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PRE- FEASIBILITY REPORT
For
Proposed expansion of
Sugar Plant from 4750 TCD to 7500 TCD
Cogeneration power from 15 to 34 MW &
Distillery of 60 KLPD along with 3 MW power plant
E.I.D. – PARRY (INDIA) LIMITED
NAGARAL & NAINIGALI VILLAGE, BAGALKOT TALUK
BAGALKOT DISTRICT, KARNATAKA
E.I.D. - Parry (India) Limited (Bagalkot)
Expansion of Integrated Sugar Complex
Pre-feasibility report
1
1.0 EXECUTIVE SUMMARY
E.I.D. - Parry (India) Limited is an existing Sugar & Cogeneration Power plant at Nagaral & Nainigali
Village, Bagalkot Taluk and District.
The following is the capacity of the existing Plant
Sr. No Unit Capacity
1. Sugar 4750 TCD
2. Co-gen Power plant 15 MW
Total area already in possession of the management is 177.2 acres.
Now the company has proposed to enhance the Sugar Plant capacity along with Co-gen Power and
put up a new 60 KLPD Molasses based Distillery. The proposed expansion will be taken up in the
existing plant premises only.
The following will be the capacities after proposed expansion
Sr. No Unit Capacity
Existing Expansion Total
1. Sugar 4750 TCD 2750 TCD 7500 TCD
2. Co-gen Power plant 15 MW 19 MW 34 MW
3. Distillery -- 60 KLPD 60 KLPD
4. Power from
incineration boiler
-- 3 MW 3 MW
The following is the summary of the proposed expansion project
S.
No.
Parameters Description
1. Existing Plant capacity Sugar – 4750 TCD
Co-gen power – 15 MW
2. Proposed expansion Sr. No Unit
Capacity
Existing Expansion Total
1. Sugar 4750 TCD 2750 TCD 7500
TCD
2. Co-gen
Power plant
15 MW 19 MW 34 MW
3. Distillery -- 60 KLPD 60
KLPD
4. Power from
incineration
boiler
-- 3 MW 3 MW
3. Total area already in
possession
177.2 acres
4. Sy. No. of the land 29, 32/1, 32/2, 33/1/B and 33/1A, 36, 27/2, 27/3,28/1,
E.I.D. - Parry (India) Limited (Bagalkot)
Expansion of Integrated Sugar Complex
Pre-feasibility report
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S.
No.
Parameters Description
28/2. 29/1, 30/6, 30/3, 30/4b, 30/4a, 30/4c, 30/5a, 30/5b,
33/2a, 35/2, 36/1b, 36/2, 48/1a, 48/1b/1. 39/1, 36/3,
62/1a, 3/3 + 4/1, 30/1+2, 39/2b, 43/1+2/c, 43/1, 135/1
5. Project cost Rs: 351 Crores
6. Water requirement
a. Water requirement for
existing plant
406 KLD
b. Water requirement for the
proposed expansion
1504 KLD
c. Total water requirement 1910 KLD
d. Source of water Krishna river
7. Total effluent generation
a. Effluent generation from the
existing plant
596 KLD
b. Effluent generation from the
proposed expansion
1083 KLD
c. Total effluent generation 1679 KLD
8.
Existing Effluent treatment Sugar Plant
Effluent generated from the Sugar plant is being treated
in specially designed ETP and treated effluent is being
utilized for greenbelt development after ensuring quality
of treated effluent with standards stipulated for onland for
irrigation by CPCB / KSPCB.
Power Plant
Effluent from the power plant is being treated in Sugar
Plant ETP and treated effluent is being utilized for
greenbelt development in the plant premises after
ensuring quality of treated effluent with standards
stipulated for onland for irrigation by CPCB / KSPCB
9. E Effluent treatment (proposed
expansion)
Sugar Plant
Effluent generated from the Sugar plant will be treated in
specially designed ETP and treated effluent will be
utilized for greenbelt development after ensuring quality
of treated effluent with standards stipulated for onland for
irrigation by CPCB / KSPCB.
Power Plant
Effluent from the power plant will be treated in Sugar
Plant ETP and treated effluent will be utilized for
greenbelt development in the plant premises after
ensuring quality of treated effluent with standards
stipulated for onland for irrigation by CPCB / KSPCB
E.I.D. - Parry (India) Limited (Bagalkot)
Expansion of Integrated Sugar Complex
Pre-feasibility report
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S.
No.
Parameters Description
Distillery Plant
Spent wash generated from the Process will be
concentrated in Multiple Effective Evaporators up to 55%
solids and will be incinerated in the Boiler mixing with
other fuels like coal or biomass
10. Steam requirement (existing) Steam requirement existing sugar plant is being met from
existing 85 TPH Cogeneration power plant Boiler
11. Steam requirement
(expansion)
Steam required sugar plant will be met from proposed
110 TPH Cogeneration power plant Boiler
Steam required for the Distillery plant and Multiple
Effective Boilers will be met from the 25 TPH Incineration
Boiler
12. Air emissions (existing) Emissions from Project are Particulate matter, SO2 and
NOx
ESP has been provided to Boiler to bring down the
particulate matter to below 100 mg/Nm3.
The exhaust gases from the boiler are being discharged
into the atmosphere through a stack of 70 m height for
effective dispersion of gases into the atmosphere.
13. Air emissions (expansion) Emissions from Project will be Particulate matter, SO2
and NOx
ESP will be provided to 110 TPH Boiler to bring down the
particulate matter to below 50 mg/Nm3.
The exhaust gases from the boiler will be discharged into
the atmosphere through a stack of 67 m height for
effective dispersion of gases into the atmosphere.
14. Noise levels Ambient Noise levels are within the standards prescribed
by MOE&F Notification and its amendments and after
proposed expansion also similar practice will be followed.
15. Solid waste generation
(existing)
Sugar Plant
Press mud generated from the Sugar plant is being given
to farmers as organic manure
Bagasse generated from the Plant is being utilized for
power generation in Co-gen Power plant boiler
Power Plant
Ash generated form the power plant is being given to
farmers as organic manure when bagasse / biomass is
used as fuel and being to disposed off to brick
manufacturers when coal is used as fuel.
16. Solid waste generation
(expansion)
Sugar Plant
Press mud generated from the Sugar plant will be given
to farmers as organic manure
Bagasse generated from the Plant will be utilized as fuel
for power generation in Co-gen Power plant boiler
E.I.D. - Parry (India) Limited (Bagalkot)
Expansion of Integrated Sugar Complex
Pre-feasibility report
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S.
No.
Parameters Description
Power Plant
Ash generated form the power plant will be given to
farmers as organic manure when bagasse / biomass is
used as fuel and will be disposed off to brick
manufacturers when coal is used as fuel.
E.I.D. - Parry (India) Limited (Bagalkot)
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Pre-feasibility report
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2.0 INTRODUCTION:
2.1 Identification of project and Project Proponent
EID Parry (India) Limited is a distinguished and rapidly expanding sugar producer in India. Our
sugar manufacturing facility is certified ISO 9001:2008, FSSC:22000:2005 and the distillery is
certified "zero-effluent.”
We are deeply committed to a larger vision of our social responsibility, of looking after the needs
and quality of life of the farmers and local communities. Through our effective farmer partnership
model we provide assistance in farming practices and undertake various economic initiatives for the
benefit of the local communities.
The Promoters
The following is the list of promoters of the group
S.No Name Designation
1. Mr. A.Vellayan Chairman
2. Mr. V.Ravichandran Vice Chairman
3. Mr. Anand Narayan Bhatia Director
4. Mr. V.Manickam Director
5. Mr. M.B.N.Rao Director
6. Mr. Rca Godbole Director
7. Mr. V.Ramesh Managing Director
8. Mr. S.Suresh Dy. Managing Director
2.2 Brief Description of nature of Product:
2.2.1 Sugar
Sugar known as sucrose or saccharose is an anhydrous crystalline organic product of comparatively
99.96% purity. The physical properties of sucrose are defined as follows
CRYSTALLINE NATURE:
Sucrose crystals are hard and belong to the mono-clinic system, characterized by three axes of
unequal length. Density of sucrose is equal to 1.606 gm/cu.cm. The presence of impurities in sugar
has a remarkable influence on the formation of the crystals.
E.I.D. - Parry (India) Limited (Bagalkot)
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SOLUBILITY:
Sucrose is very soluble in water and in dilute ordinary alcohol. The solubility in water increases with
the rise in temperature, such that for a 10% sucrose solution, the boiling point is 100.04 Deg.C and
for a 90% sucrose solution the boiling point is 130 Deg.C. It is insoluble in chloroform, in cold
absolute alcohol, either and glycerine.
SPECIFIC GRAVITY:
The specific gravity of sucrose varies from 1.033 to 1.106 according to the concentration of the
solution. The density of the sugar solution is determined in practice by brix and beaume spindles or
balling saccharimeter.
OPTICAL ROTATION:
Sucrose and glucose rotate the plane polarised light in a `clockwise‟ direction or to the right and are
called dextro-rotatory. Fructose, rotate in a `counter clock wise‟ direction or to the left and is known
as levorotatory. The specific rotation of sucrose is 66.5 Deg.
CHEMICAL PROPERTIES:
Dry sugar (sucrose) melts at 160 Deg.C into a thick transparent liquid which on cooling again
becomes crystalline. If heated for a long time at 160 Deg.C sucrose splits up into glucose and
levulosane. At higher temperatures between 190 to 220 Deg.C the decomposition is more complete
and caramel is produced. On further, heating, carbondioxide, carbon monoxide, acetic acid and
acetone are produced.
In the presence of moisture, sucrose decomposes at 100 Deg.C and becomes dark in colour
liberating water. On prolonged heating of sucrose at the boiling point and at ordinary pressures, the
dissolved sucrose combines with water and breaks up into glucose and fructose in equal parts and
the phenomenon is called Hydrolysis of Inversion.
APPLICATIONS:
The principal use of sugar as explained is as the sweetening agent in foods. The consumption of
sugar is distributed in the various sectors such as for daily human consumption in household sector
for food processing industries, beverages, baking industry, confectioneries and miscellaneous
users. Sucrose serves as raw materials for manufacture of glucose, fructose, invert sugar syrups
etc.
