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PREFEASIBILITY REPORT
OF
PROPOSED SUGAR EXPANSION (4900 TCD TO 7500 TCD),
30 MW COGENERATION
&
60 KLPD MOLASSES BASED DISTILLERY UNIT
BY
M/S VENKATESHKRUPA SUGAR MILLS LTD.
A/ Post - Jategaon Bk, Tal- Shirur, Dist - Pune,
Maharashtra
CHAPTER 1 SUMMARY
1.0 Project at a Glance
Venkateshkrupa Sugar Mills Ltd. (VKSML) is registered in the State of Maharashtra under the
Companies Act, 1956 on 20th
September, 2001 vide registration No U15421PN2001PLC016453.
VKSML is an existing private sugar factory with present cane crushing capacity of 4900 TCD
along with 7 MW back pressure type turbo- generator set up. Since beginning, VKSML has made
good progress by ensuring higher productivity and energy saving by adopting cost effective
modern technology. The sugar mill management has done exceedingly uncommon and unique
social and agricultural development work which has turned sugar plant area of operation into a
green belt.
In view of above, VKSML has proposed to carry out modernization cum expansion project from
4900 TCD to 7500 TCD. This will ensure crushing of all cane in the area of operation and
increase the viability of the plant. VKSML also proposes to go for 30 MW bagasse-based Co-
generation plant and new 60 KLPD integrated molasses and cane juice-based distillery plant to
produce Rectified spirit, ENA and fuel Ethanol with incineration boiler (19TPH) and 2 MW TG
set to achieve zero liquid effluent discharge.
The integrated sugar complex project comprises of a sugar mill for the manufacture of high
quality sugar, thereby making available required molasses and cane juice for distillery as well as
the saved bagasse which can be used for power generation. The command area of the proposed
sugar mill has adequate irrigation facilities, potential for sustained cane supply to the sugar mill
and biomass availability.
The aggregated capital investment for the proposed project has been estimated at Rs. 260 Cr.
The operational area of VKSML comprises of total 86 villages from tehsils of Shirur, haveli and
Rajgurunagar of Pune District. The total area under sugarcane cultivation of the operational area
is 6943.80 ha in the year 2017-18, with total sugarcane production of 78 MT per Ha.
The existing licensed crushing capacity of VKSML is 4900 TCD which is effected from the
crushing season 2018-19. The technical performance of some key parameters of VKSML for last
five crushing seasons is as follows.
Sr.
No.
Particulars Crushing Season
2013-14 2014-15 2015-16 2016-17 2017-18
1 Installed Capacity, TCD 2500 2500 2500 2500 2500
2 Season days 132 166 137 58 145
3 Total Cane Crashed,
Lakh MT
3.182 5.030 4.440 2.078 5.415
4 Sugar Recovery, % cane 10.78 11.04 11.21 11.05 11.28
5 Sugar production,
Quintals 343100 555550 497800 229570 610810
6 Molasses % cane 4.12 3.85 3.90 4.11 4.17
7 Molasses Production,
MT
13113 19343 17314 8541 22583
8 Bagasse % cane 28.51 28.44 28.41 28.21 27.14
9 Bagasse production, MT 90,730 1,43,065 1,26,147 58,608 1,46,963
10 Bagasse saved, % cane 11.50 12.20 12.90 15.14 12.92
11 Pressmud % cane 2.79 3.12 2.94 3.37 3.40
12 Lime Consumption, %
cane
0.163 0.141 0.149 0.174 0.190
13 Sulphur Consumption, %
cane
0.052 0.043 0.044 0.055 0.055
The Govt of Maharashtra has made mandatory to install micro irrigation system thereby there is
going to be not only 50 percent saving of water but also 30 to 35 % increase in productivity of
cane. Thus, the yield per hectare will increase from existing 78 MT/ha to 100 to 105 MT/ha. The
availability of cane will not be a problem. The expected increase in cane in area of operation in
next 2 to 3 years’ time will be in the range of 9 lakh MT to 12 lakh MT.
The expected performance for next five years to be achieved for VKSML is as follows-
Sr.
No.
Particulars Crushing Season
2018-19 2019-20 2020-21 2021-22 2022-23
1 Installed Capacity, TCD 4900 6000 7500 7500 7500
2 Season days 165 160 160 160 160
3 Total Cane Crashed,
Lakh MT
8.085 9.60 12.00 12.00 12.00
4 Sugar Recovery, % cane 11.25 11.35 11.40 11.35 11.40
5 Sugar production,
Quintals
909562 1089600 1368000 1362000 1368000
6 Molasses % cane 4.2 4.2 4.00 4.25 4.00
7 Molasses Production,
MT
33957 40320 48000 51000 48000
8 Bagasse % cane 29 29 29 29 29
9 Bagasse production, MT 2,34,465 2,78,400 3,48,000 3,48,000 3,48,000
10 Press mud % cane 3.5 3.5 3.5 3.5 3.5
11 Press mud production, 28,297.5 33,600 42,000 42,000 42,000
MT
11 Lime Consumption, %
cane
0.18 0.18 0.175 0.175 0.175
12 Sulphur Consumption, %
cane
0.05 0.05 0.05 0.05 0.05
Table 1.1 Salient features of the existing sugar plant
Sr No. Particulars Details
1 Existing capacity 4900
2
Existing bagasse-based Boilers 45 TPH, 45 Bar(g), 510 C
40 TPH, 45 Bar(g), 510 C
Flue gas Temp.-130 C in each case.
Pollution Control Devices- Wet Scrubber
system in each case
3 Stack details Common RCC stack, 4 M dia., Stack
height- 72 M
4 Turbo generator set Type-7 MW Back Pressure type
Specific steam Consumption- 6MT/MW
5 Steam Consumption, MT/hr (26.06 % on
cane)
Average 41MT/hr for season 2017-18
6 Power Consumption, MW (30 Kwh/MT
cane)
Average 4.67 MW
7 Existing DG set 1) 320 KVA,
a) Make- Powerika,
b) Spec. fuel consumption-0.26
lit/Kw
c) DG stack height- 15 M
2) 750 KVA
a) Make-Supernova
b) Spec. fuel consumption-0.31
lit/Kw
c) DG stack height- 15 M
8 Water consumption per MT of cane 25 lit/MT of cane
9 Water source a) Excess vapor condensate from
sugar process after treatment used
b) From Chaskaman canal &
Kondhapuri minor dam
10 Waste water generation Less than 100 Lit/MT cane crushed
Table 1.2 Summary of Proposed Sugar Expansion, New Cogeneration and Distillery Unit
1 Name and Address
M/s Venkateshkrupa Sugar Mills Ltd.
Gat. No. 204, 205, 206, 219, 220, 226,
Village – Jategaon (Bk), Tal. –Shirur, Dist. - Pune, Pin – 412
208 Maharashtra.
2 Area of the project
Gut nos.- 204,205,206,219,220,226
Total Plot Area – 26.61 Acre
Built up area – 2.6 Acre (sugar & admin), 1 Acre (proposed
Cogen), 6 acre (proposed distillery & incineration boiler) = 9.6
Acre
Green Belt area – 8.78 Acre
3 Latitude & Longitude Latitude – 18°44'12.20"N
Longitude – 74° 8'10.17"E
4 Plant Capacity
Expansion & Modernization of sugar unit from 4900 TCD to 7500 TCD
Bagasse based Co generation-30 MW
Molasses / Cane Juice based Distillery Unit – 60 KLPD
5 Operational days Sugar unit- 150 days Co-gen unit- Season -150 days & off season- 102 days Molasses based distillery – 300 days/annum
6 Proposed Project Cost Rs. 260 Cr.
7 Capacity of Boiler
Existing:45 TPH and 40 TPH boiler & will be scrapped
once co gen boiler is put in to operation successfully
Proposed Co gen boiler - 150 TPH, 110 ata,540 C
Proposed Spent wash Incineration boiler- 19 TPH,45 ata,
400 0C
8 Total water
Requirement
Existing: -
Sugar Unit (4900 TCD) -530 CMD
Domestic- 20 CMD
Proposed: -
Sugar expansion (7500 TCD) & Co-gen(30MW) : 1051.70
CMD
Distillery Unit - 519 CMD
Domestic - 20 CMD
Total - 1590.70 CMD
9 Total Power
Requirement
1. Power consumption for the existing sugar factory (4900
TCD) & existing Boiler units as 4.67 MW
2. Power consumption for 7500 TCD after expansion and TG
set(30MW) during season as 11.25 MW
3. Power consumption for proposed distillery unit-
Power consumption for 60 KLPD Distillery unit(835Kwh)
& 19 TPH, 45 bar(g) and 400 C incineration boiler (300
Kwh) as 1135 Kwh
Moreover, electricity will be available from State Electricity
Board in emergency.
