PREFEASIBILITY REPORT

Transcription

1 PREFEASIBILITY REPORT PROPOSED 45 KLPD MOLASSES BASED DISTILLERY UNIT, AT DATTATRAYANAGAR, A/P PARGAON VIA AWASARI BK, TAL - AMBEGAON, DISTRICT- PUNE, MAHARASHTRA M/S BHIMASHANKAR SAHAKARI SAKHAR KARKHANA LTD, AT DATTATRAYANAGAR, A/P PARGAON VIA AWASARI BK TAL. AMBEGAON, DISTRICT PUNE

2 1.0 Introduction M/s Bhimashankar Sahakari Sakhar Karkhana Ltd is duly registered under Cooperatives Act with registration number is PNA/AGN/PRG (A) S-47 / 1994 dated 31/03/1994 and with Sugar Directorate Licence No. LI-167 (94) dated 22/03/1994. M/s Bhimashankar Sahakari Sakhar Karkhana Ltd is loacted at Dattatrayanagar, A/P Pargaon Via Awasari Bk Tal. Ambegaon, District Pune. The factory is located on the state highway connecting Manchar and Shirur. The nearest airport is Pune. A major perennial river, Ghod is nearby and a dam on the river at a distance of 2.0 kms from factory site, supplies clear and clean water both for irrigation as well as factory. The area is rich for sugarcane and vegetables cultivation and supplies to nearby urban areas like Pune, Nasik, Sangamner, etc. The Bhimashankar Sahakari Sakhar Karkhana Ltd., Dattatrayanagar, Pargaon via Awasari, Tal. Ambegaon has a team of dynamic and progressive members in the Management Board lead by Shri Diliprao Dattatray Walse Patil the founder chairman. The other members of the board are 1. Shri Bhagwanrao Malharrao Bende - Vice chairman 2. Shri Devdatta Jaywantrao Nikam - Director 3. Shri Ashok Laxman Ghule - Director 4. Shri Pradeep Prataprao Walse Patil Director 5. Shri Ramchandra Jayram Dhobale Director 6. Shri Babasaheb Dhondibhau Khalkar - Director 7. Shri Dadabhau Bajaba Pokharkar - Director 8. Shri Dagadu Maruti Sinde Director 9. Shri Dnyaneshawar Genbhau Gawade Director 10. Shri Shantaram Tukaram Hinge - Director 11. Shri Balasaheb Vitthal Thorat - Director 12. Shri Annasaheb Raghunath Padwal Director 13. Shri Ramsheth Gajanan Kale Director 14. Shri Bhagwan Ganpat Borhade - Director Page 1

3 15. Shri Tanaji Khevaji Jambukar - Director 16. Shri Dnyaneshwar Harku Asware Director 17. Smt Kalpana Dattatray Gadhave Director 18. Smt. Mandakini Sampatrao Hande Director 19. Shri Ramesh Yashwant Kanade Director 20. Shri Ramesh Haribhau Labde Director 21. Shri Uttam Laxman Thorat -Expert Director 22. Shri Chandrakant Gangadhar Dhage -Managing Director In the dynamic leadership of the board the factory has been making new mile stones and has won several state level as well as National level awards for best performance in Sugar cane development etc. A few of which are given below: Awards details Sr. Season Institute Awards No Vasantdada Sugar Institute, Manjari, (B.K.) Best Financial Management Award National Federation of Cooperative Sugar Factories Ltd., New Delhi Second Prize of Cane Development Award Vasantdada Sugar Institute, Manjari, (B.K.) Technical Efficiency Award - Third Price Vasantdada Sugar Institute, Manjari, (B.K.) Best Cane Development Award National Federation of Cooperative Sugar Factories Ltd., New Delhi Best Technical Efficiency Award -Best Price National Federation of Cooperative Sugar Factories Ltd., New Delhi Best Technical Efficiency Award - First Price Vasantdada Sugar Institute, Manjari, (B.K.) Best Financial Management Award First Price National Federation of Cooperative Sugar Factories Ltd., New Delhi Overall best cooperative sugar factory in India Vasantdada Sugar Institute, Manjari, (B.K.) Best Technical Efficiency Award Second Price National Federation of Cooperative Sugar Factories Ltd., New Delhi Overall best cooperative sugar factory in India Vasantdada Sugar Institute, Manjari, (B.K.) Best Financial Management Award First Price National Federation of Cooperative Sugar Factories Ltd., New Delhi Overall best cooperative sugar factory in India Vasantdada Sugar Institute, Manjari, (B.K.) Best Technical Efficiency Award First Price Page 2