E.I.D. - Parry (India) Limited (Bagalkot)
Expansion of Integrated Sugar Complex
Pre-feasibility report
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Non food uses of sugar constitute a small amount of total sugar consumption. They include use of
sugar as a scurose octacetate, a denaturant in ethyl alcohol, as sucrose diacetate, Hexa-
isobutyrate, octa benzoate, as mono and difatty acid esters for surfactants, as allyl sucrose, in
plasticisers and as raw materials for manufacture of various chemicals like glycerol, mannitol etc.
Dextran is a polysaccharide produced from sucrose by the biological process and is a very effective
plasma volume expander. Sucrose when administered by intravenous infusion relieves shock and
prevents loss of body fluids after excessive burns, wounds or infectious diseases. Other industries
wherein sucrose is finding application include drying oil esters for surface coating industries and
sugar derived detergents.
PRODUCT SPECIFICATIONS:
The specifications required for white sugar complying with Indian sugar standards are defined as
follows:
Characteristics Requirements
Moisture (%) weight 0.05% Max.
Pol 99.5% Min.
Reducing sugars (%) by weight 0.10% max.
Conductivity x [106] 100 max.
Sulphur dioxide (ppm) 70 max.
Calcium oxide (CaO) (mg/100gm) 30 max.
Turbidity, (%) by weight 15 ax.
2.2.2 Power
Power is generated by converting the mechanical energy i.e steam generated from Boiler into
electrical energy through Turbine.
The power generated will be utilized for meeting the power requirements for sugar, Distillery and
other auxiliaries. Remaining power after meeting the power requirement for the project, will be
exported to nearby grid
2.2.3 DISTILLERY PRODUCTS
Extra Neutral Alcohol
ENA IS 6613 – 1972 is an Extra Neutral Alcohol, Basic raw material for IMFL.
Produced from Molasses, Sweet Swargam, Cane Juice and Grain etc.
Rectified Spirit IS 323 – 1959 Quality is inferior to ENA.
ENA is nothing but refined Rectified Spirit.
ENA Process is a physical process in which Aldehydes, Esters and Fusel Oils impurities are
separated by virtue of their difference in Boiling Points by steam Distillation.
E.I.D. - Parry (India) Limited (Bagalkot)
Expansion of Integrated Sugar Complex
Pre-feasibility report
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ENA RS ETHANOL
01 Ethanol content percent by Volume at 15 . 6O C,Min
94.68 94.68 99.50
02 Acidity gms/100 ml1 Max 0.002 0.002 0.006
03 Residue on Evaporation gms/100 ml1 Max
0.002 0.005 0.005
04 Ester content gms/100 ml Max 0.01 0.02 0.02
05 Aldehydes gms/100 ml1 Max 0.004 0.006 0.006
06 PP Times, Minutes 30 Nil Nil
2.3 Demand – Supply Gap:
The sugar industry today is facing fierce competitive situation due to fluctuations in sugar prices in
the national & international markets, higher cane prices to be paid to the cane growers, rising input
costs, etc. The survival and growth of this industry depends on energy efficiency, cost optimization
and revenue generation from bi-products and down steam products including power, ethanol,
chemicals, etc.
The implementation of cogen power plant concurrently with the sugar modernization cum expansion
project along with other by-products, right from the beginning goes a long way to integrate the
operations and improve sustainability.
Sugar Industry Overview, India & Karnataka
The origin of Indian sugar industry dates back to 1930, when the first sugar factory was set up in the
pre-independence era. Over the last 76 years, the sugar industry has steadily grown and has
become the backbone of the agricultural and rural economy in India. Today, sugar is the second
largest agro processing industry, next to the textile industry. India is one of the largest producers of
sugar in the world, with a production of over 15 million tones. Sugar factories are located mostly in
the rural India. They act as centers of development, provide largest direct employment in the rural
areas and contribute substantially to the Central and State exchequers. The prospects of earning
foreign exchange from export of sugar are also quite high.
Sugar factories in India have capacities ranging from 1250 TCD to 10000 TCD. The Indian sugar
industry has developed indigenous capabilities for design, manufacture, supply, operation and
maintenance, R&D and cane development. The major stakeholders of this industry in India are
Ministry of Agriculture, Govt. of India, Ministry of Consumer Affairs, Food and Public Distribution,
federations of co-operative and private sector sugar factories at the national and the State levels,
sugarcane growing farmers, equipment and technology suppliers, research institutions, consultants
and service providers, financial institutions and Central / State Governments.
A total of 619 sugar factories are in operation today, with additional few new sugar factories under
implementation in different parts of the nation. The area under sugar cane cultivation, sugar cane
E.I.D. - Parry (India) Limited (Bagalkot)
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production, sugar cane crushing in sugar factories, average season days, sugar recovery and sugar
production has increased steadily over the years. The crop yield per hectare and recovery has
improved, particularly in the last decade.
Sugar factories in India are spread over the entire country, however 92.73% of them are located in 9
States viz., Uttar Pradesh, Bihar, Punjab and Haryana in the north, Maharashtra and Gujarat in the
west and Karnataka, Andhra Pradesh & Tamil Nadu in the south. More than 80% sugar factories
are below 3500 TCD capacity and balance have higher capacities. About 61.23% of the Indian
sugar factories are in the co-operative and Government / joint sectors / Public and balance 38.77%
in the private sector.
Following Table no 1.3 shows the distribution of sugar factories all over India.
Status of Sugar Factories in India
State Private Public Co-op Total
Assam 1 2 3
Orissa 4 4 8
Bihar 13 15 28
Uttar Pradesh 116 14 28 158
Uttarakhand 4 2 4 10
Punjab 8 16 24
Haryana 3 13 16
Andhra Pradesh 20 1 12 33
Telangana 10 1 11
Tamilnadu 27 3 16 46
Maharashtra 80 169 249
Gujarat 5 22 27
Madhya Pradesh 16 2 5 23
Kerala 1 1 2
Rajasthan 1 1 1 3
Karnataka 48 3 25 76
Pondicherry 1 1 2
Goa
1 1
Chattisgarh
1 1
Dadra Nagar & Haveli
1 1
West Bengal 2 1 3
All India Total 360 42 325 727
Source: Sugar India Year book, 2016
E.I.D. - Parry (India) Limited (Bagalkot)
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The Ministry of Consumer Affairs, Food & Public Distribution, and Government of India revised the
standard specifications for sugar plant & equipment, in the year 1987. The special committee
finalized specifications for economical capacity of 2500 TCD, expandable to 3500 TCD, employing
higher-pressure boiler and turbine configuration and efficient equipment, with a potential to export
incidental surplus power to the grid.
The Indian sugar industry was de licensed in the year 1998 vide press note No. 12 issued by the
Government of India, Ministry of Industry, Department of Industrial Policy and Promotion, on August
31, 1998. The salient features of de licensing are as follows:
The sugar industry stands deleted from the list of industries requiring compulsory licensing
under the provisions of Industries Development and Regulation Act, 1951. However, in order
to avoid unhealthy competition among sugar factories to procure sugarcane, a minimum
distance of 15 km would continue to be observed between and existing sugar factory and a
new factory, by exercise of powers under the Sugar Control Order, 1966.
The entrepreneurs, who wish to de-license their sugar factory, would require filing an
Industrial Entrepreneur Memoranda (IEM) with the secretariat of industrial assistance in the
Ministry of Industry, as laid down for all de-licensed industries, in terms of the press note
dated August 2, 1991, as amended from time to time.
Entrepreneurs who have been issued Letter of Intent (LoI) for manufacture of sugar need not
file an initial IEM. In such cases, the LoI holder shall only file Part B of the IEM at the time of
commencement of commercial production against the LoI issued to them. It is however
open to entrepreneurs to file an initial IEM (in lieu of LoI / industrial license held by them) if
they so desire, whenever any variation from the conditions and parameters stipulated in the
LoI / industrial license is contemplated.
The statistics on economic and commercial performance for the industry is quite fluctuating. The
changes in the agro climatic conditions and sugarcane crop production, as well as the sugar
markets have been mainly responsible for these fluctuations. Efficiency, quality, and integration
have become order of the day for this industry. The industry has grown till today over the last seven
decades. The strength and capacity built so far will surely help meet these challenges. The
following are major options to meet these challenges:
a. Effecting substantial improvement in cane development and management, including
cultivation practices, varietals and water management, so as to improve yield and
recovery, without affecting the average fibre content.
b. Effecting visible improvement in the operational efficiencies and reduction of sugar losses.
c. Effecting and sustaining improvement in energy efficiency, both in steam and power, for
saving of additional bagasse, for both sugar and by-products manufacture.
E.I.D. - Parry (India) Limited (Bagalkot)
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d. Expansion of capacities and diversification into absolute alcohol/ethanol and cogeneration
power projects.
e. Effecting adequate capacity building within and without.
f. Maximizing sugar exports for value addition.
g. Effective marketing in the national and international markets.
h. Product quality and diversification.
i. Commercializing the excess power capacity by exporting to utilities or to other bulk power
consumers.
Ministry of Consumer Affairs, Food & Public Distribution Department of Food & Public Distribution
Government of India has issued a revised order dated November 10, 2006, amending Sugarcane
(Control) Order, 1966. The key provisions of this order are outlined below:
a. No new sugar factory shall be set up within a radius of 15 km of any existing sugar factory or
another new sugar factory in a State or two or more States.
b. Before filing the Industrial Entrepreneur Memorandum (IEM) with a Central Govt., a
certificate from the Cane Commissioner or Director Sugar or specified authority of the
concerned State Govt. shall be obtained regarding the distance criteria re-defined as above.
c. Submission of performance guarantee of Rs. 1 crore to Chief Director, Sugar, Dept. of Food
& Public Distribution, within 30 days of filing the IEM, as a surety for implementation of the
IEM within the stipulated or extended time.
d. The stipulated time for taking effective steps shall be 2 years and commercial production
shall commence within 4 years from the date of filing of the IEM, failing which the IEM shall
stand de-recognized and performance guarantee shall be forfeited.
e. If an IEM remains un-implemented within the stipulated or extended time limits, the
performance guarantee shall be forfeited after giving a reasonable opportunity of being
heard.
f. The above clauses will be applicable for IEM already acknowledged as on the date of this
notification, but who have not taken effective steps for its implementation, duly defined, shall
furnish a performance guarantee of Rs. 1 crore to the Chief Director, Sugar.