10 Steam Requirement
Proposed units
After expansion of Sugar unit (7500 TCD)- 95 TPH
Distillery unit with incineration boiler(19 TPH,45 Bar(g)
400 C – 14.6 TPH
11 Total Fuel Requirement
Existing –
45 & 40 TPH at 45 kg/cm2 Boilers – Bagasse 617 MT/day
DG Sets (320 kVA, 750 kVA) – HSD 67 Lit/hr and 187
Lit/hr respectively
(Note- Existing boilers will be scrapped once 30 MW Co gen
put in to operation)
Proposed –
7500 TCD sugar unit and 30 MW co gen Unit- 1161.6
MT/day
Incineration Boiler- 6.2 TPH Conc. spentwash & 4TPH
bagasse
D. G. Set (500 KVA) – HSD – 120 lit/hr
12 Manpower
Total Manpower = 315 Nos.
For Existing Unit – 236 Nos.
For Cogen Unit- 15
For Proposed distillery Unit - 64 Nos. Out of which 39 shall be
skilled staff and rest shall be unskilled staff.
CHAPTER 2 INTRODUCTION
2.1 Nature of Project
M/s Venkatesh krupa Sugar Mills Ltd proposed integrated project with expansion and
modernization of sugar unit(4900 to 7500 TCD), 30 MW Co gen project and molasses/cane
juiced based 60 KLPD Distillery unit with with spent wash incineration boiler (19 TPH, 45
Bar(g), 400 C) and 2MW TG set.
2.2 Project Concept and Justification
2.2.1 Expansion of Sugar Unit;
Cane Availability
I) Sugarcane Potential in Command Area:
The command area comprises Shirur tahsil, Rajgurunagar and haveli tahsil. The Cane
availability in this area is as follows-
Sr
No.
Tahsil Area under Cane
Ha
Ave. Cane yield,
MT/Ha
Ave. Cane
production, Lakh
MT
1 Shirur 21000 95 19.95
2 Rajgurunagar 3500 95 3.32
3 Haveli 8500 95 8.07
Total 33000 31.34
II) Sugar Units
Sr
No.
Name of Sugar
Unit
Crushing
Capacity, TCD
No. of Crushing
days
Total crushing,
Lakh MT
1 Raosahebdada
Pawar,
Ghodganga
SSK,Tal- Shirur
4500 160 7.20
2 Vankateshkrupa
Sugar Mills, Tal-
Shirur
2500 160 4.00
3 Parag Sugar,
Tal- Shirur
3500 160 5.60
4 Yashwant SSK,
Tal- haveli
3500 160 5.60
Total 14000 160 22.60
Thus, availability of excess cane is 8.74 Lakh MT in the command area.
III) Area of Operation and Cane Availability to VKSML in year 2017-18
The area of operation of Venkateshkrupa Sugar Mills Ltd. comprises of 86 villages from Shirur
Tehsil, Haveli Tehsil and Rajgurunagar Tehsil of Pune district. Based on this, total area under
sugarcane in the operational area, average cane productivity in the year 2017-18 is presented in
following table:
Cane Availability in year 2017-18
Sr.
No.
Particular Area under
sugarcane, Ha
Cane
production/annum
MT
1 Cane available in 5 km radius 735 64000
2 Cane available in 6 – 10 km radius 1103 96000
3 Cane available in 11 – 50 km
radius
5977 520000
Total 7815 680000
2.2.2 Distillery Plant
VKSML has proposes 60 KLPD molasses/ cane Juice based distillery unit at their existing sugar
unit. Distillery unit will operate 300 days/annum. Alcohol has assumed a very important place in
the country’s economy. It is a vital raw material for a number of chemicals. It has been a source
of revenue by way of excise duty levied by the State Government on alcoholic liquors. It has
potential as a fuel in the form of power alcohol for blending with petrol in the ratio of 20:80. The
use of alcohol for the purpose of potable liquor is as higher as its use for industrial purposes.
Alcohol is used for manufacture of country liquor consumed by common masses. Alcohol is
produced by fermenting sugar and is used in industry as industrial alcohol or power alcohol or for
drinking purpose as potable alcohol. The basic raw material used is molasses (sugar) / cane juice.
Molasses availability in the country:
India is the largest producer of sugarcane as well as sugar in the world. The sugar industry
occupies a pride of place in rural economy. Most of the sugar industries are located in rural areas
providing employment to rural masses. There are about 564 installed sugar factories in India.
The following tables provide the information on number of sugar factories in operation and
sugar cane crushed in the last five years in the country as well as in Maharashtra.
Table 2.1: Number of sugar factories in operation in India
Year Sugar
factories in
operation
Sugarcane
crushed
(Lac MT)
Avg. Sugar
recovery
(%)
Sugar
production
(Lac MT)
Molasses
production
(Lac MT)
Average
Molasses
% Cane
2008-9 489 1449.83 10.03 145.38 65.42 4.51
2009-10 490 1855.48 10.19 189.12 83.92 4.69
2010-11 527 2398.07 10.17 243.94 109.70 4.57
2011-12 529 2569.75 10.25 263.43 118.24 4.60
2012-13 526 2505.98 10.03 251.41 117.45 4.69
2013-14 513 2381.76 10.23 243.60 108.50 4.56
2014-15 516 2771.90 10.20 282.73 126.12 4.55
2015-16 526 2364.98 10.62 251.25 108.85 4.60
2016-17 489 1934.34 10.48 202.62 90.02 4.65
2017-18 550 3033.17 10.55 320.00 141.04 4.65
Source Co-op. Sugar, May, 2018, Vol.- 49, No. 09
The molasses is used mainly for production of ethyl alcohol. There are more than 400 distilleries
in the country with an annual installed capacity of around 4.50 billion litres of alcohol production
and licensed capacity of 4.42 billion litres. The alcohol production in the country during the year
2013-14 was 2.575 billion litres. At present the state of Maharashtra is having 96 nos. of
molasses-based distilleries, 23 nos. of grain based distilleries and 2 nos. of distilleries using
feedstock other than molasses and grains, one distillery in co-operative sector and eight
distilleries in private sector are in pipeline
Table 2.2: Number of sugar factories in operation in Maharashtra
Year Sugar factories in
operation
Sugarcane
crushed
(Lac MT)
Avg.
Sugar
recovery
(%)
Sugar
production
(Lac MT)
Molasses
production
(Lac MT)
Average
Molasses
% Cane
2008-9 147 (Co-op. sec-117 Nos.) 400.27 11.46 45.79 15.88 3.96
2009-10 142(Co-op. sec-107 Nos.) 613.90 11.55 70.66 24.31 3.97
2010-11 167(Co-op. sec-125 Nos.) 802.15 11.31 90.54 32.83 4.09
2011-12 173(Co-op. sec-119 Nos.) 771.27 11.66 89.82 31.54 4.09
2012-13 172(Co-op. sec-109 Nos.) 700.48 11.43 79.94 29.26 4.17
2013-14 157(Co-op. sec-96 Nos.) 678.75 11.45 76.09 26.85 4.01
2014-15 180(Co-op. sec-99 Nos.) 930.65 11.30 105.05 38.46 4.15
2015-16 178(Co-op. sec-99 Nos.) 743.01 11.38 84.17 31.65 4.25
2016-17 151(Co-op. sec-89 Nos.) 373.13 11.32 42.00 15.82 4.23
2017-
18*
187(Co-op. sec-101 Nos.) 952.47 11.25 107.09 40.00 4.20
Source Technical Performance of sugar mills in Maharashtra, Published by VSI, Pune, *- Estimate
Molasses is considered as one of the valuable by-product of sugar industry. The total molasses
availability in the country in the year 2013-14 year and 2014-15 was 108.50 Lac MT and 126.12
lac MT respectively. Therefore, the required quantity of molasses can be made available to all the
distilleries in the country.
Molasses Potential:
In the command area, the total area under sugarcane cultivation in 2017-18 was 33000 ha, with
total sugarcane production of 31.34 lakh MT, with average yield of 90 MT/Ha.
The command area of VKSML comprises of 4 sugar mills. Out of which 3 are operating and one
is sick. The total crushing capacity of these mills is 14000 TCD, with total crushing capacity of
22.60 lakh MT at 100% utilization. Hence, surplus sugarcane available in the command area is
8.74 lakh MT.
The total molasses requirement for 60 KLPD distillery plant will be about 57120 MT/Annum at
80 % capacity considering working days 270 per annum. The sugar mill will produce its own
molasses to the extent of 40,000 MT in the year 2018-19. Considering the present surplus
sugarcane, the requirement can be made available within the command area.
Future five years expected performance of sugar mills
Sr.