4 National Federation of Cooperative Sugar Factories Ltd., New Delhi Vasantdada Sugar Institute, Manjari, (B.K.) Vasantdada Sugar Institute, Manjari, (B.K.) National Federation of Cooperative Sugar Factories Ltd., New Delhi Overall best Technical Efficiency Award - First Price best Technical Efficiency Award - First Price Best Technical Efficiency Award - First Price High sugar crushing award first price The existing crushing capacity of sugar unit is 2500 TCD and 19 MW bagasse based cogeneration unit. BSSKL has secured environmental clearance for the existing cogeneration from SEIAA, Maharashtra vide letter no. SEAC-2011/CR-755/TC2 dated 30/06/2012 The project is proposed to be set up 45 KLPD distillery Unit & 1.5 MW Power unit on slop fired boiler located at Dattatrayanagar, Pargaon via Awasari Bk Tal. Ambegaon, Dist Pune Maharashtra State. 1.1 Nature of the Project Proposed 45 KLPD distillery will be based on molasses as a raw material. The distillery proposes to achieve zero discharge by implementing multi effect evaporation followed by spent wash incineration boiler. 1.2 Need of the Project In order to further improve in financial strength of the mill and society by tanking benefit of the ethanol blending program of the Govt. of India, present demand of Extra Neutral Alcohol and trend of fast increasing demand for fuel ethanol as well as ENA for potable liquors, the management of the mill society has decided to set up a distillery for production of 45 ENA and fuel ethanol as alternate products by utilizing the by-product of the sugar mill i.e. molasses. The installation of the distillery will not only utilize its by product for value addition but also generate employment opportunities and ancillary business opportunities to local people thus will lead to all round development of the area. As the well-being of sugar mill is dependent on the full utilization of the by-products from sugar production, M/s. Bhimashankar had already installed a Cogeneration power Page 3

5 plant with a capacity of 19 MW to export surplus power to the grid after meeting the full requirement in the mill. The other valuable waste product is molasses, which is a ready source for the production of alcohol which has many consuming centers and hence is a valuable product. Hence, the management has rightly chosen to install a distillery to produce ethyl alcohol from the molasses from the mill. Page 4

6 2.0 Project Description 2.1 Project Location The project is located at Sr. no 147/3 & 148, Dattatrayanagar, Pargaon via Awasari bk Tal. Ambegaon, Dist. Pune, Maharashtra. Site is geographically located at 18 58'30.35"N, 74 5'30.13"E. Figure No.1 Project Location Page 5