Power Sector Review
The maximum demand met by the state has increased from 7,815 MW in FY 2011 to 9,549 MW
in FY 2015 showing a growth of 22% during the 4 year period, while energy requirement has
increased by 29% during the same period. The maximum demand deficit has however reduced
due to many DSM activities undertaken by DISCOMs and sourcing of power on short term
basis to meet the need.
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The average daily consumption of registered rural domestic consumers has increased to 1.19
kWh in FY 2015 at CAGR of 4% during the last 6 years. On the other hand, the average
daily consumption of registered domestic urban consumers has increased to 3.00 kWh in FY
2015 at CAGR of 3% during the same period.
As per projections made in 18th EPS of CEA, the projected energy demand and maximum demand
for the state of Karnataka was 89,285 MU and 14,945 MW in FY 2019 as against the now
calculated energy requirement of 87,626 MU and maximum demand of 14,710 MW in FY
2019.
Ethanol Sector Overview, India and Karnataka
The use of alcohol as a drink is an age-old story. It appears that in India the technique for
fermentation and distillation was available even in the Vedic times. Alcohol is an integral part of the
Ayurvedic system of medicine also.
Carew & Co. Ltd. set up the first distillery in the country at Cownpore (Kanpur) in 1805 for
manufacture of Rum for the British army. The technique of fermentation, distillation and blending of
alcoholic beverages was developed in India on the lines of practices adopted overseas, particularly
in Europe.
The original use of alcoholic fermentation was of course for preserving fruit juices. Now the
fermentation is adapted for the preparation of fermented grain beverages and then distilled
beverages. The utilization of Ethanol, for industrial use is a recent phenomenon. It became
important towards the end of the Second World War.
When large-scale production of alcoholic beverages was taken up, various Governments found that
alcohol was a good source for increasing government revenue through collection of tax. When
synthetic organic chemistry advanced rapidly, about a century ago, alcohol became an
indispensable chemical for this industry. However extensive manufacturing of alcohol for industrial
use was hampered due to excessive taxes. The problem was to device a means for conserving
government‟s interest in tax collection on potable alcohol and at the same time making alcohol for
industrial use relatively free of tax. Thus different governments introduced the process of
denaturation of alcohol for industrial use.
During the Second World War, the demand for the industrial alcohol increased 4-5 times, above the
prewar period, due to the production of smokeless powder for weapons. The imports of molasses
were hampered due to war conditions. This leads to evolving the process of grain fermentation for
meeting the requirement of Ethanol.
E.I.D. - Parry (India) Limited (Bagalkot)
Expansion of Integrated Sugar Complex
Pre-feasibility report
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In India, after the protection granted to the sugar Industry in 1932, a large number of sugar factories
were established in the country, particularly in Maharashtra and Uttar Pradesh where irrigation
facilities existed for cultivation of sugarcane. Increase in sugar production resulted in accumulation
of molasses, which resultantly, caused unmanageable environmental problems. At that time the
demand for molasses was almost insignificant and the sugar mills had to incur considerable
expenditure for disposal of molasses. For resolving these problems a joint committee of U.P. and
Bihar was constituted in 1938 to explore the possibilities of using molasses for developing alcohol-
based industries. The Committee recommended establishment of distilleries for production of
alcohol, utilizing molasses as a substrate.
The committee also recommended that alcohol produced by the distilleries should be admixed with
petrol, to supplement motor fuel. This helped in solving the problems of disposal of molasses. It also
filled up the gap in the demand and supply of motor spirit.
As a result, after meeting alcohol requirement for manufacture of gasohol, substantial quantity of
alcohol was diverted for production of alcohol based chemicals.
Present Status
Fossil fuels are declining. Transportation sector consumes more than 50% of the fuels.
Environmental degradation from these fuels is a major problem all over the world. World oil
production is expected to last till 2125 A.D., if consumption at the present level is maintained. On
this background the use of Ethanol for fuel blending should be given a top priority.
India requires ethanol for the following three major purposes:-
For potable liquor
For industrial use
For fuel blending
Today, the distillery industry of India uses only molasses for manufacturing alcohol. There are
handful of grain distillery units (e.g. Seagram Manufacturing Ltd.) and the alcohol produced by them
is used for captive use to make value added liquors.
All other liquor (IMFL) manufacturers use alcohol produced from molasses. In advanced countries,
liquor for human consumption is made only from grain alcohol. It is known that alcohol produced
from molasses can have residues such as sulphates, sulphites, higher aldehydes, higher alcohols,
higher acids and ketones etc., which are not present in alcohol from, grains.
E.I.D. - Parry (India) Limited (Bagalkot)
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However, no such above-mentioned distinction is made in India. Thus alcohol produced only from
one source i.e. molasses is used for all 3 purposes (liquor, industrial use, fuel blending). There is an
urgent need to bring in above quality consciousness in the IMFL industry and appropriate policy
measures by the Govt.
Today, Indian distillery industry broadly consists of two parts:
One is alcohol production from molasses for industrial alcohol and two alcohol production from
molasses for liquor purposes.
Ethanol demand for fuel blending is a recent phenomenon. For this purpose, alcohol from molasses
is used.
The potable distillery producing Indian Made Foreign Liquor (IMFL) has a steady but limited
demand. The alcohol produced is now being utilized in the ratio of approximately 52 per cent for
potable purpose and the balance 48 percent for industrial purpose.
Ethanol blending
Ethanol blending is the practice of blending petrol with ethanol. Many countries, including India,
have adopted ethanol blending in petrol in order to reduce vehicle exhaust emissions and also to
reduce the import burden on account of crude petroleum from which petrol is produced. It is
estimated that a 5% blending (105 crore litres) can result in replacement of around 1.8 million
Barrels of crude oil . The renewable ethanol content, which is a byproduct of the sugar industry, is
expected to result in a net reduction in the emission of carbon dioxide, carbon monoxide (CO) and
hydrocarbons (HC). Ethanol itself burns cleaner and burns more completely than petrol it is blended
into. In India, ethanol is mainly derived by sugarcane molasses, which is a by-product in the
conversion of sugar cane juice to sugar.
The practice of blending ethanol started in India in 2001. Government of India mandated blending of
5% ethanol with petrol in 9 States and 4 Union Territories in the year 2003 and subsequently
mandated 5% blending of ethanol with petrol on an all-India basis in November 2006 (in 20 States
and 8 Union Territories except a few North East states and Jammu & Kashmir). This was also an
attempt to reduce the Under-recovery of Public Sector Oil Marketing Companies (OMCs). Ministry
of Petroleum and Natural Gas, on 1 September, 2015, inter-alia has asked OMCs to target ten
percent blending of ethanol in Petrol in as many States as possible. In countries like US, blending is
allowed upto 10%. Subsequent to Brazil's bio-fuel programme, which began in 1976, close to 94%
of cars sold in Brazil are flexible fuel cars that can handle ethanol blends from 18 per cent upward .
Ethanol blending first found mention in the Auto fuel policy of 2003. It suggested developing
technologies for producing ethanol/ bio fuels from renewable energy sources and introducing
E.I.D. - Parry (India) Limited (Bagalkot)
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vehicles to utilise these bio fuels. Later, as per National Policy on Bio-fuels, announced in
December 2009, oil companies were required to sell petrol blended with at least 5% of ethanol. It
proposed that the blending level be increased to 20% by 2017.
Ethanol, being a by product of the sugar industry, was expected to be freely available. However, Oil
marketing companies (OMCs) were not even able to get bids for more than 50% of the amount
offered for purchase . Further, the Government decided on 22.11.2012 that procurement price of
ethanol will henceforth be decided between Oil Marketing Companies (OMCs) and suppliers of
ethanol. In addition, on 03.07.2013, it was decided that ethanol would be procured only from
domestic sources. This led to a rise in ethanol prices, which to a great extent reportedly eroded the
economy of the blend. At present, government has permitted OMCs to implement the ethanol
blending programme in notified 20 States and 4 Union Territories as per the availability of ethanol.
There are reportedly significant transaction barriers which impede smooth supplies of ethanol for
blending. In several States, State not only imposes levy on molasses but also regulates the
movement of non-levy molasses. Inter-state movement of ethanol requires No-Objection-
Certificates (NOCs) from the State Excise Authorities along with permits from dispatching and
receiving States. Most States impose “Export/Import” duties on ethanol leaving and entering their
boundaries. There are some instances where Octroi is levied on ethanol for entry into municipal
limits. Hence States were requested by the Central Government to liberalise restrictions on the
supply of ethanol so that its blending with petrol can be encouraged while improving the financial
health of sugar sector and also liquidation of cane dues of farmers.
As per the estimates given in Auto Fuel Vision and Policy 2025 issued in May 2014, blended petrol
is available only in 13 states and the average blend is 2%. During the sugar year 2014-15, OMCs
have achieved a blending percentage of 2.3% as per the press release dated 25 April 2016.
Hence, in order to improve the availability of ethanol, the Government, on December 10, 2014, fixed
the price of Ethanol in the Range of Rs. 48.50 to Rs. 49.50, depending upon the distance of
distillery from the depot/installation of the OMCs. (The rates are inclusive of all central and statutory
levies, transportation cost etc, which would be borne by the Ethanol suppliers). Fixation of ethanol
price based on distance, has encouraged movement of ethanol to longer distances, including States
having lack of distilleries. Further, ethanol produced from other non-food feedstocks besides
molasses, like cellulosic and ligno cellulosic materials including petrochemical route, has also been
allowed to be procured subject to meeting the relevant Bureau of Indian Standards (BIS)
specifications.
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2.4 Employment generation (Direct & Indirect):
The man power required for the industry is 500 Nos. which is inclusive of 275 nos. on permanent
basis and rest all will on Temporary or contract basis.
S.No. Particulars No. Employees
1. Technical & Administrative Staff 150
2. Skilled & Semi Skilled 275
3. Unskilled & Helpers 75
Total 500
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3.0 PROJECT DESCRIPTION:
3.1 Type of the Project:
The proposed Project mainly involves
Production of Sugar from Sugarcane
Power generation using Bagasse / Coal as fuel
Production of Rectified Spirit / ENA / Ethanol using Molasses as raw material
3.2 Location
E.I.D. - Parry (India) Limited is an existing Sugar & Cogeneration Power plant at Nagaral & Nainigali
Village, Bagalkot Taluk and District.