No. Particular
Season
2018-
2019
2019-
2020
2020-
2021
2021-22 2022-23
1 Cane to be crushed (Lac
MT)
8.085 9.60 12.00 12.00 12.00
2 Recovery % Cane 11.25 11.35 11.40 11.35 11.40
3 Sugar to be produced (Qtls) 909562 1089600 1368000 1362000 1368000
4 Molasses to be produced
(MT)
33957 40320 48000 51000 48000
5 Press-mud to be produced
(MT)
28,297.5 33,600 42,000 42,000 42,000
6 Bagasse Production (MT) 2,34,465 2,78,400 3,48,000 3,48,000 3,48,000
2.3 Demand Supply Gap
Alcohol has assumed very important place in the country’s economy. It is vital raw material for a
number of chemicals. It has been a source of large amount of revenue by way of Excise Duty
levied by state government on Alcoholic liquors. It has a potentiality as fuel in the form of fuel
ethanol for blending with petrol in the ratio of maximum 26:74.
The world total ethanol production in the year 2017-18 was 119.48 billion litres and major
consumption of alcohol was for fuel purpose. Many countries, including Brazil, USA, Canada,
Sweden and China have already started using anhydrous ethanol for blending with petrol. In our
country, the central government has taken a policy decision to start using anhydrous alcohol (fuel
ethanol) for fuel purpose is going to increase in coming years.
Details of year wise production of Alcohol, consumption of alcohol for various applications and
consumption of molasses are summarized in table 2.3
Table: 2.3 Production and consumption of alcohol in India, Million Lit (2010-11 to 2016-17)
Sr.No. Particulars Years
2011 2012 2013 2014 2015 2016
1 Beginning stocks 1021.0 627.0 624.0 468.0 377.0 166.0
2 Alcohol Production 1681.0 2154.0 2057.0 2002.0 377.0 166.0
3 Imports 39.0 34.0 33.0 107.0 120.0 300.0
4 Exports 119.0 177.0 234.0 175.0 200.0 140.0
5 Alcohol consumption 1995.0 2015.0 2012.0 2025.0 2350.0 2350.0
6 Fuel-Ethanol consumption 365.0 305.0 382.0 350.0 800.0 900.0
7 Ending stocks 627.0 624.0 468.0 377.0 166.0 162.0
8 Molasses used (Million MT) 7.004 8.975 8.573 8.343 9.246 9.108
9 Gasoline consumption 365.0 305.0 382.0 350.0 800.0 900.0
10 Blend (%) 1.8 1.4 1.6 1.4 2.8 2.9
*Estimated
Source: GAIN Report Number – IN 5079, Dated 07/01/2015
Table 2.4 states the total consumption of petroleum products for the period 2012-13 to 2017-18.
Table 2.4: Total consumption of petroleum products for motor vehicles (Quantity in million tons)
(Indian fiscal year April/March)
Item 2012-
13
2013-
14
2014-
15
2015-
16
2016-
17
2017-
18
Average
Growth
Rate,%
Gasoline (“Motor
spirits”)
15.74 17.12 19.08 21.85 23.76 26.18 11.05
High Speed Diesel
(HSD)
69.08 68.36 69.42 74.65 76.03 81.07 2.89
Source: Petroleum Planning & Analysis cell, Ministry of Petroleum and Natural gas, Government
of India (2018)
Table no 2.5 state the consumption of gasoline, corresponding requirement for 5 % and 10% fuel
ethanol blending and overall requirement of alcohol for potable and industrial purpose.
Table: 2.5 India-Gasoline & alcohol demand
Year Gasoline
consumption
(m.MT)
Alcohol
consumption
for potable
& Industrial
(m Litres)
E5 (m.
litres)
(fuel
ethanol)
Total
demand of
alcohol @
E5 (m.
litres)
E10
(m.litres)
(Fuel
Ethanol)
Total
demand of
alcohol @
E10 (m.
litres)
1 2 3 4 5=(3+4) 6 7=(3+6)
2012-13 15.74 1700 996 2696 1992 3692
2013-14 17.12 1611 1076 2387 2152 3763
2014-15 19.08 1658 1200 2858 2400 4058
2015-16 21.85 1510 1374 2884 2748 4258
Table no.3.4 contains the details of state wise number of fuel ethanol plants and total installed
capacity in million litres per annum.
Table 2.6: Ethanol (anhydrous) plants and production capacity in India
State No. of Plants Total installed capacity
(Million litres)
Maharashtra 55 798
Uttar Pradesh 39 900
Andhra Pradesh 10 126
Gujarat, Daman Diu and Nagar Haveli 08 90
Karnataka 09 146
Tamilnadu and Pondicherry 07 120
Bihar 03 60
Total 131 2240
Source: ISO Ethanol year book 2012, page 62.
*In Maharashtra out of 55 No.s of fuel ethanol plants, 23 No.s are in Co-op sector with an
installed capacity of 196.0 million litres. The remaining plants are in private sector and operate as
standalone plants (i.e R.S. to Anhydrous ethanol). Many of these standalone plants are now not
working or have been liquidated.
Table no. 2.7 shows five years data about sugar cane crushed, molasses produced and its
utilization as well as alcohol production and its utilization in Maharashtra.
Table 2.7: Five years production and utilization of molasses and alcohol production in
Maharashtra
Sr.No. Particulars Years
2009-10 2010-11 2011-
12
2012-13 2013-14
1 Number of sugar factory 141 164 190 170 157
2 Total cane crushing, Lac
MT
615.0 803.0 772.0 694.91 675
3 Molasses production,
Lac MT
24.60 32.20 30.88 27.80 27.67
4 Opening stock of
molasses, Lac MT
3.10 2.70 3.90 4.80 13.02
Total 27.70 34.90 34.78 32.60 40.69
5 Utilization of Molasses
Alcohol Production, Lac
MT
20.0 24.10 22.43 16.00 ---
Cattle feed, Lac MT 2.00 1.90 1.85 1.40 ---
Export internal state 1.00 1.00 1.20 0.70 ---
Export outside country 2.00 4.00 4.50 1.48 ---
Total 25.00 31.00 29.98 19.58 ---
6 Closing stock of
molasses, Lac MT
2.70 3.90 4.80 13.02 ---
7 Alcohol production,
crore litre
50.00 59.75 56.70 40.00 33.38
8 Opening stock, crore
litre
3.70 4.02 5.46 4.40 13.15
Total Crore litre 53.70 63.77 62.16 44.40 46.53
9 Utilization of Alcohol, Crore litre
Chemical project 23.90 21.50 24.85 15.00 17.32
CL and IMFL 14.88 15.26 15.50 9.00 14.42
Army and other 2.00 2.00 1.80 1.25 0.45
Small chemical
project/O.D.S
2.80 3.20 2.40 1.60 3.25
Export internal state 6.10 6.75 4.00 3.90 1.05
Export outside country --- 2.20 3.50 0.50 ---
For ethanol production --- 10.40 5.70 --- 0.41
Total 49.68 58.31 57.75 31.25 36.90
10 Closing stock of Alcohol 4.02 5.46 4.40 13.15 9.63
Based on information from various sources, we anticipate demand for alcohol in the Maharashtra
state as given below:
Industrial 300-320 million litres
Potable 150-170 million litres
Fuel 320 million litres (for 10% blending)
Total 770-810 million litres
During last few years, substantial quantity of alcohol (R.S, ENA and Anhydrous ethanol) from
the country has been exported to mostly Africa and countries of south-East Asia.
The demand of alcohol for industrial, potable & anhydrous (fuel) ethanol in Maharashtra as well
as in whole country will increase significantly in coming years. The distillery plant will
contribute in fulfilling the alcohol and anhydrous (fuel) ethanol requirement of Maharashtra and
neighboring deficit states.
2.4 The Promoters & Project Preparedness
Mr. Sandeep suresh Taur, managing Director
Mr. Sachin Suresh Taur, Director
Dr. Laxman krishna Kadam, Director
Mr Bijawant Jayawant Shinde, Director
Mr Vikramsingh Bhimrao Yadav Inamdar, Director
Managing Director of the VKSML is a most experienced person. He is an active social worker
engaged in organizing social activities such as Health Club, Blood Donation Camps, assisting
poor and needy students by providing books, uniforms etc., providing medical assistance to local
villagers, participating in various social activities in the area etc.
The team of Venkateshkrupa Sugar Mills Ltd. shall be working under the most able guidance.
VKSML is in the process of appointing technical/managerial team of qualified engineers,
contract & arbitration experts, agricultural officers and managerial personnel for implementation
and operation of the proposed integrated project.