7 Figure No 2 Project Location on Toposheet & 10 km radius from Project Site Page 6

8 Figure No. 3 Project Layout Page 7

9 2.2 Size or Magnitude of Operation The BSSKL proposes 45 KLPD distillery to manufacture ENA, rectified spirit, technical alcohol from molasses. The products and by-products considered for manufacture are as given below, Rectified Spirit/ impure spirit /ENA/ Absolute alcohol Project information in brief Sr No Particulate Description 1 Land Total land 145 Acre Industrial Activity: 53.5 Acre Sugar & Cogeneration: 45 acre Proposed Distillery : 8.5 acre Green Belt : Existing: 14 acre Proposed: 5 acre 2 Product Products Rectified spirit(rs) : 45 KLPD or Extra Neutral Alcohol (ENA): LPD or Absolute Alcohol (AA): LPD 3 Operation days Molasses Requirement Total : MT Own : 41, MT Other : 11, MT 5 Total water Requirement 430 M3/day 6 Source of water Ghod River 2 km 7 Electricity 1365 KW 8 Steam T/hr 9 Boiler 16 TPH 10 DG set 500 KVA 11 Spent wash generation 360 M3/day 12 Effluent Treatment System Spent wash will be concentrated at MEE, concentrated Spent wash will be used as Page 8

10 fuel for 16 TPH Boiler and condensate will be treated in CPU and will be used in process 13 Air Pollution Control Stack 60 m and ESP with 99.9 % efficiency 14 Man Power Cost of Project 7300 lakh 16 Total EMP Cost Capital Cost of Rs cr & 0.37 Cr for O & M 2.3 Manufacturing Process Details Sugarcane molasses is chosen as the raw material for the production of various grades of alcohol proposed to be produced, in as much as the distillery is a captive unit of Bhimashankar SSK Ltd, Ambegaon, Dist. Pune, Maharashtra. There are two grades of alcohol proposed to be manufactured primarily. These are Extra Natural Alcohol (ENA), and fuel grade absolute alcohol (AA). Based on the technology review, it is proposed to use modified batch fermentation followed by multi pressure distillation for the production of ENA. Absolute Alcohol is proposed to be manufactured from R.S. drawn from intermediate column, based on molecular sieves distillation process. Impure Spirit cut, though produced is blended to a large extent with R.S. for A.A. production subject to level of aldehyde impurity. The flow schemes as conceived are discussed as below: Fermentation Yeast is developed from fresh slant in laboratory flask and the culture thus obtained is further propagated in 3 stage S.S. Yeast propagation vessels where sterilized dilute molasses are taken after adjustment of ph and addition of nutrients for culture development. Culture from lab is pitched into the first stage yeast vessel and kept under continuous aeration with sterile air through air sparger. Temperature of the culture is maintained to about 30 C through a cooling cum heating coil or jacket provided. After about 6 to 8 hours the desired growth is obtained the culture is transferred to next stage yeast vessel and then to third stage for similar operation. When enough bio-mass strength is developed, it is pitched into prefermenters from thereon to fermenters. The yeast vessels are fitted with jacket for sterilizing and cooling the medium in situ. Sterile Page 9

11 air is supplied to these vessels through non-lubricated, oil free compressor and a sterilization system comprising a series of fine filters followed by HEPA filters. Molasses from the molasses tank in the yard are pumped by transfer pump into molasses day tank and thereon to molasses receiving tank and then on to tipper type molasses weighing system and to molasses feed tank from where molasses feed pump pumps it to yeast vessels (when necessary) or to fermenter through a static mixer type molasses diluter. There are four fermenters each of 300 K.L. The feeding of bio-mass and dilute broth are periodic and regulated so that the sugar content and yeast population are regulated to give best of efficiency and activity. The exothermic heat of fermentation is extracted by circulating the fermenter contents through wort coolers. Temperature in the fermenter is to be maintained at about 32 C. Carbon dioxide evolved during fermentation is vented out through a scrubber to recover entrained alcohol in the gas. The final fermented wash is transferred by wash transfer pump to wash settling tank. The supernatant wash is transferred to wash holding tank from where wash feed pump pumps the same to distillation plant. Thick wash containing sludge is separated from the bottom of the wash settling tank and pumped to a sludge settling cum washing tank from where semisolid sludge is separated and clear liquid is sent to wash holding tank. Anti foam oil is added whenever necessary when the level in the fermenter rises beyond a limit due to foaming because of run away fermentation rate. Process water is taken into scrubber and from there to scrubber water tank. All process water in the fermentation section is supplied by water supply pump from this tank Distillation While fermentation section is the heart of productivity, distillation section is the heart of quality production. This section, as mentioned earlier, is the most energy consuming and hence is provided with utmost automation and is designed for maximum energy conservation. The system is designed to give Extra Neutral Alcohol (ENA) with a minimum of steam consumption quality rectified spirit. Impure spirit cut may be mixed back with rectified spirit as feed for production of absolute alcohol or blended with R.S. to make SDS. Page 10