Now the company has proposed to enhance the Sugar Plant capacity along with Co-gen Power and
put up a new 60 KLPD Molasses based Distillery. The proposed expansion will be taken up in the
existing plant premises only.
3.3 Details of the Alternate sites:
No Alternate sites have been examined as existing premises has been given permission to set up
Sugar Plant.
3.4 Size or Magnitude of Operation:
The following will be the capacities after proposed expansion
Sr. No Unit Capacity
Existing Expansion Total
1. Sugar 4750 TCD 2750 TCD 7500 TCD
2. Co-gen Power plant 15 MW 19 MW 34 MW
3. Distillery -- 60 KLPD 60 KLPD
4. Power from
incineration boiler
-- 3 MW 3 MW
3.5 Process details:
3.5.1 Sugar Process Description
Milling:
Sugarcane from the fields are weighed and fed in cane carrier by means of cane unloaders. The
cane is passed through kicker, leveler and Fibrizer. The Fibrizer improves the extraction of the mills
by breaking the rigid ness of the cane and so facilitating its disintegration and extraction of its juice.
The fibres are then crushed in mill house, consisting of the 4 mills. During crushing, juices present in
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the cane cells are extracted by the mills. The juice obtained from milling is sent for process, fibre
that comes out from 4th mill is termed as bagasse and it is used as fuel in boilers.
Boilers:
In boilers condensate water is converted into steam by burning bagasse as fuel. Steam produced in
boilers is used in the steam turbine to generate power and the exhaust steam coming out from the
turbine is used in the process for sugar manufacturing.
Power House:
Power House consists of steam turbine and alternator. The alternator is driven by steam turbine and
power is generated. The generated power is used to meet the in-house power requirement of the
factory and the surplus power is exported to grid. The in-house LP steam from the steam turbine is
used for sugar processing at the boiling house.
Clarification:
The extracted juice from mills is called as raw juice and it is heated to 70 – 75 Deg. C. in juice
heaters and treated simultaneously with the milk of lime and sulphur dioxide gas in order to
separate the impurities. The sulphited juice is again heated to 102 Deg. C through juice heaters and
allowed to settle in the clarifier. The purified juice, which comes out from clarifier, is called as clear
juice and is sent to evaporator for concentration. The settled impurities are called mud. The mud
contains small amount of juice, which is separated in vacuum filters.
Evaporation:
The clear juice after clarification is concentrated in evaporators by evaporating the 75% of the water
present in it. Evaporators are huge vessels consist of calendria where the juice is made to flow
through the tubes and around w3hich steam is passed. The clear juice of 12 – 15 Brix is
concentrated to 60 Brix. Concentrated juice is then called syrup. The syrup is again treated with
sulphur dioxide (Bleaching agent).
Crystallization:
The sulphited syrup is concentrated further in the vessels called pans. During the above process,
sugar crystals are developed by means of exhaustion. The formed crystals are then cooled in
crystallisers. The crystals are surrounded by thin film liquid called as mother liquor. The crystal
along with the mother liquor (Molasses) is called as massecuite.
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Curing:
The above massecuites are centrifuged in centrifugals, where crystals are separated from the
mother liquor. Separated mother liquor of A & B massecuites are again used for boiling and
maximum exhausted mother liquor is called as Final Molasses, which is stored in the steel tanks
and sent to distillery for manufacture of Ethyl alcohol. The separated sugar crystals are dried in
hopper, sieved in graders and bagged.
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Bagging:
Sugar is bagged in `A‟ Twill Gunny bags and each bag contain 100 kg / 50 kg sugar nett. The bags
are stacked in sugar godowns and are dispatched as per the directions given by the Directorate of
Sugar, New Delhi.
3.5.2 Co-generation Power Plant
Sugar plant will be installed with 2750 TCD in addition to existing 4750 KLD capacity. The
cogeneration capacity is so designed that the plant will be able to feed steam and power
requirements entire Sugar Complex. The capacity of the boiler will be 110 TPH at 108 ata and
540ºC. The turbine capacity would be 19 MW at 110 TPH at 108 ata and 540ºC steam parameters.
The turbine will have 3 extractions and condensing mode. The two numbers of HP extractions will
be uncontrolled and one no. of LP extraction controlled. The first HP extraction (higher pressure) will
feed HP heater – II and second HP extraction will feed HP heater – I and process HP steam
requirement of Sugar and Distillery. The controlled LP extraction will feed the requirements of LP
steam of Sugar process Dearator and Distillery.
For off-season operation, we have to utilize the purchased biomass fuel and imported coal. The
season period will be 5 to 6 months and off-season will be 3 to 4 months depending on the
availability of fuels at economical price.
3.5.2.3 Fuel Balance:
Cane crushing per hr 315 TPH
Bagasse % on cane is 30%
Bagacillo consumption 1.0% on cane
Net bagasse available for cogeneration 29%
Steam fuel ratio for bagasse is 2.50 for new Boiler of 110 TPH @ 108 ata
Steam generation from mill bagasse is 110 TPH and Procured Bagasse.
For off season we have to procure biomass fuels and imported coal to ensure 25% of the total fuel
consumption is from coal and other biomass in a year.
3.5.3 Manufacturing Process (Rectified Spirit/Ethanol/ENA)
Yeast propagation:
Yeast seed material is prepared in water-cooled yeast vessels by inoculating molasses with yeast.
The contents of the yeast vessel are then transferred to the Yeast activation vessel. The purpose of
aerated yeast activation in the yeast activation vessel is to allow time for the yeast cell multiplication.
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Fermentation:
The fermentation technology adopted in the industry is of continuous fermentation with yeast
recycle with this technology the total spent wash generation will be restricted to a max. of 10 kl/kl of
R.S. (As per latest CPCB recommendation).
The purpose of fermentation is to convert the fermentable sugars into alcohol. During fermentation,
sugars are broken down into alcohol and carbon-di-oxide. Significant heat release takes place
during fermentation. However the fermentation temperature is maintained at 32 – 35 0C by forced
recirculation heat exchangers.
At the end of fermentation, the wash is fed through a yeast separator where the yeast cream is
separated, acidified in the yeast treatment tank and returned to the yeast activation vessel for
activation. Sludge is separated in a sludge decanter. The clear wash from both the yeast separator
and sludge separator flows to the clarified wash tank. The wash is then pumped to distillation.
Distillation:
Fermented Wash about 8% v/v alcohol is preheated in two stages i.e. in the beer heater using the
Rectifier vapours and then in the Fermented wash PHE using the effluent. The preheated wash is
then fed the Degasifying Column to remove residual CO2 and volatiles.
The wash then flows down to Analyser Column, which acts as a total stripper. The alcohol water
vapour mixture which rises upward in this column is fed to the Rectifier Column. The spent wash,
which is devoid of alcohol, flows down the Analyser Column for suitable treatment.
The lower boiling impurities are concentrated in the Aldehyde Column where about 5% spirit is
drawn off as impure spirit with a minimum strength of 660 OP.
The alcohol vapours are concentrated in the Rectifier Column to produce Rectified Spirit of 95% v/v
strength. Higher boiling impurities, which are formed during fermentation, are removed by taking
side draw purges to a decanter from the Rectifier Column. A trace stream of spirit is drawn off as
impure spirit (about 2% of plant capacity) to remove the concentrated volatile compounds. The high
grade Rectified Spirit is taken as a draw from the upper trays of the Rectifier Column.
The Rectified spirit is fed to the purification column. Dilution water is fed on the top most tray of the
column with a dilution ratio of 1: 9. This column serves to remove the impurities based on the
principle of HYDROEXTRACTION. The water is fed to the column in such a way that it selects the
higher alcohols and other impurities to move upwards and extracts ethanol down. The purifier
bottom alcohol composition is maintained at 12 % v/v. At this composition there is an inversion in
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relative volatiles of higher alcohols as compared to ethanol and these alcohols get separated in the
top distillate. Top draw for volatiles is fed to the Fusel oil concentration column.
The purified dilute ethanol is removed from the bottom of the purification column and fed to the
rectification column, which concentrates the ethanol to 96% v/v. The high grade spirit is drawn from
one of the upper trays of the rectification column. A small heads cut is removed from the overhead
stream as technical alcohol (T.A.) cut to with draw impurities and is fed to the heads concentration
column. The lees from the exhaust column is recycled as dilution water after a part of it is purged.
The purged spentlees is used to preheat the make-up dilution water.
Lower side draw streams are taken from rectification column to avoid fusel oil build up in the
column. These streams are then taken to the fusel oil column. This column concentrates the dilute
streams of ethanol containing esters and fusel oils to approximately 95% v/v of ethanol. The
concentrated ethanol is removed as T.A. cut from the top of the column. T.A. cut is removed out of
the system in order to remove propanol and remaining is fed to the heads concentration column
where the heads from the purification column and rectification are fed to the static mixer. Soft
water, which has been preheated, is used for diluting the high proof ethanol. An impure spirit cut of
about 5% of the rectified spirit feed is drawn from the top of the column. The dilute ethanol solution
at the bottom of this column is pumped back to the purification column for repurification.
Carbon Dioxide Recovery System (By Product): Carbon dioxide produced during fermentation will be recovered by means of scrubbing
arrangement, chemical treatment drying process and finally liquefaction. The water utilized for
scrubbing will be recycled back into the fermentor.
CO2 gas will pass through scrubbing tower, where the gas is scrubbed with water. From the
scrubber after washing the gas will pass through air compressor and then the gas will pass through
a tower containing sodium dichromate to eliminate the impurities, if any and then to drying
arrangement with sulphuric acid. Subsequently it passes through a tower containing coke coated
with washing soda to eliminate odour. Finally it goes to the chilling unit to cool the gas before
passing through different cylinders, where the cooled gas will be filled into the cylinders under
pressure. The scrubber blowdown will be recycled into the fermenters.
Total CO2 production : 45.6 T/day
This carbon dioxide in cylinders will be sold to industries like soft drink manufacturing units, etc.
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Ethanol Production:
This plant is filled with imported 3A grade Molecular Sieve. It is operated with vaporized Alcohol and
removes water completely. Then Molecular sieves are regenerated under vacuum of 710 mm Hg.