2.5 Strengths of the Project
This proposal was targeted to enhance benefits to the sugarcane farmers. Government intends to
implement the program early and this will be possible with a fixed price initially and thereafter
dynamic formula based pricing recommended by the Expert Committee. The program would
become sustainable with the dynamic pricing formula which will ensure that there is no adverse
impact on oil or the sugar industry. The proposal relating to variable percentage of blending
would ensure that surplus of ethanol available in different states is adequately absorbed in the
EBP and deficit in supply in some parts of the country does not adversely affect the program on
all India basis.
The main strengths of this integrated project include:
Background and experience of the shareholder, as well as the leadership from the promoters
Adequate support from the GOM/ MERC/ SDF/ MNRE
Availability of basic infrastructure including approach, land, water, bagasse, experienced
manpower.
Close to demand / load centers
Low transmission cost as transmission line already exists
Excellent response to the project, at the local farmer level, State Government, National and
International financial institutions and equity partners.
CHAPTER 3 PROJECT DESCRIPTION
3.1 Type of Project
M/s Venkateshkrupa sugar Mills Ltd. has proposed following projects-
Sugar Expansion cum Modernization from 4900 TCD to 7500 TCD
Co-generation – 30 MW
60 KLPD integrated distillery plant to produce Rectified spirit, ENA and fuel ethanol
from sugarcane molasses/ cane juice with incineration boiler (19 TPH, 45 bar(g), 400 C)
and 2 MW TG set.
3.2 Location of Project
M/s Venkateshkrupa sugar Mills Ltd. located at Gat No. 204, 205, 206, 229,220, 226, Village
Jategaon (Bk), Tal - Shirur, Dist. - Pune, Maharashtra. The area is 26.61 Acres. The
Geographical Location of this Industry is at 18044’11.82” N Latitude & Longitude 74
008’10.26”
E Longitude with an elevation of 606 M (1984 ft) above mean sea level (MSL).
Fig 3.1 Showing Location of Project Site
Fig 3.2 Showing Google Image
Table 3.1: Environmental Sitting of Proposed Project
Sr. No. Particulars Details
1 Latitude 18044’11.82” N
2 Longitude 74008’10.26” E
3 Elevation above MSL 606 M (1984 ft) above mean sea level
(MSL).
4 Climatic Conditions
Maximum Temperature : 38oC
Minimum Temperature : 110C
Average Annual Rainfall : 600 mm
5 Present land use at the proposed site Existing Sugar factory (4900 TCD)
6 Transport Connectivity Road
7 Nearest Highway Pune – Ahmednagar state Highway 27
– 5.15 Km
8 Nearest Railway Station Pune Railway Station – 36.08 Km
9 Nearest air port Pune Airport – 29.63 Km
10 Nearest School Z.P.School, Wable wadi- 3.2 Km
11 Nearest Hospital Dhanwantari Hospital- 4.5 Km
12 Nearest Water Body Bhima river- 13.15 Km
13 Hills/Valleys There are no hills/valleys within 15 km
radius distance of the project site
Sr. No. Particulars Details
14 Ecologically sensitive zones within 15
km distance
There is no ecologically sensitive zone
within 15 km radius distance of the
project site
15 Historical/ Archaeological places
There are no Historical/ Archaeological
places within 15 km radius distance of
the project site
16 Nearest Defense and other
Establishments
There are no nearest defense and other
establishments from the project site
17 Industries/Industrial area
There are no industries or industrial
area within 10 km radius distance of the
project site
3.3 Project Layout
The project is an integrated industrial project which comprises of various units like plant &
machinery, administrative building, residential colony, garden etc. This project contains
environmental features like ETP, RWH, Gardening, landscaping. The plan showing the layout
of the proposed project is shown in Figure 3.4. The Project has been considered with the
following special features:
Rainwater Harvesting Tank.
ETP to treat effluent.
Green Belt along the periphery
Health facilities including First Aid
Fig 3.3 Plant Layout
Table 3.2 Project details in brief
1 Name and Address
M/s Venkateshkrupa Sugar Mills Ltd.
Gat. No. 204, 205, 206, 219, 220, 226,
Village – Jategaon (Bk), Tal. –Shirur, Dist. - Pune, Pin – 412
208 Maharashtra.
2 Area of the project
Gut nos.- 204,205,206,219,220,226
Total Plot Area – 26.61 Acre
Built up area – 2.6 Acre (sugar & admin), 1 Acre (proposed
Cogen), 6 acre (proposed distillery & incineration boiler) = 9.6
Acre
Green Belt area – 8.78 Acre
3 Latitude & Longitude Latitude – 18°44'12.20"N
Longitude – 74° 8'10.17"E
4 Plant Capacity
Expansion & Modernization of sugar unit from 4900 TCD to 7500 TCD
Bagasse based Co generation-30 MW
Molasses / Cane Juice based Distillery Unit – 60 KLPD
5 Operational days Sugar unit- 150 days Co-gen unit- Season -150 days & off season- 102 days Molasses based distillery – 300 days/annum
6 Proposed Project Cost Rs. 260 Cr.
7 Capacity of Boiler
Existing:45 TPH and 40 TPH boiler & will be scrapped
once co gen boiler is put in to operation successfully
Proposed Co gen boiler - 150 TPH, 110 ata,540 C
Proposed Spent wash Incineration boiler- 19 TPH,45 ata,
400 0C
8 Total water
Requirement
Existing: -
Sugar Unit (4900 TCD) -530 CMD
Domestic- 20 CMD
Proposed: -
Sugar expansion (7500 TCD) & Co-gen(30MW) : 1051.70
CMD
Distillery Unit - 519 CMD
Domestic - 20 CMD
Total - 1590.70 CMD
9 Total Power
Requirement
4. Power consumption for the existing sugar factory (4900
TCD) & existing Boiler units as 4.67 MW
5. Power consumption for 7500 TCD after expansion and TG
set(30MW) during season as 11.25 MW
6. Power consumption for proposed distillery unit-
Power consumption for 60 KLPD Distillery unit(835Kwh)
& 19 TPH, 45 bar(g) and 400 C incineration boiler (300
Kwh) as 1135 Kwh
Moreover, electricity will be available from State Electricity
Board in emergency.
10 Steam Requirement
Proposed units
After expansion of Sugar unit (7500 TCD)- 95 TPH
Distillery unit with incineration boiler(19 TPH,45 Bar(g)
400 C – 14.6 TPH
11 Total Fuel Requirement
Existing –
45 & 40 TPH at 45 kg/cm2 Boilers – Bagasse 617 MT/day
DG Sets (320 kVA, 750 kVA) – HSD 67 Lit/hr and 187
Lit/hr respectively
(Note- Existing boilers will be scrapped once 30 MW Co gen
put in to operation)
Proposed –
7500 TCD sugar unit and 30 MW co gen Unit- 1161.6
MT/day
Incineration Boiler- 6.2 TPH Conc. spentwash & 4TPH
bagasse
D. G. Set (500 KVA) – HSD – 120 lit/hr
12 Manpower
Total Manpower = 315 Nos.
For Existing Unit – 236 Nos.
For Cogen Unit- 15
For Proposed distillery Unit - 64 Nos. Out of which 39 shall be
skilled staff and rest shall be unskilled staff.
3.4 Manufacturing Process Details
3.4.1 Sugar unit
3.4.2 Cogeneration
3.4.3 Distillery Plant
Technology: Continuous Fermentation Process
Molasses is the chief raw material used for production of alcohol. Molasses contains about
50% total sugars, of which 30 to 33% are cane sugar and the rest are reducing sugar. During
the fermentation, yeast strains to the species Saccharomyces Cerevisiae, a living
microorganism belonging to class fungi converts sugar present in the molasses such as
sucrose or glucose in to alcohol. Chemically this transformation for sucrose to alcohol can be
approximated by the equation: -
Thus 180 gm. of sugars on reaction gives 92 gms of alcohol. Therefore, 1 MT of sugar gives
511.1 kgs of alcohol. The specific gravity of alcohol is 0.7934, therefore, 511.1 kg. of alcohol
is equivalent to 511.1 / 0.7934 = 644.19 litres of Alcohol. During Fermentation of other by-
products like glycerin, succinic acids etc. also are formed from sugars. Therefore, actually
94.5% total fermentable sugars are available for alcohol conversion. Thus, one MT of sugar
will give only 644 x 0.945 = 608.6 litres of alcohol, under ideal condition theoretically.
Normally only 80 to 82 % efficiencies are realized in batch type plant. One MT of molasses
containing 45 % fermentable sugars gave an alcoholic yield of 230 liters per MT.
