposal
Waste
Material
Type Quantity Upshot
Bagasse Solid 2466MT/day Used as a Fuel at sugar/Cogeneration and
distillery project
Molasses Liquid 320MT/day Used as a raw material for distillery
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Prefeasibility Report Sugar and Cogeneration Project
Karmayogi Shankarraoji Patil SSKL, Indapur 22
Pressmud solid 320MT/day Used as a raw material for making bio-compost,
final disposal system for the spentwash i.e.
distillery effluent
Ash Solid 33.80MT/day Used as a filler material for bio-compost, final
disposal system for the spentwash i.e. distillery
effluent
VIII) Power Requirement and source
Proposed cogeneration will generates the power which is the source for all industrials
utilization as well as all subunits and needful uses the generation and consumption of
power is as follows
Table 15: Power balance
Total Generation of power
from T,G sets of 15 MW and 1.5 & 3.0 MW
18.585 MW
Sugar Factory power cogeneration unit consumption 10.500 MW
administration, colony load. Workshop and ETP 0.425 MW
Total Captive consumption, 10.925 MW
Surplus power to be exported to state grid 07.660 MW
The total energy exported by the cogeneration power plant during the crushing
season would be 26.473 MU (7.66 MW X 160 days X 24 hrs/day X 0.9) @90 %
factor.
7. Rehabilitation and Resettlement (R & R) Plan
Proposed expansion of sugar unit along with additional 15MW turbine to make
cogeneration of 19.5MW installed capacity, will be located within the existing sugar
industry, hence there is no need of rehabilitation and resettlement (R & R) Plan.
8. Project Scheduled & Cost Estimates
Table 16: Project scheduled & cost estimate
1. Date of start of constriction (Anticipatory) Aug. 2012
2. Date of completion (Anticipatory) Oct.2013
3. Project cost Rs. 121.00 crores
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Prefeasibility Report Sugar and Cogeneration Project
Karmayogi Shankarraoji Patil SSKL, Indapur 23
4. EMP cost Rs. 4. 50 crores
9. Analysis of proposal (Final Recommendations)
a) Improvement in the social infrastructure: Some prime benefits of the project
are highlighted below
The sugar factory expansion will fulfill the pressing demand of farmers to crush all
the available cane, so local farmer will get benefitted
It will save the money indirectly for reduce in the transportation of cane to nearby
other factory, and reduce the environmental consequences due to it
Shareholders are likely to get good rates for the cane
Captive power demand of the factory is going to be fulfilled
Cogeneration is of back pressure route, which requires lesser fresh water and
wastewater generation is also minimal and mild polluted
The process is straight line and the technology even for the pollution
control/disposal are available indigenously
Waste products generated in the sugar factory are useful as a raw material and
fuel at sugar factory and its own distillery
Direct employment opportunities for 80 local youths
Indirect employment to many since, the project will be exporting electricity to
local grid
The aggregate effect of the project is likely to boost the local economy
The employment opportunity will be for local people
Factory will be go for take a CDM benefits in the form of money after this project
b) Improving power reliability
Proposed cogeneration system is focused on effective utilization of energy. It will
provide high-quality and reliable power and heat energy to the industry. It also helps to
reduce the electricity load of local grid. In this way, cogeneration project effectively
assist or support the electric grid, by providing enhanced reliability in electricity
transmission and distribution.