Feed Alcohol comes to this Plant in a Day Tank continuously from bulk storage tank. From this tank
alcohol is pumped to a steam vaporizer at 4 Kg/cm2 pressure. This is vaporized in a steam heater
and then vapor is super heated to 160oC in a super heater and taken to Molecular Sieve Unit. This
super heated vapor now pressure through one Molecular Sieve column for moisture removal. There
are 2 Molecular Sieve columns. At a time one column remain in drying cycle while other columns
under goes vacuum regeneration. Each column remains in cycle for 6 minutes. Here drying process
takes place at 3.0 Kg/cm2 pressure and dry alcohol vapor of 99.8% purity comes out as final
product. This alcohol vapor is condensed in a water cooler and then collected in another day tank.
From this tank dry alcohol is continuously pumped to bulk day storage tank through a level
controller and a control valve. In the regeneration process some left over alcohol also comes out
which is condensed in regeneration condenser. This alcohol is around 95% strength and is re-
cycled in to rectifier column continuously.
The other Molecular Sieves column under goes regeneration by a vacuum pump. In this column
vacuum pumps pulls and creates vacuum of 710 mm Hg. At this vacuum the moisture from
Molecular Sieve pores comes out and along with 30% pure alcohol from on line Mole Sieve bed is
sprayed. Thereafter during vacuum process, some left over alcohol and water from Molecular
Sieves comes out and is condensed. Concentration of this lean alcohol is around 70% alcohol,
which can be recycled to the Rectifying Column. From Rectifier the pure water will be sent out
automatically.
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3.6 Raw Materials
The following will be the raw material requirement for the for the existing and proposed expansion project
S.NO RAW MATERIAL SOURCE QUANTITY ( TPD)
METHOD OF TRANSPORT Existing Expansion Total
Sugar plant :
1 Sugar Cane From Bagalkot 4750 2750 7500 By trucks
2 Lime Local area 11.875 6.875 18.75 Through covered trucks by Road
3 Sulphur Local area 3.325 1.925 5.25 Through covered trucks by Road
4 Phosphoric Acid Local area 0.285 0.165 0.45 Through covered trucks by Road
Co-gen power plant :
1 Fuel
Bagasse From Sugar plant 1050 1200 2250 Conveyor
(or)
Coal Imported 395 495 890 By Sea/ Rail/Road Covered trucks
Distillery :
1 Molasses From Sugar plant &
External
--- 230 230 Through Pipeline/Tanker
2. FUEL For 25 TPH Boiler
Concentrated Spent wash From Distillery Unit --- 166 166 Through Pipeline
Coal (100%) Karnataka --- 116 116 Through covered trucks by Road
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3.7 Resource Optimization / recycling and reuse: Sugar Plant
Condensate from the Sugar Plant will be utilized for Cooling tower make up
Power Plant
The effluent generated from the Plant will be treated in Neutralization pits and will be utilized for
dust suppression, ash conditioning and Greenbelt development after ensuring compliance with
stipulation for on land irrigation by MoEF / CPCB
Distillery
Spent wash generated during the process of Fermentation, will be treated in Multiple Effective
Evaporators to concentrate the solids content up to 55% and concentrated spent wash will be
incinerated in the Boiler along with Coal.
The condensate generated during the process of Multiple Effective Evaporators will be reused in the
Process thus decreasing the net water requirement.
3.8 Availability of Water:
Water requirement for the existing Plant is being met form the Krishna River. For the proposed
expansion also, water required will be met from the Krishna River.
Water requirement for the existing plant 406 KLD and for proposed expansion will be 1504 KLD.
Hence after proposed expansion the total water requirement will be 1910 KLD.
Prior permission from Irrigation Department will be for enhanced water requirement in due course.
WATER CONSUMPTION (in KLD)
Section
Sugar Co-gen Total after
expansion Existing
(4750 TCD) Expansion (2750 TCD)
Existing (15 MW)
Expansion (19 MW)
a)Domestic 10 10 10 10 40
b)Industrial purpose
1. Process water 23 14 -- -- 37
2. Boiler feed
234 270 504
3. DM plant regeneration
30 40 70
4. Cooling water make up
89 100 189
5. Service water 10 10 20 Total 33 24 373 430 860
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WATER REQUIREMENT FOR 60 KLPD DISTILLERY PLANT & 3 MW CO-GEN. POWER PLANT
SECTION Water requirement
Process water 560
Make up water for Boiler 40
DM water for RS dilution 190
Cooling tower make up 220
DM plant regeneration 30
Domestic water 10
Net water Requirement 1050
Water requirement for Sugar (Existing) : 33.00
Water requirement for Sugar (Expansion) : 24.00
Water requirement for Co-gen power (existing) : 373.00
Water requirement for Co-gen power (expansion) : 430.00
Water requirement for Distillery : 1050.00
Total water requirement for after proposed expansion will be : 1910 cum/day
3.9 Power Requirement:
The power required for the existing and expansion project will be met from the Co-generation Power
plant and proposed 3 MW Captive power plants.
3.10 Quantity of wastes generated:
3.10.1 Waste water generation
Waste water generation from the existing Plant 596 KLD. Waste water generation from the
proposed expansion will be 1083 KLD. Hence total waste water generation after proposed
expansion will be 1679 KLD
SECTION
SUGAR CO-GEN Total after proposed expansion
Existing (4750 TCD)
Expansion (2750 TCD)
Existing
(15 MW)
Expansion (19 MW)
a)Domestic 8 8 8 8 32
b)Industrial purpose
1. Process & Washings
82 48 -- -- 130
2. Boiler Blow down -- -- 24 28 52
3. Tube cleaning 218 122 340
4. DM plant regeneration
-- -- 30 40 70
5. Cooling tower blow down
176 104 40 45 365
6. Service water -- -- 10 10 20 Total 484 282 112 131 1009
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WASTE WATER GENERATION FROM
60 KLPD DISTILLERY PLANT & 3 MW CO-GEN. POWER PLANT
SECTION Water requirement
Spent wash 600
Cooling tower blow down 23
Boiler blow down 9
DM water regeneration 30
Domestic water 8
Total 670
Waste water generation from Sugar (Existing) : 484.00 KLD
Waste water generation from Sugar (Expansion) : 282.00 KLD
Waste water generation from Co-gen power (existing) : 112.00 KLD
Waste water generation from Co-gen power (expansion) : 131.00 KLD
Waste water generation from Distillery : 670.00 KLD
Total waste water generation for after proposed expansion will be : 1679 KLD
3.10.2 Waste water Treatment: Sugar Plant
Total wastewater generation will be 750 cum/day. Effluent generation per ton of cane crushed will
be below 100 lit/ton of cane crushed as per CREP recommendations.
Capacity of the existing ETP is 1000 KLD. Hence existing ETP is adequate for proposed expansion
also.. The following is the ETP description.
Design Data & Performance Projections
This Wastewater Treatment plant is designed for following parameters & shall perform as under
upon reaching steady state of its operation:
PARAMETER RAW WASTEWATER TREATED WASTEWATER
Flow (KLD) 750 750
pH (S U) 5.0 – 6.5 6.5 – 8.0
BOD (mg/l) 3000 < 30
COD (mg/l) 6000 < 250
TDS mg/L 2000 < 2100
TSS mg/L 500 < 100
Oil & Grease mg/L 100 < 10
Note: The Sugar ETP has been designed for 1000 KLD, to treat 750 KLD of trade effluent from
Sugar plant with a cushion of 25% in order to treat the non process effluent like cooling tower blow
down and tube cleaning. However necessary provision shall be made to operate the ETP with a
minimum flow of 750 KLD of trade effluent in the Digester and Aeration tank.
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PROCESS DESCRIPTION
The proposed wastewater treatment plant shall consist of following treatment units.
PRIMARY TREATMENT
Screen
Oil & Grease trap
pH adjustment
Equalization Tank
SECONDARY TREATMENT
UASB Anaerobic reactor
Aeration Tank
Secondary Clarifier
Sludge Drying Beds
Screen Chamber:
Screen chamber constructed in RCC shall be provided with SS 304 fabricated bar screen for
removal of free and floating material. The screen shall be inclined at 45 Deg with horizontal.
Oil & Grease Trap:
Oil and grease trap constructed in RCC shall be provided for removal of free and floating oil from
the Wastewater. The oil trap shall of gravity type and shall be provided with Belt type oil Skimmer.
Lime Preparation Tank:
A lime preparation tank constructed in RCC. In this tank is used for lime solution preparation and
continuous mixing of lime. Lime solution is then feed to equalization tank for pH correction in a
required proportion. 1 HP agitator shall be provided for mixing in the tank content.
Equalization:
Wastewater emanating from sugar has fluctuations in wastewater quality and quantity. Equalization
tank shall be provided for dampening these fluctuations. In equalization tank the raw effluent is
collected and equalized for adequate time. An equalization tank shall be provided with an agitator to
mix the tank content thoroughly. The equalized effluent from equalization tank shall then be pumped
to buffer tank. A stand by floating mixer shall also be provided for equalization tank
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Buffer Tank:
Buffer tank constructed in RCC shall be provided for preconditioning / pre-acidification of the raw
effluent. In buffer tank the Raw Effluent is mixed with treated effluent form UASB Reactor. The
nutrient required for the process will also be added to the effluent in Buffer tank. The content of
buffer tank shall be mixed hydraulically using UASB Reactor feed pumps. The tank content will
then be pumped to UASB Reactor for first stage biological treatment.
UASB Reactor:
Upflow Anaerobic Sludge Blanket reactor is provided for anaerobic treatment of dairy effluent. The
UASB reactor shall be constructed in RCC M-25. The reactor consists of three zones viz. Influent
distribution zone, Reaction zone, Gas solid liquid separation zone.
Influent Distribution zone: The raw wastewater enters into the at the bottom through influent
distribution zone. A sophisticatedly designed piping net work is provided for uniform distribution of
the effluent in the tank. The effluent then travels upward in the reactor.