VKSML will operate the distillery unit according to following scheme:
1. Latest Technology of fermentation – Multi pressure distillation for production of RS
& ENA, Molecular sieve for fuel alcohol
2. Concentration of raw spentwash (60%)
3. Burning of conc. Spentwash in incineration boiler
4. Air pollutants emission from boiler will be controlled by installing air pollution
control system – Electro Static Precipitator (ESP)
5. Also, adequate stack height will be provided to boiler stack to control pollution
6. Raw spent wash generated = 530 M3/day
C12H22O11 + H2O
Cane Sugar Invertase 2C6H12O6
Glucose + Fructose
C6H12O6
180
Glucose/Fructose
Zymase 2C2H5OH + 2 CO2
2 x 46 + 2 x 44
Ethyl alcohol + Carbon di-oxide
MANUFACTURING PROCESS FOR MOLASSES BASED DISTILLERY
Raw material
Arrives
Weighed & Diluted
Rectifier column
Yeast Propagated in sterilized separate vessel
Pre-Rectifier column if required
Analyzer Column
Fermentation
Clarified Wash
Tank
Exhaust column
Incin.Boiler
Fusel oil separated & alcohol returned
Rectified Spirit/ENA/ absolute alcohol
Fuel Oil
CO2
Molasses Based Fermentation Technology
Molasses after weighing is diluted and also pre-treated to an appropriate sugar concentration while
pumping through molasses broth mixer into the fermenter. The partial pretreatment of
molasses used is required to reduce scaling of the equipment due to the sludge present in to
the molasses which is separated out very easily in this pre- treatment the fermenters are they
inoculated with culture developed in the culture vessels. The culturing with suitable yeast is
carried out only during the start –up of the plant the culture thus developed maintains itself in
fermenter on a continuous basis.
Continuous yeast growth in yeast vessel YV03 by adding pasteurized molasses and recycling
partly the yeast separated in yeast separated after acidification and activation treatment,
which helps to avoid contamination and maintain consistency in operation.
To help the fermentation sustain, the nitrogen is added in the medium in the form of Urea and
DAP as required temperature in the fermenters is maintained to an optimum level as required
for efficient reaction with the help of plate heat exchanger and recirculation pumping system.
Recirculation also helps in proper mixing of fermented wash. The retention time for the
reaction is about 22 to 24 hours. Air blowers are provided to supply the necessary oxygen
required for the yeast and also for agitation.
The fermentation technology uses genetically marked high osmotolerant yeast strain. This
system uses the cooling system to maintain fermented broth temperature to 32 -35º C which
result in improve yeast cell mass activity.
The technology incorporated yeast recycle, which maintain high yeast concentration and
reduced fermentation time result in lower fermenter volume saving in capital and operating
cost.
After completion of reaction of fermentation, the fermented wash is delivered to yeast
separation centrifugal machine to separate the yeast creams. The technology incorporates
yeast acidification and activation, which ensure the yeast, recycle in continuous propagation
vessel & fermenter is bacteria free and ensure no contamination.
In wash setting clarifier, settable solid settle down. The Supernatant goes to clarifier wash
tank (CWT) and sludge from bottom goes to sludge tank.
The fermented wash collected in the clarifier wash tank is then pumped to stripping column
for distillation.
The CO2 which is liberated is scrubbed in water in with the help of CO2 Scrubber. This CO2
contains ethanol, which is recovered by collecting CO2 scrubber water into sludge
decantation.
The technology incorporated sludge decantation system, which consist of specially designed
to settle to settle the sludge tank.
The technology incorporated sludge decantation system, which consists of specially designed
lamella separator as against convectional, designed to settle the sludge. The settled sludge
after dilution, from CO2 scrubber water passes through the decanter. this ensures the clarified
wash going to distillation is free from sludge which results in clean distillation Column, re-
boiler tubes and integrated spent evaporated tubes. This also helps to maintain consistency in
operation and avoid losses due to stoppages. Alternatively, the technology also offers pre-
clarification of molasses for high sludge /VFA content in molasses.
A closed loop cooling tower system with an induced draft –cooling tower with circulation
pumps is also provided to ensure higher cooling efficiency and to minimize water wastages.
The system incorporates mechanical ejector in place of air sparger, increase the dissolved
oxygen level facilitate better contact between yeast and fermentable sugar avoid
hydraulically dead zones. increase yeast cell mass activity for high efficiency & better yield.
The technology achieved 8-9 %( v/v) alcohol in fermented wash.
Multipressure Distillation Technology
After fermentation the next stage in the manufacture of alcohol is to separate alcohol from
fermented wash and to concentrate it to 95% (v/v) alcohol called as rectified spirit. For this
purpose, method of distillation is employed.
The distillation columns consist of number of bubble cap/ Rh grid plates where wash is
boiled and alcoholic vapours are separated and concentrated on each plate stage by stage.
Multi-pressure distillation
Multi-pressure distillation system for production of rectified spirit consists of distillation
columns namely-
For- Rectified spirit mode
1. Degasifying cum analyzer column
2. Rectification column
3. Fusel oil concentration column
4. Extractive distillation column
Advantages of MPR Distillation:
1. Maximum heat integration is possible
2. Few columns operate under vacuum, few under pressure and few under atmospheric
pressure.
3. Resolution of impurities is better.
4. Analyzer column operates under vacuum. Therefore, scaling is minimized in distillation.
5. Formation of by-product such as acetal is minimized- improvement in quality of alcohol.
6. Pre-rectification column ensure removal of sulfur compounds / Mercaptans, reduces load
of lower boiling volatile compounds.
7. Low steam consumption with reboiler (2 Kg/lit of rectified spirit)
8. Spentwash generation is less.
MANUFACTURING PROCESS FOR ANHYDROUS (FUEL) ETHANOL
Fuel ethanol is an important product required by industry. As per IS specification it is nearly
100% pure/water free alcohol. Alcohol as manufactured by Indian distilleries i.e. rectified
spirit, which is 94.68% alcohol and rest is water. It is not possible to remove remaining water
from rectified spirit by staright distillation as ethyl alcohol forms a constant boiling mixture
with water at this concentration and is known as azeotrope. Therefore, special process for
removal of water is required for manufacture of fuel (anhydrous) alcohol.
In order to extract water from alcohol it is necessary to use some dehydrant or entrainer,
which is capable of separating, water from alcohol.
Simple dehydrant is un-slacked lime, Industrial alcohol is taken in a reactor and quick lime is
added to that and the mixture is left over night for complete reaction. It is then distilled in
fractionating column to get anhydrous alcohol. Water is retained by quick lime. This process
is used for small-scale production of anhydrous alcohol by batch process. The latest
technology of Molecular Sieve will be used for production of Fuel Ethanol.
The process used for dehydration of alcohol is as follows-
Dehydration with Molecular Sieve Process-
The rectified spirit from the rectifier is superheated with steam in feed super heater.
Superheated rectified spirit from feed super heater is passed to one of the pairs of molecular
sieve bed for several minutes. On a timed basis the flow of super-heated rectified spirit
vapors is switched to the alternate bed of the pair. A portion of the anhydrous ethanol vapors’
leaving the fresh absorption bed is used to regenerate the loaded bed. A moderate vacuum
pump operating after condensation of the regenerated ethanol water mixture. This condensate
is transferred from recycle drum to the Rectified column in the hydrous distillation plant via
Recycle pump. The anhydrous alcohol draw is condensed I product condensed and passed to
product storage.
The life of molecular sieve may be around five to seven years. However, the operating coast
is considerably less than azeotropic distillation.
3.5 Raw material
3.5.1 Sugar Expansion
Cane Availability
Sugarcane Potential in Command Area:
The command area comprises Shirur tahsil, Rajgurunagar and haveli tahsil. The Cane
availability in this area is as follows-
Sr
No.
Tahsil Area under Cane
Ha
Ave. Cane yield,
MT/Ha
Ave. Cane
production, Lakh
MT
1 Shirur 21000 95 19.95
2 Rajgurunagar 3500 95 3.32
3 Haveli 8500 95 8.07
Total 33000 31.34
Sugar Units
Sr
No.
Name of Sugar
Unit
Crushing
Capacity, TCD
No. of Crushing
days
Total crushing,
Lakh MT
1 Raosahebdada
Pawar,
Ghodganga
SSK,Tal- Shirur
4500 160 7.20
2 Vankateshkrupa
Sugar Mills, Tal-
Shirur
2500 160 4.00
3 Parag Sugar,
Tal- Shirur
3500 160 5.60
4 Yashwant SSK,
Tal- haveli
3500 160 5.60
Total 14000 160 22.60
Thus, availability of excess cane is 8.74 Lakh MT in the command area.
Area of Operation and Cane Availability to VKSML in year 2017-18
The area of operation of Venkateshkrupa Sugar Mills Ltd. comprises of 86 villages from
Shirur Tehsil, Haveli Tehsil and Rajgurunagar Tehsil of Pune district. Based on this, total
area under sugarcane in the operational area, average cane productivity in the year 2017-18 is
presented in following table:
Cane Availability in year 2017-18
Sr.