12 2.3.3 Multi pressure vacuum distillation The vacuum distillation has many advantages over conventional atmospheric distillation plants like lower energy requirement, better quality products and less scaling on the distillation trays due to operation at comparatively low temperature. The vacuum distillation produces ethanol of international quality standards and there is a lot of demand of ethanol from the vacuum distillation process. Alcohol quality, which is produced from this latest technology, meets to most of the international quality standards like US, British and Japanese standards. The multi pressure vacuum distillation approximately requires 50% less steam as compared to conventional old distillation technologies. The vacuum distillation consists of distillation columns with high efficiency column trays, condensers, Reboilers, vacuum pumps and reflux pumps. In this vacuum distillation, alcohol is separated and concentrated using of fractional distillation. This is based on difference in boiling points of involved compounds in mixture. There are eight distillation columns in the system. These are Primary column and Degasser column, Pre-Rectifier column, Hydro extractive distillation column, Rectifier column, Refining column, FOC and De-Aldehyde column Primary cum degasser column Primary column (Analyzer column) is operated under vacuum and it is heated using the top vapours of the Rectifier column. The vacuum operation of the Primary column decreases the overall energy requirement of column. Due to vacuum, scaling is also reduced in this column & plant can be operated for long time smoothly. The fermented wash is pre-heated using a beer heater and followed by a plate heat exchanger, then it is fed at the top of Degasser column. The pre heating of mash in two stages recovers energy and saves steam required for the distillation. Degasser column separates the impurities on the basis of boiling point. impurities are sent to De-aldehyde column. These Alcohol and other volatile compounds are separated from the top of the Primary column & fed to Pre-Rectifier column. Page 11

13 The liquid waste in fermented wash is reached at the bottom of Primary column. This liquid waste is called as spent wash & sent to Effluent treatment plant for further concentration Primary rectifier column Primary Rectifier column is derived on steam indirectly with the help of one reboiler. The column gets vapour feed from Analyzer column & bottom of De-aldehyde column. This column is operated under vacuum. Steam is used as heating medium in its reboiler. Heavy & light Fusel Oils are separated from this column & fed to De fusel Oil column, which is operating at atmospheric pressure. Impure spirit is also separated from the condenser of this column. Column top vapors are condensed in one beer heater & remaining in straight condensers. Alcohol is concentrated in this column & spent water (spent lees) is separated from the bottom of the column. Rectified spirit separated from this column is fed to Hydro extraction column Hydro extraction column This column is driven on steam with the help of one reboiler. Rectified spirit which is separated from Primary Rectifier column is fed to this column. Extraction process takes place in this column. So, water is added in this column. Impurities which are soluble in water are taken out from the bottom of this column. Esters in the form of ethyl acetate are also separated from this column & sent to De-fusel oil column. Bottom stream of this column is fed to rectifier column. Top vapors of this column drives the Refining column. Alcohol condensed in the reboiler of Refining column, sent back return to Hydro column as reflux Rectifier column The bottom product from Hydro Extractive column is transferred to Rectifier column as feed. The impurities which are not separated in Pre-Rectifier column are separated in this column. Steam is given to this column indirectly through reboiler. This column operates under pressure. Heavy & light fusel oil is separated from this column & sent to De-fusel Oil Page 12