Reaction Zone: In the reaction zone the anaerobic bacteria are maintained in the form of sludge
blanket. The organic matter in the wastewater comes in contact with the bacterial population and is
degraded anaerobically to methane rich biogas, the end product of anaerobic digestion. The
process of conversion of organic matter in to the biogas is a two-stage process. In the first stage the
organic matter in the raw effluent is converted in to the volatile acids by acid forming bacteria. In the
second stage the acid produced in the first stage are converted in to methane by another group of
bacteria i.e. methane formers. In UASB process both the stages are completed in single reactor.
The biogas so produced is bubbled through the effluent and is separated out in the third section i.e.
Gas-Solid-Liquid separation zone. The suspended solids are also separated to prevent escape of
solids from the reactor.
Gas-Solid – Liquid Separation: In gas solid liquid separation a hood fabricated in M S and duly
painted with corrosion resistant paint is provided. The hood separates the solid from the overflowing
reactor content. Gas collectors are provided for collection and conveyance of gas. The treated
effluent overflows through a launder and will take to a secondary treatment.
Aeration tank:
The partially treated effluent from UASB shall then be subject to activated sludge process for further
reduction of organic matter. Aeration tanks are provided for degradation of organic matter through
biological process. Microorganism in the controlled environment carries out the biodegradation
process. The container i.e aeration tank of requisite capacity is provided for this purpose. The tank
shall be provided with an aeration mechanism to transfer the oxygen from air to tank content for
survival for microorganisms. Slow speed fixed type surface aerators shall be provided for this
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purpose. The content in the aeration tank is kept under constant aeration and mixing. The aeration
thank shall be constructed in RCC.
Secondary Clarifier:
A secondary Clarifier in the form of circular tank shall be provided for settlement of fully aerated
Effluent from the aeration tank. The tank shall be provided with centrally driven fixed bridge type
clarifier mechanism. Part of the settled sludge at the bottom of the settling tank will be pumped to
the aeration tank and part of it will be discharged on sludge drying beds as per operational
requirement. This sludge being fully mineralized is suitable for sun drying on sand drying beds.
Sludge Drying Beds: In aeration system the sludge is sufficiently mineralized and does not need
any further treatment before dewatering and disposal. Sand filtration drying beds will be provided,
where sludge will be dewatered by filtration through sand bed and sun drying of the dewatered
sludge is scraped & may be used as manure after composting.
Note: All the civil structures in the ETP except sludge drying beds will be constructed with
RCC M20 grade to make them impervious. Sludge drying beds will be constructed with brick
masonry. Sugar ETP diagram shown below
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B) Cogeneration Power Plant
Total wastewater generation from power plant will be 227 Cum/day. The effluent generated from
power plant will be sent to Sugar plant ETP. The treated effluent will be utilized for Greenbelt
development, Dust suppression and ash conditioning.
Sanitary waste water will be treated in septic tank followed by soak pit. Hence there will not be any
adverse impact on environment due to the proposed activities. ETP diagram shown in below.
C) Distillery Plant:
With Molasses:
As per CPCB recommendations the spent wash quantity will be restricted to a maximum of 10 kl/kl
of R.S. for Molasses by adopting continuous fermentation technology with yeast recycle. The
Maximum Spent wash generation from the proposed Ethanol plant with Molasses as raw material
will be 600 KL/day.
The spent wash will be concentrated to 60% solids in Multiple Effect Evaporators and then will be
incinerated in exclusive 25 TPH Boiler. This is a ZERO discharge system already approved by
Central Pollution Control Board.
EVAPORATION SYSTEM
The objective of Evaporation is to concentrate a solution consisting of a volatile solute and a volatile
solvent. Evaporation is conducted by vaporizing a portion of the solvent to produce a concentrated
solution of thick liquor with 60% solids and 40 % moisture content.
The evaporation system consists of 5 evaporators, which are connected, in series. The spent wash
will be pumped from distillation section, which will be fed to the evaporator by using feed pump. Gas
Liquid separator (5 Nos.) will be used to separate the vapor and liquid. Both Vapor & Spent wash
will be fed to the next evaporation effect so it is called as feed forward effect evaporation. The vapor
from last evaporator will be condensed in condenser and transferred to the dryer while the
condensate from the evaporators is first utilized for heat recovery. While vacuum pump maintains
vacuum in the entire system. Product final thick spent wash with 60% solids will be used in boiler for
incineration.
INCINERATION OF CONCENTRATED SPENT WASH
The final concentrate from the Evaporators (60% solids w/w) will be incinerated in the Boiler by
mixing with coal. The condensate from the Evaporation system will be reused in the plant operation.
Zero discharge will be implemented as per CREP recommendations. ETP diagram shown below
Figure – 10.1
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Non Process Effluent Treatment & Disposal:
The boiler blow down & DM Plant & Softener regeneration water will be treated in a neutralization
tank and after treatment it will be mixed with CT Blow down. All these treated effluent streams will
be stored in a Central Monitoring Basin (CMB). The treated effluent will be used for dust
suppression / ash conditioning and onland for irrigation within the premises after ensuring
compliance with CPCB / KSPCB standards. The scrubbed water from CO2 Scrubber will be
consumed in the Fermentation section. The effluent will be used for greenbelt development within
the plant premises after ensuring the compliance with CPCB / KSPCB standards.
Storage Lagoon:
A Spent wash storage lagoon of storage capacity of 5 days which is less than 30 days will be
provided as per CPCB protocol. Closed storage tank will be provided.
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3.11 Solid Waste:
The following are the solid waste generation & disposal.
S.No Solid waste Quantity (TPD)
Disposal Existing Expansion Total
Sugar Plant
1. 1.
Bagasse 1425 825 2250 Will be used as fuel in Co-gen Boiler
2. 2.
Molasses 213.75 123.75 337.5 Will be used in the proposed Distillery
3. 2.
Filter cake 190 110 300 Will be given to the farmers to use as manure in the Agricultural fields
4. ETP Sludge 0.19 0.11 0.3 Will be used as manure Cogeneration Power plant
5.
When Bagasse used as fuel in Boiler 24.25 26.25 50.5
Will be disposed to farmers to use as manure in Agricultural lands
When Coal used as fuel in Boiler 18.8 24 42.8
Will be given to cement plants/brick manufactures
Distillery
6. Yeast Sludge -- 2.2 2.2 Mixed with spent wash and incinerated in the boiler.
25 TPH Incineration Boiler
7.
When concentrated spent wash used as fuel in Boiler
-- 10 10
Ash generated will be used as
manure
When Bagasse used as fuel in Boiler
-- 3.5 3.5 Ash Will be disposed to farmers to use as manure in Agricultural lands
E.I.D. - Parry (India) Limited (Bagalkot)
Expansion of Integrated Sugar Complex
Pre-feasibility report
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4.0 SITE ANALYSIS
4.1 Connectivity:
Component Description
Road The site can be well approached by a NH # 13
Rail Nearest Railway station located at 27 Km South west
Air port Nearest Airport located at Belgaum which is at distance of 145 Kms
from the Plant site
Sea Port Goa port is at a distance of 230 Kms from the Plant site
4.2 Land form, Land use and Land ownership:
The present use of the land is Industrial as Sugar and Co-generation power plant is under
operation. Now the proposed expansion of Sugar and Co-gen power plant and new Distillery plant
activities will be taken in the existing plant premises only.
4.3 Topography:
The topography of the land is more or less flat without undulations.
4.4 Existing land use pattern:
The present use of the land is Industrial
4.5 Existing Infrastructure:
The infrastructure required for operating the 3500 TCD of Sugar Plant and 15 MW Co-gen Power
plants exists at the Plant site
4.6 Soil classification:
The soil at the site is Black soil.
4.7 Climatologically data: GEOGRAPHICAL LOCATION:
Bagalkot district is located in the northern part of Karnataka state. The district lies between 15º46¹
and 16º46¹ north latitude and 74º59¹ and 76º20¹ east longitude. The district has boundaries with
Bijapur district in north and Belgaum district in west and Raichur & Koppal in east and Gadag in
south directions. Bagalkot district has an area of 6593 sq.km. The total Population of Bagalkot
district according of 2001 census is 1.65 million.
E.I.D. - Parry (India) Limited (Bagalkot)
Expansion of Integrated Sugar Complex
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CLIMATE:
The climate of the district is generally dry and hot. The hot weather season begins by middle of
February reaches peak during April / May and slowly temperature declines. From beginning of June
followed by the southwest monsoon season extending to the end of middle of September and last
up to November end. The cold season starts from December, end by the middle of February. The
season from December to February is a period of generally fine cool weather.
TEMPERATURE & RELATIVE HUMIDITY:
The highest mean daily maximum temperature in the district is in the month of May which ranges
between 38ºc which is the warmest month, Over major part of the district with the onset of monsoon
early in June here is appreciable drop in the day‟s temperature, January is generally the coolest
month with mean daily minimum temperature ranges between 15ºc to 18ºc.
The average relative humidity in July and August month is about 60 to 80% over major part of the
district. The lowest relative humidity is in April / May months which is about 30% and even as low as
10% on individual days.
RAINFALL:
The average rainfall in the district is 562 mm. The actual rainfall for the last year is 228 mm. The
district receives 40% of the total rainfall in the south west monsoon period from June to September.
4.8 Social Infrastructure Available:
The following are the educational and other infrastructural facilities in the district
S. No Particulars Numbers / Values
01 Educational facilities
a) Pre-primary NA
b) Primary
LPS 608
HPS 1035
Others 22
c) Middle NA
d) High 349
e) Higher- secondary NA
02 Professional colleges
a) Medical 1
b) Engineering 1
c) Agriculture / Horticulture 1
E.I.D. - Parry (India) Limited (Bagalkot)
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d) Veterinary / Fisheries -
e) Others (Please specify) -
03 Number of Arts and Science Colleges 88
04 Institutional Credit Facility
a) Name of the Lead Bank Syndicate Bank
b) Number of branches of lead bank in the
district
182
c) Other Commercial Banks 88
d) Primary Land Development Bank 6
e) District Central Co-operative Banks 1
f) Urban Banks 14
g) Primary Agricultural Co-operative Credit
Society
207
h) Housing Co-operative Societies 20
i) Employees Co-operative Societies 58
j) Weavers Co-operative Society 111
k) Industrial Co-operative Society -
l) Khadi and Village Industries Societies -
m) Industrial Co-operative Societies 07
n) Primary Co-operative Stores 2
o) Co-operative Sugar mills 1
q) Other Marketing Society (please specify) 6
E.I.D. - Parry (India) Limited (Bagalkot)
Expansion of Integrated Sugar Complex
Pre-feasibility report
37
5.0 PLANNING BRIEF
5.1 Planning Concept:
The integrated complex will be of Sugar, Co-gen, & Distillery. Project at SSL will integrate sugar mill
operations with enhanced energy efficiency measures and optimum usage of Molasses and
Bagasse. During season, the Co-gen Plant will operate on procured bagasse, other bio-mass fuels
and coal.