No.
Particular Area under
sugarcane, Ha
Cane
production/annum
MT
1 Cane available in 5 km radius 735 64000
2 Cane available in 6 – 10 km
radius
1103 96000
3 Cane available in 11 – 50 km
radius
5977 520000
Total 7815 680000
3.5.2 Cogeneration
Bagasse Balance
The bagasse balance details are indicated in the following Table.
Sr No. Particulars Unit Value
I About Factory
1 Capacity of Plant MT/day 7500
2 Working hrs/day Hrs 22
3 Capacity TCH 340.9
4 Days of operation days 150
5 Total cane crushing in season MT 11,25,000
6 Bagasse % cane % 27.14
7 Bagasse available for the season MT 3,05,325
8 Bagacillo used for the process (0.7% on cane) MT 7875
9 Bagasse available as fuel 2,97,450
II Steam to Fuel Ratio 2.67
III Fuel Balance
1 Steam load MT/hr 140.03
2 Bagasse required MT/hr 52.80
3 Bagasse required per season for sugar unit (150 days) MT/season 1,74,240
4 Bagasse required for distillery incineration
boiler(300days) as support fuel @ 4TPH (96TPD)
MT/annum 28,800
5 Bagasse available for Cogen unit for Off Season MT 94,410
The bagasse available as fuel for co gen plant from 7500 TCD will be 2,97,450 MT per
annum. The bagasse required during crushing season of 150 days for sugar and co gen plant
will be 1,74,240 MT. For incineration boiler of distillery, bagasse required will be 28800 MT
/annum. The balance bagasse of 94410 MT will be available for co gen unit in off season.
Thus, it is possible to operate co gen plant for 102 days/annum during off season.
Calculations of co gen plant during off season is shown in following Table-
Calculation of Co Gen Parameters (30 MW), during Off Season
Sr No. Particulars Unit Value I Co gen Plant off season day 102
1 Bagasse available for co-gen in off season MT 94,410
1 Boiler capacity MT/hr 150
2 Boiler operation at capacity MT/hr 103
3 Steam to fuel ratio 2.67
4 Bagasse required to boiler/hr MT/hr 38.60
5 Bagasse required per day (24 hrs) MT/day 926.4
II Steam Demand
1 Steam to Hp heater1(9ata,240C) MT/hr 9.207
2 Steam to Hp heater2 (18ata,306C) MT/hr 7.00
3 Steam to deaerator (1.5ata, 130C) MT/hr 4.10
4 Steam to condenser (105 ata,540 C) MT/hr 81.60
5 Sugar Process (1.5ata, 130C) MT/hr 0.0
6 Total steam demand at TG inlet MT/hr 101.967
V Power Generation
1 Through Extraction 1(9ata,240C) Mw 1.41
2 Through Extraction 2(18ata,306C) Mw 0.82
3 Through Extraction 3(1.5ata, 130C) Mw 0.85
4 Through condenser (105 ata 540 C) Mw 26.92
5 Total power generation Mw 30
VI Power Consumption
1 Power consumption for workshop+ colony MW 0.50
2 Power for boiler & TG set MW 2.50
3 Total Power required MW 3.00
4 Power Export to Grid MW 27
3.5.3 Distillery Unit
The Industry proposes to establish the integrated Molasses based distillery. The name & quantity of
products are given below.
List of Products & By-product
Products & Co-products Unit Quantity
Molasses/ Cane Juice based Distillery Unit KLPD 60
Anhydrous Ethanol KLPD 54.28
Impure spirit KLPD 3.00
: List of Raw Material Required
Raw Material Unit Quantity
Molasses/ Sugar Cane Juice based Distillery (60 KLPD)
Molasses (FS – 42%) TPD 238
TPA 71400
Molasses required for 240 days (80% capacity for 1st year) Tons 57120
Own Molasses Tons 40320
Molasses from outside Tons 16800
Nutrient Kg/day 120
Biocide PPM 20
TRO Kg/day 160
Sulphuric Acid Kg/day 120
Performance parameters
Fermentation efficiency (Min) 89-90%
Distillation Efficiency (Min) 98.50%
Fermentation wash to fuel ethanol 2.8 kg/lit
Standalone evaporation 1.12 kg/lit of alcohol production
Electricity consumption 960KW for distillery
Yield of spirit (R.S. & I.S) 270 Litres/MT of molasses (46.0 % F.S.)
Yield of Anhydrous alcohol .: 257 Litres/MT of molasses (46.0 % F.S.)
Impure spirit production (from fermented wash to
alcohol)
≈5 % during R.S./Anhydrous ethanol
production
Potassium permanganate time: Rectified spirit Not less than 30 minutes
Fresh Water consumption 519 m3/day for 60KLPD plant
3.6 Water Requirement
Water Requirement and Source
The total water required for the project i.e. 1590.70 CMD
Source of Water for existing factory – From Chaskaman canal & Kondhapuri minor dam
Source of water for proposed units – From Chaskaman canal & Kondhapuri minor dam
3.6.1 Existing Sugar Unit
The existing sugar unit is 2500 TCD. The second expansion of sugar unit is done in the
crushing season of 2017-18 to achieve crushing of 4900 TCD. The unit will operate with full
capacity in crushing season of 2018-19. The water requirement and waste generation of 4900
TCD will be as follows:
Sr.No. Particulars Input Reuse Loss Waste water
1 DM regeneration reject 50 38 12
2 Boiler 1470 1400
(condensate)
40 30
(blow down)
3 Cooling Tower Make Up
(Sugar)
980 490 245 245
(blow down)
4 Water Scrubber units 30 5 25
5 Ash Quenching 26 3 23
6 Floor washing 5 - 5
7 Juice heater washing 140 - 5 135
8 Evaporator washing - - -
9 Mill washing 90 80 - 10
10 Pump gland leakage 10 8 -- 2
11 Line leakage & trap
losses
5 2 3
12 Sugar plant process
680
110
20
0.25
-
680
110
20
0.25
Bagasse
Filter cake
Molasses
Sugar
TOTAL 3616.25 2016.00 1110.25 490.00
Note- All figures in Cu M/day
The salient features of existing unit are-
Lowest steam consumption for sugar unit in India i.e. 26 to 28 percent cane
Raw water consumption is almost zero.The sugar plant runs on water available from
sugar cane.
Use of vertical continuous pans with mechanical circulators and falling film
evaporators in multi effect evaporator system for energy efficient working of sugar
plant.
Individual mill roller drive for efficient mill extraction and control.
Centralized DCS system for almost all sugar plant machinery.
No mill stoppage for cleaning of evaporator bodies during all cane crushing period.
Lowest land availability for sugar plant in India.
3.6.2 Expansion of sugar Plant & Co gen
VKSML has planned to expand sugar unit from 4900 TCD to 7500 TCD and 30 MW co gen
unit with extraction cum condensing with air cooled condenser system. The Combined water
requirement and waste generation for 7500 TCD sugar unit and 30 MW Co gen unit is given
in Table
Sr.No. Particulars Input Reuse Loss Waste water
1 DM regeneration reject 60 45 - 15
2 Boiler Cogen 3452 2942
(condensate)
462.7 47.3
(blow down)
3 Cooling Tower Make Up
(Sugar)
1500 915 375 210
(blow down)
4 Floor washing 5 - 5
5 Juice heater washing &
Evaporator washing
215 - 10 205
6 Mill washing 125 110 - 15
7 Pump gland leakage 10 8 -- 2
8 Line leakage & trap
losses
10 4 6
9 Sugar plant process
1080
168
30
0.40
-
1080
168
30
0.40
Bagasse
Filter cake
Molasses
Sugar
TOTAL 6655.40 4020.00 2130.10 505.30
Note- All figures in Cu M/day
Input side:
a. Fresh water for industry (sugar & co-gen) - 1051.70
b. Sugar cane water - 5250.00
c. Recycling of treated effluent for process (70% of total) - 353.70
Total Input - 6655.40
Output side:
a. Loss/reuse from Industrial use -6150.10
b. Effluent moderately polluted sent to ETP - 505.30
Total Output -6655.40
Thus, water requirement for 7500 TCD unit and 30 MW bagasse - based co-gen after reuse
and recycling of water will be 1051.70 Cu M/day. The effluent generation will be 505.30 Cu
M/day which will be treated and 70% recycled and balance used for gardening. During off
season, the water requirement for co gen will be 443.52 Cu M/day and the waste water
generation will be 33.36 Cu M/day.