14 column. Top vapors of this column drives Analyzer column. Impure spirit is separated from this column & fed to De-Aldehydes column. The Separated export quality rectified spirit from rectifier is sent to Refining column. The waste water is separated from Rectifier column is pumped out from bottom of the column. 70% of spent lee is recycled to hydro column to reduce the water consumption Fusel Oil Concentration Column All fusel oil & esters impurities are fed to this column. Heavy Fusel Oil & Light Fusel Oil is drawn out from the column & concentrated in decanters. Water is also used for washing of fusel oil & to recover the alcohol. decanter, fusel is oil transferred to fusel oil storage Refining column When fusel oil gets concentrated in Relatively high grade R.S. from all tray of this column are made of De-Oxy Copper. The main purpose of this column is to remove the methanol from Extra Neutral Alcohol. Technical alcohol is separated from its condenser & sent to storage after cooling. Extra Neutral Alcohol is collected at the bottom of this column & sent to receiver after passing it from cooler Ethanol production Absolute alcohol is manufactured by dehydration of Rectified Spirit. The process adopted here is based on Pressure Swing Adsorption (PSA) system using Molecular Sieves (3-A). The flow scheme is shown in above referred flow diagram. Rectified spirit, after preheating by waste hot streams, is vaporized and superheated in E-03 and E-04 by using medium pressure steam at 3.5 kg /cm3 pressure. The super heated vapours at temperature of 130 C pass through PSA column S-01A/S-01B where the water vapors are retained while water free alcohol is released as vapors. The vapors are condensed in E-07 and E-08 and collected as Absolute Alcohol. When the molecular sieve bed is saturated with water the alcohol vapors are shifted to the other tower and the first tower is taken for regeneration. Regeneration is done first by pressure releasing and creating vacuum and then by elutriating with dehydrated alcohol vapors from the tower in dehydration operation. The vapors are condensed in E-06 and E-05 and the vent vapors are recovered through scrubber C-02. The Page 13

15 condensate is fed into column C-01 for re-concentration and vaporization. Vacuum can be created vacuum by P-04. (Eductor may also be considered for this duty). Product is cooled in E-09 and transferred to Absolute Alcohol receiving tank and then on to storage tank 2.4 Basic Requirement of the project Raw material The Distillery will be operate for 300 days. Molasses requirement for a production capacity of LPD total spirit will be Tonnes/ year at a yield of 260 lit. T.S. per tonne of molasses. Total sugar cane crushing of sugar unit is about 10.8 lakh tonnes. The molasses 3.8% of cane which works out to MT per season & will be available for the distillery. Remaining MT. molasses will be procured from from nearby sugar mills. Sr. No Item Ethanol Plant on own/procured Molasses 1 Cane crushing, TCH No. of hrs. per day 22 3 No. of season days Cane crushing, MT No. of days of operation Ethanol capacity, KLPD 45 7 Molasses, % cane Molasses MT Ethanol recovery, liters / MT of molasses 10 No. of days on 260 Own molasses 235 Procured molasses 65 Total days Quantities Molasses required MT per day Molasses required MT per Annum Own Molasses, MT Procured Molasses, MT Page 14

16 2.4.2 Water Requirement River water already coming to sugar mill, having a storage capacity about 10,000 m 3 will be pump to distillery as per requirement. The river water is clear however, to remove any suspended material etc. it will be filtered through a filtration system consisting of bag filer and ultra filter / pressure filter before use in distillery. Water requirement comprises of process water in fermentation, cooling water in fermentation, distillation, power plant and evaporation sections. Soft water is required as make up for cooling water losses. De-mineralized water is required for use in chemical and biochemical laboratory, ENA production and boiler feed water make up. Water required in an R.S./ethanol plant comprises of process water in fermentation, cooling water in Fermentation, distillation, power plant and in evaporation sections Other requirement is by way of domestic requirement. Details of water requirement Process Water : 345 M 3 /day DM Water : 85 M 3 /day. Cooling tower make up : 339 M/day Washing & DM plant back wash etc. : 30 M 3 /day. Total : 799 M 3 /day Process Water This is mainly in Fermentation for diluting molasses. No special treatment is required other than filtration and elimination of microbial contamination and suspended particles. Soft Water Soft water of commercial zero hardness is required as make up in cooling towers. Soft water requirement is KL /day. or 14.2 m 3 /hr. However, this will be sourced from recovered process condensate. Page 15