All excess available power is exported to the KPTCL grid. During off-season procured Bagasse /
biomass from nearby sugar mills will be used in the Co-gen plant and power generated, less
auxiliary consumption will be pumped to the KPTCL grid. KPTCL has an attractive policy on the
guidelines of MNES, to buy power from sugar cogenerations. Molasses generated from the Sugar
Plant will be utilized for Distillery plant operation.
Further, the integrated Sugar, Co-gen, and Distillery projects will improve the overall profitability of
SSL, through its additional revenue generation. This will enable SSL to give higher dividend to
promoters & higher price per ton of cane to its cane growers. Also the project will help to improve
Karnataka State‟s power situation apart from providing ethanol for use.
5.2 Population Projection:
Unskilled Man Power required for the proposed expansion Project will be met from the local villages
completely. Qualified semi skilled man power require will be met from local villages if available.
Hence there will not be much population increase in the area.
5.3 Land use Planning:
The following is the Land use Planning of the area
ITEM EXTENT OF LAND (ACRES)
Existing Expansion After expansion
Built-up area 57 25 82
Internal roads 5 5 10
Storage areas 15 5 20
Parking area 5 0 5
Greenbelt 60
Vacant area 0.2
Total 177.2
5.4 Amenities / Facilities:
Facilities like canteen, rest rooms and recreation facilities will be provided in the proposed
expansion project. No other additional facilities are proposed.
E.I.D. - Parry (India) Limited (Bagalkot)
Expansion of Integrated Sugar Complex
Pre-feasibility report
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6.0 PROPOSED INFRASTRUCTURE:
6.1 Industrial area
The following Plant and machinery will be installed in the Industrial processing area
List of Plant and Machinery for proposed expansion
Sugar Plant
SUGAR PLANT MASTER EQUIPMENT SCHEDULE
Item
No. Item Description Nos. Type/Capacity
0100 Cane Weighment
0101 Cane weighbridges 2 1 #60 T capacity
1 #10 T capacity
0200 Cane Unloading
0201 Cane unloader 2
Sling Type cane unloaders 7.5T
SWL Capacity,
0201.1 Gantry and structure 1
0202 Feeder table 2 1 # 7 m X 7 m
0300 Cane handling & Preparation
0301 Feed Cane Carrier 1
Head end shall be suitable to 2200
mm swing dia. Fibrazor.
Chain strength should be 60 T
breaking load. Head end
Sprocket is 16 teeth.
0302 Prepared cane carrier 1
0303 Chopper 1
2 #250 HP HP motor will run in
reverse direction at 300 rpm
through gear box having 1.95:1 ratio
0304 Leveler 1
2 #350 HP HP motor will run in
forward direction at 585 rpm
0305 Fibrazor 1
2200 mm swing dia, 144 nos.
hammers of 23kg with new
Pocketed type anvil.
0305.1 Cane pusher 1
1400 mm dia pusher driven by 30
HP/1440 rpm through
speed reducer and open spur gear
0306 Auto cane feed control Lot
0400 Juice Extraction Plant
0401 Donnelly chute 2
0402 Mills 2
2 # Mills 42" x 84" with pressure
feeding system.
First and last mill s to be provided
with GRPF
0402.1 Under feed roller 2 UFR of 1100 mm PCD
0403 Mill drive 2
2# 1250 HP AC /Planetary drives
E.I.D. - Parry (India) Limited (Bagalkot)
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0404 Inter carrier 2
Rake carrier with 50 HP drive carrier
speed shall be
25m/min
JUICE HANDLING
EQUIPMENT
0406 Juice Screen 1 Rotary screen with 0.35 slit opening.
0406.1 Cush - Cush conveyor 1
Double scroll type 410 mm dia x
7000. The screw
conveyor is driven by 10 HP / 1440
rpm
0407
Mass flow meter for imbibition
water 1 150 cu.m/hr capacity, 50 m head
JUICE PUMPS
0408.1 Unscreened juice pump 2 350 cu.m/hr, 12 m head 960 rpm
0408.2 Screened Juice pump 3 400 cu.m/hr, 12 m head 960 rpm
0408.3 Imbibition juice pump 2
350 cu.m/hr, 12 m head, 30 HP/960
rpm - 2 nos.
0408.4 Imbibition water pump 2
200 cu.m/hr, 50 m head, 50
HP/1440 rpm
0409 Mill house crane 1 Install 1# 40 t EOT crane
0409.1 Mill house gantry Lot
0410 Millhouse lathe 1
Install 1# lathe to be procured to
suit 1200 x 5000 mm rollers
grooving
0500 JUICE TREATMENT
0501 Water flow meter 1 0-200 t/h, volumetric flow meter
0502 Water weighing scale 1
0503 Juice flow meter 1
Install 1 # volumetric flow meter with
density compensation
in parallel with the flow meter.
Capacity 200 t/h
0504 Juice weighing scale 1
0505 Driver trough 1
0506 Check weighing scale
0507 Weighed juice receiving tank
0508 Weighed juice pumps
0509 Phosphate addition system
0509-A Preparation tank
Install 1 # phosphoric acid
preparation tank.
Capacity 1 cu.m
0509-B Storage tank
0509-C Dosing pump
Install 1 # dosing pump of capacity
100 lph
0510 Juice flow stabilization system 1
Install common control system
suitable for 400 t/h
for both the flow meters.
0511-A Juice sulphitor 1 250 HL capacity
E.I.D. - Parry (India) Limited (Bagalkot)
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0511-B Prelimer 1
0512
pH control system for juice
sulphitor 1 pH control system
0513 Sulphured juice receiving tank 1 Cylindrical tank, Cap : 12.5 cu.m
0514 Sulphured juice pumps 3
Install 2 # 400 cu.m/h, 60 m head
pumps.
0600 CLARIFIER & FILTERATION
0601 Flash tank 1
Install 1# flash tank suitable for
clarifier
Install 1# volumetric flow meter &
control
valve to control flow to the clarifier
0602 Clarifier 1
Install 1 # clarifier of 36' dia or
Install 1# short retention time
Clarifier suitable for 2750 TCD.
0603 Polyelectrolyte preparation tank 1 Install along SRT clarifier
0604
Polyelectrolyte storage / dosing
tank 1 Install along SRT clarifier
0605 Polyelectrolyte dosing tank 1 Install along SRT clarifier
0606 Rotary vacuum filters 2
2 # Dia 3600 x Long 7200 mm (12' x
24')
0607
Vacuum filtrate Pick-up
receivers 3 2 # Dia 600 x Long 1200 mm MS
1 # Dia 900 x Long 1500 mm MS
0608 Vacuum filtrate wash receivers 3 2 # Dia 600 x Long 1200 mm MS
1 # Dia 900 x Long 1500 mm MS
0609 Filtrate collection tank 1 SS make dia 1100 x 2490 long
0610 Filtrate pumps 2 Cap : 70 cu.m/h, 21.5 m head
0611 Filter condenser 3 2 # Dia 600 x Long 2400 mm MS
1 # Dia 750 x Long 1500 mm MS
0612 Entrainment separator 3 2 # Dia 450 x Long 900 mm MS
1 # Dia 600 x Long 1200 mm MS
0613 Vacuum pump 2
2# 1200 cu.m/hr with 30 hp motor,
motor rpm 1460
pump rpm 1250
1# 300 mm size water jet air
extractor for both filters
0614 Mud overflow circulation tank 1 Dia 2235 x 1500 long
0615 Mud recirculation pump 3 Cap : 70 cum/hr, 21.5 m head
0616 Cake wash water pump 1
Install 1# pump Cap : 10 cum/h,
55.6m
head.
0617 Feed mixer 1
1 # Dia 1000 x 3500 mm long for
both filters, U shaped.
0618 Bagacillo blower and chute 2 Connected with 20 hp motor
0619 Bagacillo piping 2 1 # pipe of 500 mm dia
1 # pipe of 350 mm dia
E.I.D. - Parry (India) Limited (Bagalkot)
Expansion of Integrated Sugar Complex
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0620 Cyclone separator 2 1 # MS make dia 1500 x 3150