3.6.3 Distillery Unit
Water requirement and waste generation in 60 KLPD Distillery Unit
WATER INPUT TABLE
Sr. No. Section Water Quantity (m3/day)
1 Water in Molasses 43
2 Process water in Fermentation 512
3 Soft water for process 31
4 DM water for RS dilution 437
5 DM water for boiler & DS 377
6 Soft water for cooling tower 416
7 Soft water for vacuum pump & blower 331
8 Washing water for WTP 99
9 Other domestic uses 10
TOTAL WATER INPUT 2214
WATER OUTPUT TABLE
Sr. No. Section Water Quantity (m3/day)
1 Spent Lees 550
2 Water in Raw Spent Wash 474
3 Water in sludge after decanter 17
4 Vacuum Pump & Blower 318
5 Water in Product 2.4
6 Washing Water 10
7 Blow Down Water & Reject streams 109
10 Steam generation 351
TOTAL WATER OUTPUT 1832
Loss during Continuous Operation
Sr. No. Section Water Quantity (m3/day)
1 Vacuum Pump loss 13
2 CT Evaporation & drift loss 356
3 Boiler Blow down 11
Total Water 380
Recycle Streams
Sr. No. Section Water Quantity (m3/day)
1 Spentleese Recycle for RS dilution 392
2 Vacuum Pump recycle 317
3 Steam Condensate 279
4 Treated Effluent 664
Total Recycle 1652
Total Water requirement without Recycle, M3/day 2171
Total treated water and internal streams recycle, M3/day 1652
Total fresh water requirement for distillery 519
8.65 lit/lit of total spirit
3.6.4 Treatment of Waste water
A) Treatment of Sugar ETP- Anaerobic Followed by Aerobic System
Brief Flow Sheet Details:
1. Screen chamber
2. Oil & Grease Skimmer
3. V – Notch
4. Equalization Tank
5. Primary Clarifier
6. Anaerobic digester
7. Aeration Tank
8. Secondary Clarifier
9. Sludge Drying Beds
10. Recovery of treated water
1. Screening:
Coarse screen or rack is used for removal of large pieces of gunny bags, plastics,
branches, rubbers, packing materials, gaskets, cotton waste and other floatable. It is used
as protecting devices so that large suspended solids and floating material do not damage
pumps, agitators, mixers and aerators. Coarse screens have openings ranging from 75mm
to 150 mm and racks are usually set at an angle of 450 – 60
0. The cleaning of screens is
done either manually or mechanically.
2. Oil & Grease Skimmer:
Oil being is lighter than water, floats. This property is used to separate it out. However,
if there is more turbulence or if the travel distance is high, gradient slop is more, or if
boiler blows down, excess condensate, stream trap, cooling purging co-enters, the oil gets
emulsified and then does not float out easily. It has to avoid such situations to the
maximum extent possible by either providing the traps very near to the source, or by
segregating the sub – streams. If the oil does not float and a thick film does not develop,
the physical removal by big spoon becomes difficult. In such case, the oil & grease
escapes out to further downstream units of the ETP to spoil the situation. In aeration tank
the contents are further churned and the oil may cover the bacterial cell wall, stopping
their work of adsorbing and absorbing the food (BOD) and utilizing the same in turn for
their life and growth cycle. The BOD will not get utilized for removal, and the shining
oil will escape out from the secondary clarifier to the disposal site.
Removal of oil and grease is necessary to increase treat ability. In an industry oil and
grease traps are situated close to the source of oil and grease. Various patterns are
available for oil and grease trap. The most common is the one in which inlet is below the
surface and outlet is at the bottom with sufficient retention period (10-30min). The
floating material rises and remains on the surface of the wastewater. The oil & grease will
be collected in a separate sump, by manually or mechanically, from where it can be
removed with the help of a hand pump. Considering floating matter and oil & grease in
the effluent. It is advised to provide oil & grease trap near mills as major oil & grease
come from milling section.
3. V-Notch:
The triangular or V-notch sharp-crested consist of an angular notch cut into a
bulkhead in the flow channel. The apex of the notch is at the bottom, and the sides
are set equally on either side of a vertical line from the apex. The angle of the notch
most commonly used is 90o
.The discharge equation of a free flowing triangular weir
takes the form.
Q = 8 x (2 g) 1/2
CDh5/2
---------m3/S
15
Where - h (m) = head referred to the vortex of the notch
- g = 9.81 m/S2
- CD = discharge coefficient, which is given by following table.
Head,h(M) 0.050 0.075 0.100 0.125 0.150 0.200 0.300
Value of CD 0.608 0.598 0.588 0.588 0.586 0.585 0.585
4. Equalization Tank:
Equalization is often used for smoothening out individual wastewater stream flow
variations so that a composite stream of relatively constant flow rate is fed to the
treatment plant and, also to even out variations in effluent feed BOD to the treatment
facility.
The equalization tank should not work as settling tank. The solids should be kept is
suspension. For this, the water must be in motion. A stirrer, mixer, agitator, or
diffused air is employed.
5. Primary Clarifier:
Purpose of this process is to reduce settable suspended solids content of the
wastewaters. When a liquid containing such solids is detained without disturbances
for a time, particles of higher specific gravity will settle and those with lower specific
gravity will float. About 50-65 % removal of suspended solids and 20-40 % of the
BOD removal can be achieved in a properly designed and operated primary clarifier.
Common retention time is 90-150 minutes based on average rate of flow. If these
precede a biological treatment unit, 30-60 minutes retention time is sufficient. Sugar
factory effluent contains bagacillo particles as a suspended particle. These should to
be separated out before the biological treatment.
6. Anaerobic Digester:
The supernatant from primary clarifier is further subjected to anaerobic digester. It is
submerged digester with plastic media. The microbial growth is retained on the plastic
media making possible higher loading rates and efficient digestion. The BOD removal
is about 80%.
Advantages: 1) Higher degree of stabilization.
2) Little sludge production.
3) Low capital and operating cost.
7. Aeration Tank:
The effluent from anaerobic lagoon is further subjected to aeration tank. The
biological treatment of effluent by aeration process with sludge culture is very
sensitive. The efficiency depends on pH, temperature, air contact, suspended solids,
culture growth, and concentration of floc that is optimum mixed liquor suspended
solids concentration (MLSS). The microbial culture concentration is to be maintained
in the range of 1500 to 4000 mg/l. Hence initial culture development and maintaining
of activated sludge rate by re-circulation of sludge and addition of cow dung, urea,
DAP and their mixing are essential. The nutrients are to be in liquid form. The ratio
of BOD: N: P is 100:5:1 will be maintained. Care is to be taken not to destabilize the
microbial culture.
8. Secondary Clarifier:
It is a cylindrical concrete tank with conical bottom. There is a central well to which
water is fed to avoid short-circuiting of water into the overflows. The central stirrer is
rotated at 2 RPH. Sludge will be collected at the bottom from where it re-circulated
to aeration tank and excess sludge is taken on sludge drying beds by pumping. There
is circumferential overflow from which treated effluent is collected and sent for
agricultural use.
9. Sludge Drying Beds:
Sludge drying beds will be provided for the disposal of sludge from clarifier. The
dried cakes will be scrapped off periodically and can be utilized as manure.
10. Recovery of treated water-
For recovery of water from waste water, the treated water from ETP may be sent to
tertiary system consisting of polishing tank followed by pressure filtration, activated
carbon system and disinfection by chlorination.
The RO plant will be installed in the Sugar & co-gen plant. After RO treatment, the
DM water will be used in Boiler. RO reject water is send to high TDS consuming
plants.
B) Distillery Spent wash Treatment-
The mother liquor left behind after distilling-off alcohol is called as spent wash. The spent
wash of distillery poses a very serious problem by way of threat to the environment.
The sugar mill management has proposed to install 60 KLPD distillery based on continuous
fermentation with provision to operate the process on Fed-batch mode (if VFA content in
molasses is high) and Multi pressure distillation with MSDH technology to produce
Anhydrous ethanol. Sugar mill management has decided to concentrate the raw spentwash in
the order of 55 to 60 % concentration and burn the concentrated spentwash with a supportive
fuel as bagasse in a specially designed boiler to achieve “Zero Spentwash Discharge” as per
CPCB norms.
The spentwash evaporation condensate and distillation plant spent lees will be treated in
condensate polishing unit (CPU) and treated water will be reused for distillery cooling water
or for fermentation process (molasses dilution as make-up water).
Condensate Polishing Unit:
Following condensate polishing treatment schemes are adopted by industry-
i. Conventional aerobic treatment (Extended aeration)
ii. Conventional aerobic treatment followed by membrane technology
iii. Conventional anaerobic treatment followed by membrane technology
iv. RO-MBR technology
v. Soil biotechnology
The block diagram of the proposed “zero spentwash Discharge” scheme of 60 KLPD distillery of M/s
Venkateshkrupa Sugar Limited, Tal-Shirur, Dist-Pune is given below:
C) Domestic effluent – Sewage Treatment Plant of capacity 20 m3 has been already exists
on the industry premises. Sewage generated during the proposed activity will be treated in
the upgraded sewage treatment plant.