17 Demineralized Water D.M. water is required for boiler make up water, dilution water for spirit and for laboratory uses. Its requirement is estimated as 85 M 3 /day. Thus, the DM plant capacity will be about 5 m 3 /hr. Cooling Water Cooling water shall be a closed system with a certain portion of purging in order to maintain a TDS of not more than 1000 ppm. Filtered and soft water, free from algae and suspended solids with commercial zero hardness and TDS less than 250 ppm and chlorides less than 25 ppm, shall be used as make up water. Cooling water at C shall be made available at the various consuming points at a pressure of 3.0 kg/cm²g pressure. Return cooling water at 35 to 40 C from the various consuming points in the plant shall be returned to respective cooling towers for cooling the same back to the supply temperature of 32 C. Cooling water circulation rates are estimated as below : Cooling water for fermentation Distillation & Evaporation and dehyderation Cooling water for power plant & others TOTAL 350 M³/hr 725 M³/hr 50 M³/hr 1125 M³/hr Water balance TOTAL WATER INPUTS TOTAL WATER OUTPUTS Particulars Qty. in KL Particulars Qty. in KL Process Water in Fermentation 345 KL Steam condensate KL Water in Molasses 18.0 KL Water in concentrated slop 54.0 KL DM Water for Dilution 54.0 KL Spent Lees (Pre KL Page 16

18 Rectifier) DM Water for Boiler feed KL CT Evaporation losses KL Soft water Make up for cooling tower Raw water for Miscellaneous washings (Provisional) KL Boiler Blowdown & Drift 3.0 KL 10.0 KL Spent Lees (Rectifier) 54.0 KL Raw water for DM Water plant Purge 20.0 KL Cooling tower Purge & Drift 24.0 KL ---- In MEE condensate KL ---- Steam Condensate lost in different process 28.0 KL ---- DM Water plant Purge 20.0 KL Miscellaneous washings 10.0 KL Total KL TOTAL KL RECYCLING & UTILIZATION OF WATER STREAMS Particulars Steam condensate to boiler feed Treated process condensate, cooling tower purge, DM Plant purge, Washings etc. L lees recycle to fermentation Total Qty. in KL KL KL 95.0 KL KL Net fresh water consumption = KL Steam Requirement The proposed distillery comprises wash to ENA Plant and Absolute Alcohol (Ethanol) Plant. Most of the steam is required in the distillation operations of these plants. In addition steam is required for sterilizing of fermentation medium in the yeast Page 17

19 propagation equipment. Steam is also required for concentrating spent wash for burning the same in a special incineration boiler. This ensures zero liquid discharge norm (ZLD) being enforced by Pollution Control Board. In view of characteristics of slops firing, combustion air is preheated using steam. internal consumption of steam in the boiler house. Hence, there is an inherent Accordingly the steam requirement in the various sections of the distillery is given below. In arriving at the steam consumption the following basis is adopted. CONSUMPTION OF STEAM Section Ton/Hr. Sr. No. 1 Distillation Wash to ethanol 5.2 Wash to ENA 6 2 Evaporation Boiler Deaerator and SCAPH Fermentation & Others 0.5 Total : Ethanol /ENA or Plant will operate as ENA or AA plant at a time. Steam Generation Boiler is sized for a MCR capacity of 16.0 T/hr. It is proposed to operate the boiler at a working pressure of 46.0 ata and steam temperature of 400 C along with facilities for preheating the water to 140 C by exhaust steam from turbine, at 5.0 ata. The boiler will operate on concentrated slop with coal as support fuel Power Requirement As the process steam requirement is quite large and suitable for cheap power generation via cogeneration system a steam turbo alternator is provided to meet the process demand of power. A detail of power requirement in the Distillery is given below: Page 18