Fig 3.4 : ETP Flow Diagram - Proposed
Primary
clarifier A
Screen
Chamber
O&G
skimmer Equalization tank
Buffer tank
Anaerobic
digester
Aeration
tank Secondary
clarifier B
Sludge drying bed
Chlorine
contact
tank
De-chlorination
tank
Treated
water tank
MGF
MGF
ACF
ACF
Distillery (Process condensate, spent lees) liquid waste Streams for Effluent Treatment
Plant
The treatment unit consists of
Sr.
No. Particulars Remark
A Electro-Mechanical Part
1 Bar screen 1
2 Air Blowers for Equalization tank. 1+1
3 Coarse air diffusers 1 set
4 Lime agitators. 1
5 Raw Effluent Pumps 1+1
6 Air Blowers for Aeration tank 1+1
7 Fine Air Diffusers for air diffusers 1 Set
8 MBBR media 1Set
9 Sludge Pumps 1+1
10 Lamella Media for settling tank 1 Set
11 Electrical for the Plant Lot
B CIVIL WORKS
1 Bar Screen Chamber 1, RCC
2 Equalization tank 1,RCC
3 Aeration tank 1,RCC
4 Settling tank 1,RCC
5 Treated water tank 1,RCC
6 Sludge drying beds 1 Set, BB
masonry
7 Pump house BB Masonry
8 Miscellaneous pump foundations PCC/RCC
Recovery of treated water & its recycling-
For recovery of water from waste water, the treated water from ETP may be sent to
tertiary System consisting of polishing tank followed by pressure filtration,
activated carbon system and disinfection by chlorination. After treatment, efforts will
be made to recycle to maximum extent the treated effluent for the process.
3.7 Air Pollution Control Facilities:
Gaseous emission from the boiler will be passed through systems to control the emission
level of pollutants like PM10, PM2.5, SO2, and NOx within the stipulated limits. The air
pollution generation from the proposed project is given in table below:
Table 3.4 : Air Pollution generation & its mitigation measures
Sr.
No. Area of Operation Air Pollution Mitigation Measures
Stacks present at Existing Sugar Unit
1 45 TPH & 40 TPH Boiler
Units
72 m stack height has been provided as per
CPCB Norms with wet scrubber in each
case
2 D.G. Sets (320 kVA,
750kVA)
5.0 m stack height above the roof of the
building, where it is installed, as per CPCB
Norms
Stacks in proposed units
1 Distillery Boiler – 19 TPH
72 m stack height will be provided as per
CPCB Norms with ESP to achieve
maximum collection of fly ash
2 Proposed 190 TPH Boiler
70 m stack height will be provided as per
CPCB Norms with ESP to achieve
maximum collection of fly ash
3 D.G. Set (500 KVA) Adequate stack height will be provided as
per CPCB Norms
3.8 Solid Waste Management
Non-hazardous solid waste & Hazardous solid waste generated is given in the table below:
Table 3.5 : Solid Waste details
No. Type of
waste
Waste & Quantity Total Unit Treatment Disposal
Existing Proposed
1 Canteen waste 0.5 0.5 TPD Compost Own Garden
2 Domestic
waste 2.0
2.0 TPD Compost Factory farm
3 Distillation
Residue -- 0.2 0.2 TPM
Flotation
Technique
Will be mixed with
Bagasse & burnt in
boiler
4 Bagasse Ash 17.42 17.42 TPD Mixed with
PMC
Bagasse ash will be
mixed in press mud
cake & distributed to
farmers as soil
conditioner
5 Incineration
Boiler Ash -- 19.30 19.30 TPD --
Will be used as soil
manure
Table 3.6 : Hazardous Waste details
Sr.
No.
Type of
waste
Quantity Total Unit Category Disposal
Existing Proposed
1 Used /
Spent Oil 2.0 5.0 7.0 MT/Y 5.1
Would be mixed
with Bagasse &
burnt in boiler
2 ETP
Sludge 2.0 3.0
5.0 MT/M 34.3
To authorized
vendor
3 STP
Sludge 3.7 1.8
5.5 Kg/day --
To authorized
vendor
3.9 Power Requirement:
Electricity required for plant operation shall be in-house generated. Total power requirement
will be 30 MW. D.G. Set having 320 KVA & 750KVA capacities for power failure.
3.10 Green belt development:
The total plot area is 26.61 Acres. The green belt will be developed to the tune of 8.78 Acre
or 3.51 ha (33 % of the total plot area).
At present, VKSML has already planted about 1019 Nos. of trees in their existing plant. Also,
have distributed about 1373 plants among farmers. VKSML will plant additional trees as per
norms.
Table 3.7: List of Existing trees
A Plantation in Factory
Sr.No. Common Name Quantity
1 Kashid 300
2 Custard apple 15
3 Coconut 49
4 Jamun 7
5 Karanj 75
6 Tamarind 32
7 coconut 170
8 Mango 129
9 Neem 200
11 Guava 2
12 Suroo 75
13 Aola 2
14 sycus 58 15 Bahava 25
16 sisum 50
Total 1019
Table 3.7: List of Proposed trees
Sr. No. Common Name Botanical Name Quantity
1 Neem Azadirachta indica 160
2 Mango Mangifera indica 170
3 Yellow Gulmohar Peltophorum pterocarpum 300
4 Bahava Cassia fistula 220
5 Jambhul Syzigium cumini 100
7 Sita Ashok Saraca asoca 300
8 Apta Bauhinia racemosa 200
9 Palas / Flame of the forest Butea monosperma 150
10 Kadamb Anthocephallus cadamba 300
11 Ber Ziziphus mauritiana 160
12 Shivan Gmelina arborea 160
13 Shirish Albizia lebbeck 280
14 Maharukh Ailanthus excelsa 320
15 Karanj Pongamia pinnata 250
16 Katesavar Bombax ceiba 250
17 Fish tail palm Caryota urens 260
18 Nandruk Ficus retusa 260
19 Son chafa Michelia champaca 250
Total 4190
3.11 Socio-Economic Benefit:
Apart from running the mill successfully and distributing the net profit to the farmers, the
management of VKSML is also involved in several Socio-economic developmental activities
for farmers and workers. Some of the activities are briefly mentioned below:
The labour welfare activities for workers are conducted at site.
The sugar mill has arranged various schemes like drip irrigation, soil testing, cane
development council etc. for cane growers to increase sugar cane production & yield per
hectare.
The factory is also helping the farmers to improve availability of water by installing new lift
irrigation scheme.
The factory has also provided quarter facilities to the employees.
The project will generate a fair amount of direct and indirect employment in the study region
as a result of which the local economy is expected to receive a boost due to employee
spending and services generated by industry. Migration at the existing area is insignificant.
3.12 Policy to Be Adopted
The project site is located in - Jategoan (Bk), Taluka- Shirur, District -Pune Maharashtra
State. There are no rehabilitation & resettlement issues involved.
3.13 Project Schedule & Cost
Proposed Schedule for Approval & Implementation
The manufacturing of products has planned to start after obtaining environmental clearance.
Project Cost
The Capital cost of the proposed project is Rs.260 Cr.
3.14 Project Benefits
The proposed project will be provided job opportunity to the surrounding population. In good
sense, the project shall affect the socio-economy, physical infrastructure and biological
environment. The project will result in the improvement of life relative localities.
The industry will produce Ethanol which is a vital commodity in the national as well as
International market, and which will save foreign exchange. This will not disturb the
present land use because our area occupied will be only small % of Influence zone 10
km. Compatible Architecture will be adopted and No Prime Agriculture Land will be put
to this industrial use. Trees will be maintained and not razed down. No Rehabilitation is
involved. People will get jobs here. This will be beneficial to the society. Due to this
project, farmer community will get more prices for sugar cane.
Some important beneficial impact of the projects as follows:
Improvement in the physical infrastructure
Improvement in the social infrastructure
Employment generation
Better price to farming community
Improvement in the Social Infrastructure
This project will be provided better livelihood to the local people. After the setup of this project
all basic facilities will be here. And this area will be connected with world’s other areas in the
respect of transportation, communication etc.
Employment
The project will provide employment opportunity for the local community in the operation
phase. Tender specification for operation would include a favorable employment opportunity for
the locals.
The main principles are outlined below:
Employment strategy will provide for preferential employment of local labour.
General recruitment procedures will be transparent, public and open to all.
Recruitment procedures will be publicized in advance.
There will be no discrimination on basis of gender, caste or other factors.
Contractors will be required to abide to employment priority towards locals and abide by the
Indian labour laws regarding standards on employee terms and conditions.