20 Details of Power Consumption Area Fermentation Section including Molasses handling Distillation Dehydration plant Evaporation Plant Boiler with Turbine Cooling tower for Fermentation, distillation and dehydration plant WTP & CTU Other Misc. including lighting TOTAL Operating power (KW) 210 KW 95 KW 35 KW 300 KW 300 KW 225 KW 100 KW 100 KW 1365 KW NOTE : The actual power load will be around 1100 to 1200 kwh. The recommended turbine shall be 1.5 MW back pressure turbine having inlet pressure are minimum 42 kg/cm 2 (g) and back pressure of 4 kg/cm 2 (g) with dumping condenser for 1.0 ton. exhaust steam. 500 KVA D.G. Set will also be provided for back up. 3.0 Pollution Control Technology 3.1 Air Pollution Air pollutants from a distillery are basically from flue gases from boiler. These are particulates and acidic constituents in the flue coming from fuel. Fuels used are spent wash and coal. The coal consumption is 1.44 T/hr and hence the particulate emissions are controlled through ESP on the flue path prior to going to chimney. The stack height will be 60.M Ash is collected and sold to brick manufacturers or it can also be sold at potash fertilizer as it contains high percentage of K2O. 3.2 Waste Water/ Effluent: Spent wash: The proposed distillery produces about 360 M 3 of spent wash per day at the production of LPD of rectified spirit and has the characteristics as given table below Page 19

21 EXPECTED DISTILLERY EFFLUENT (SPENT WASH) COMPOSITION Parameters Value Flow, m 3 /day 414 PH Temperature, deg. C 75 BOD, mg/lit. 60,000 max. COD, mg/lit. 120,000 to 160,000 TS, mg/lit. 16 to 18 % Potassium, mg/lit. (assumed) < 8,500 Sulphates, mg/lit (assumed) < 6,500 Nitrogen, mg/lit. (assumed) 1000 Phosphorous, mg/lit (assumed) 100 Color Dark Brown Evaporation & Concentration of spent wash The raw spent wash of composition as given in table, has a TDS of 17 to 18% along with suspended solids at 4%. This needs to be concentrated to 60% to make the same suitable for burning. The hot spent wash at about 70 deg. C from analsyser column is pumped into a storage tank where suspended solids are allowed to settle. The evaporation is done in a quintuple effect evaporator system. A variety of combinations of evaporator system can be envisaged. Tentatively a combination of falling film and forth circulation evaporator is used. Feed at 70 deg. C taken into 2 nd effect, a falling film type evaporator and from thereon it flows into 3 rd to 4 th to 5 th bodies which are in increasing vacuum. 5 th body is forced circulation rising film type The last body (5 th effect) is under 640 to 660 mm vacuum. Concentrated spent was at about 40% concentration from 5th effect is pumped to first effect which is a forced circulation evaporator and is at atmospheric pressure and is supplied with live steam as heating medium. The final product is drawn at 60% solid concentration from this effect (also called finisher effect). Vapours from each effect condense in the next effect calandria and finally the last effect vapours at 660 mm. vacuum go to a surface condenser and the non condensables are drawn out by a vacuum pump. The vacuum pump also maintains the vacuum in the evaporation system. The steam condensate from first effect is returned to boiler while the process Page 20

22 condensate from the rest of the effects is collected and treated in the Condensate Treatment Unit in order to reclaim water and thus effect water conservation Incineration based Steam Generation Plant A steam generation plant generally in conformity with IBR code of practicing and operation shall be provided. It consists of one No. coal cum slops fired traveling grate water tube drum type boiler suitable to generate 16 tonne/hr of capacity super-heated steam at 45 kg/cm sq. pressure and 400 deg. C temp. with steam heated air heater and economizer with a view to obtain a boiler efficiency of 65 % on GCV of mixed fuel, is to be provided. The boiler should be provided with ESP / bag filter for limiting the solid particulate matter (SPM) level in stack gases to 100 mg/nm 3 to meet the environmental standards. Boiler shall utilize spent wash concentrate with coal as supporting fuel. Boiler shall be single / double drum type with fusion welded construction. The drum shall be provided with dished ends, manhole doors etc. as per IBR. Boiler Details Type of Boiler : Double-Drum type boiler Design code : IBR 1950 with latest amendments, as applicable Boiler capacity at MSSV outlet Kg/hr (MCR) Steam pressure at MSSV outlet Kg/cm 2 g 45 Steam temperature at MSSV outlet ( O C) 400 Fuel : Coal Water temp at Economizer inlet ( O C) 140 C Fuel characteristics Coal Slops GCV 3650 k cal/kg 1705 k.cal/kg Moisture 50% 30% Page 21

23 C 22% H2 H2S Flue gas temperature at Air heater outlet C 2% approx. 2% v/v 160 C Ambient Temperature C 40 Electrical data for motors - LT Volt (V) : 415 ± 10 - Frequency (Hz) : 50 - Type : AC 3 phase, 4 wire Electrical data for instruments - LT Volt (V) : 220 ± 10 % - Frequency (Hz) : 50 ± 5 % - Type : AC single phase Compressed air pressure : 7 Kg/cm 2 (Oil and Moisture free) Solid Waste Management: Solid wastes such as boiler ash, ETP sludge are produced from the industrial activity. These are disposed to farmers for their use as soil conditioner in land. Solid waste generation 1 Ash 325 MT/M 2 ETP Sludge 1.0 MT/M Boiler Ash: During burning of bagasse in boiler ash will be generated. It contains silica, and other metal oxides. It is a non-toxic material. It will be directly sold brick and Page 22

24 cement manufacturer unit. Ash generated from Slop fired boiler will sold to brick manufacturing. ETP Sludge: ETP sludge contains plant growth nutrient therefore it will be used for manure in agro-field 4.0 Rehabilitation & resettlement plan No rehabilitation or resettlement will occur. Hence no rehabilitation or resettlement plans. 5.0 Project schedule and cost estimate The cost of project has been estimated at Rs 73 cr. which comprises of land, civil construction, plant & machineries, misc. fixed assets, pre-operative expenses & margin money for working capital. Cost for environment management has been estimated to Capital cost of Rs Cr capital cost and 0.37 Cr for O & M cost. The estimated capital cost and financial viability of the present scheme has been worked out on the assumption that the above proposed scheme shall be completed in 12 months period A financial and social benefit has been considered while analyzing the proposal. The proposal is environmental compatible and will helps to people improving their financial status of the local people. Environmental Setting of the Study Area: The site is located in the rural area. No other industries are found in the region. Location features of the Study area are given table Latitude Longitude Site Address Particulars Environmental Setting (10 km radius) 18 58'30.35"N 74 5'30.13"E Details M/s Bhimashankar Sahakari Sakhar Karkhana Ltd., A/P Pargaon Via Awasari Bk., Tal. Ambegaon, Dist. Pune Maharashtra Page 23

25 Particulars No. of villages in the study area 42 Total Population Nearest Habitation Details Pargaon Shingave (NW):1.09 Km Pargaon Tarf Awasari (W):1.95 Km Kathapur Bk.(S):1.85 Km Kathapur (E):2.70Km Nearest River /Water Body Ghod River : 2.0 km Nearest IMD Observatory Nearest Town Nearest Railway Line Nearest Air Port Approach to site by Road Religious / Historical Place Archaeological monuments Ecological Sensitive Area/ Seismic Zone Pune 85 km Manchar 20 km Pune 85 Km Pune 85 Km NH 50 (Pune Nashik) None None None III Page 24