1 # MS make dia 1340 x 2700
0621 Mud belt conveyor 1
650 mm width troughed, 36000 mm
long
0622 Cake collection bin 1 MS make 2500 x 2500 x 1100
0623
Vibratory screen or filtrate
1
80 mesh screen vibratory type with
rectangular
screen of 1075 x 1000 x 30
Filtrate Clarification System
0624 Filtrate buffer tank 1
Cap : 20 cu.m, dia 2.5 m x 4.0 m
height, steam coil
is installed inside to maintain
temperature of filtrate
0625 Untreated filtrate pumps 2 Cap : 45 cu.m/h, 15 m head
0626 Flow meter 1 Cap : 0-50 cum/h, Magnetic type
0627 Lime sucrate preparation tank 1 Cap : 4 cu.m, dia 1.5 m x 2.25 m Ht
0628 Lime sucrate dosing tank 1 Cap : 4 cu.m, dia 1.5 m x 2.25 m Ht
0629 Lime sucrate dosing pump 2
Cap : 800 lph, 1.5 bar discharge
pressure
0630 Phosphoric acid storage tank 1 Cap : 1 cum
0631 Phosphoric acid dosage pumps 2
Cap : 100 lph, 1.5 bar discharge
pressure
0632 Flocculent preparation tank 1 Cap : 4 cum, dia 1.5 m x 2.25 m Ht
0633 Flocculent dosing tank 1 Cap : 4 cu.m, dia 1.5 m x 2.25 m Ht
0634 Flocculent dosing pumps 2
Cap : 800 lph, 1.5 bar discharge
pressure
0635 Reaction tank 1
Cap : 2 cum, Dia 1.1 m x 2.25 m Ht.,
Impeller
speed 48 rpm
0636 Aeration pumps 2 Cap : 20 cu.m/h, 15 m head
0637 Filtrate floatation clarifier 1 Cap : 13 cu.m, Dia 3.0 m x 1.8 m Ht.
0638 Automation Set Total system is automated
0700
Milk of Lime and SO2
Prepartion
0701 Quick lime elevators 1
Electric hoist for bag lifting with 0.5
hp motor
0702 Lime slaker 1
Cap : 1200 Kg/h, 5.5 KW, 12 final
rpm
0703 Lime clarifier 1
Koran, 3.7 KW, perforation dia 0.5
mm
0704 Vibratory screen 1
Circular, 60 mesh size, 3.7 KW, 1.5
m dia
0705
0706 Milk of lime storage tanks 2
Dia 3000 x 3150 mm height, 20 cum
each, 5 KW
0707 Milk of lime pumps 2
Install 1 # new pump cap: 10 cu.m/h,
20 M head.
E.I.D. - Parry (India) Limited (Bagalkot)
Expansion of Integrated Sugar Complex
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42
0708
Sulphur burners for juice,
Continuous type 2 200 kg./h. Film Type Burners
0709
Sulphur burner for syrup,
continuous 2 Cap. 70 kg/h one working
0710 Air compressor 4
Install 1# 1000 cum/h air
compressor
0711 Air receiver 1
air receiver for compressor suitable
for two compressors
0800
Juice heating and
Evaporation
0801
Raw Juice Heater (Tubular
type) 2 300 sq. m heating surface
0802 Condensate Receiver for JH 2
Collect juice condensate to common
receiver for both
juice heaters
0803 Condensate pump 2
Use both pumps for common
receiver. One working and
one stand by
0804
Sulphured Juice heater
(Tubular type) 3 300 sq. m heating surfaces.
0805 Condensate Receiver for JH 3
Use only 2# condensate receivers
one each for each
effect bleeding
0806 Condensate Pump 3
20 cum/h capacity, 30 m head
condensate
pumps for SJ1 & SJ2
0807 Clear juice Heater 2 2 # Direct contact Heaters
0808 Condensate Receiver for JH
0809 Condensate pump
0810 Clear juice column 1 Dia 3000 x 5000 height
0810 A Clear juice filters
Install 2 # leaf filter for clear juice
filtering suitable for 4000
TCD with all accessories
0811 Clear juice pump 2
Capacity 250 cum/h and 60 m
head to CJ pumping
0812
Intermediate juice receiving
tank
0813
Evaporator Set Quintuple
0814 Quint I 1
2500 sq. m body as Quintuple 1st
effect.
0815 Quint II 1
2700 sq. m body as Quintuple 2nd
effect.
0816 Quint III 1
1250 sq. m body as Quintuple 3rd
effect
E.I.D. - Parry (India) Limited (Bagalkot)
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0817 Quint IV 1
600 sq. m body as quintuple 4th
effect.
0818 Quint V 1
600 sq. m body as quintuple 4th
effect.
0820
Condensate receiver for Quint -
1st effect 1
Install 1# 1.2 mtr dia and 2.0 mtr
height mound
0821
Condensate pump for Quint-1st
effect 2
Install 1# 130 cu.m/hr, 30 m head
condensing pump as
common standby for quintuple 1 & 2
bodies
0822
Condensate receiver for Quint-
2nd effect 1
Install 1# 1.2 mtr dia and 2.0 mtr
height mound
0823
Condensate pump for Quint -
2nd effet 1
100 cum/h, 30 M head pump for this
duty pump
0824
Condensate receiver for Quint -
3rd effect 1
Quintuple 3rd effect condensate
receiver
0825
Condensate pump for Quint -3rd
effect 1 Cap : 50 cum/h, 30 m head
0826
Condensate receiver for Quint -
4th effect 1
Quintuple 5th effect condensate
receiver
0827
Condensate pump for Quint -4th
effect 1 Cap : 20 cum/h, 30 m head
0828
Condensate receiver for Quint -
5th effect 1
Quintuple 5th effect condensate
receiver
0829
Condensate pump for Quint -5th
effect 1 Cap : 20 cum/h, 30 m head
0830
Common condensate flash tank
for 2nd Condensate 1
2.5 meter dia and 5.0 meter length
receiver
0831
Common condensate flash tank
for pan and JH Condensate 1
2.5 meter dia and 5.0 meter length
receiver
0832 Syrup receiving tank 1 Dia 1000 x 1500 mm height
0833 Syrup Extraction Pump 2 Cap : 70 cu.m/hr, 30 m head
Syrup Clarification System
0834 Buffer tank 1 Cap : 32 cum, Dia 3.89 m x 2.5 m Ht
0835 Untreated syrup pumps 2 Cap : 70 cum/h, 30 m head
0836 Syrup heaters 2
HAS 77.5 sq. m, 144 tubes, 45
OD/18 SWG/4 m length, 9
tubes / pass, 16 passes
0837
Color precipitant preparation
tank 1 Cap : 1 cum
0838 Color precipitant dosing tank 1 Cap : 1 cum
0839 Color precipitant dosing pumps 2
Cap : 100 lph, 1.5 bar discharge
pressure
0840 Phosphoric acid storage tank 1 Cap : 1 cum
0841 Phosphoric acid dosage pumps 2
Cap : 100 lph, 1.5 bar discharge
pressure
E.I.D. - Parry (India) Limited (Bagalkot)
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0842 Flocculent preparation tank 1 Cap : 4 cum, dia 1.5 m x 2.25 m Ht
0843 Flocculent dosing tank 1 Cap : 4 cum, dia 1.5 m x 2.25 m Ht
0844 Flocculent dosing pumps 2
Cap : 800 lph, 1.5 bar discharge
pressure
0845 Reaction tank 1 Cap : 32 cum, Dia 1.465 m x 1.72 m
0846 Aeration tank 1 Dia 0.45 m x 2.0 m Ht.
0847 Syrup floatation clarifier 1 Cap : 32 cum, Dia 4.5 x 1.8 m Ht
0848 Clear syrup tank 1 Cap : 14 cum, Dia 2.1 x 4.0 m Ht
0849 Clear syrup pumps 2 Cap : 50 cum/hr, 35 m head
0850 Automation Set Total system is automated
0850A Leaf filters for syrup filtration
Install 2 # leaf filters to filter syrup
before going to pan floor
0851 Syrup sulphitor 1 Sulphitor of 15 cum working capacity
0852 Caustic Soda Tank 1
Cap : 19.4 cum, Rectangular type,
2900 x 2200 x 3000 mm
0853 Caustic Soda pumps 1 Cap : 100 cum/h, 20 m head
0854
Pressure reducing valve no.1
(PRV-1) P1 to P2 1
kg/sq.cm (g)
0855
Pressure reducing valve no.2
(PRV-2) P2 to P3 1
Cap : NA, 150 mm size from 7
kg/sq.cm to 1.5 kg/sq.cm
kg/sq.cm (g)
0856
Pressure reducing valve no.3
(PRV-3) P2 to P3 1
kg/sq.cm (g)
0857
Pressure reducing valve no.4
(PRV-3) P4 to P2 1
Cap : 5 t/h, from 13 kg/sq.cm to 7
kg/sq.cm
kg/sq.cm (g)
0858
Overflow surplus valve for
exhaust (OSV-1)
One exhaust over flow surplus valve
of capacity 30t/hr
0859 Overflow surplus valve (OSV-2)
2# OSV's on two Quntiple two
bodies, Cap : 1# 20 t/h
and 1# 40 t/h
0860 Overflow surplus valve (OSV-3) 1#OSV as relief valve. Cap : 20 t/h
0863 Desuperheater No.1 Dia 1500 x 3000 mm height
0864 Desuperheater No.2 Install desuperheater for PRV
0900 Graining and Crystallization
0901
Syrup & Molasses storage
tanks 17 Each capacity 20 cum
5 # syrup, 2 # Melt, 1 # AL, 4 # AH,
3 # BH & 2 # CL
0902 Molasses conditioner 3
Continuous type, between runoff
storage tank and pan
supply tank
1 # Cap : 2.58 cum for AH
1 # Cap : 2.0 cum for BH
E.I.D. - Parry (India) Limited (Bagalkot)
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1 # Cap : 1.3 cum for CL
0903 A Vacuum Pan - Batch 4
80 t with mechanical circulator. With
Pan automation.
0904 Graining vacuum pans - Batch 1
60 Ton with Mechanical circulator
with automation
0905 B' Vacuum Pan - Continuous 1
Install 1 # 30 t/h continuous pan for
B massecuite
0906 C' Vacuum Pan - Continuous 1
Install 25 T /hr continuous pan for C
Boiling
0907 Pan Condensate Receiver 2
Dia 2600 x 3800 mm for 2nd vapor,
Dia 2000 x 2700 for 1st
Vapor
0908 Pan condensate pump 3 2 # Cap : 50 cum/h, 30 m head
1 # Cap : 70 cum/h, 30 m head
0909 Dry seed crystallizer 1 U Shaped Net Cap : 40 t
0910 B Seed crystallizer 1 U Shaped Net Cap : 40 t
0911 Grain Seed Crystallizer 2 U Shaped Net Cap : 90 t
0912 A Vacuum crystallizer 1 U Shaped Net cap: 40 t
0913 B Vacuum crystallizer 1 U Shaped Net cap: 40 t
0914 C Vacuum crystallizer 1 U Shaped Net cap: 40 t
0915 Crystallizer for `A' massecuite 5 U Shaped, Net Cap : 90 t
0916
Strike receiver for `B'
Massecuite 1 U Shaped, Net Cap : 90 t
0917 B' Massecuite transfer pump 1 9 „‟ x 9 “ PSP pump, 30 m Head
0918 Strike receiver for B Massecuite 1 U Shaped, Net Cap. 90 t
0919
Vertical crystallizer for B'
Massecuite 1
Install 1 # 300 t mono vertical
crystallizer for B massecuite
0920 Liquidation pump for Vert. Cry. 1
Rota type, 8" x 8", Cap : 35 t/h, 30 m
head
0921
Strike Receiver for `C'
Massecuite 1 U Shaped, Net Cap.90 t
0922 C' Massecuite transfer pump 1
0923
Strike Receiver for `C'
Massecuite 1 U shaped, Net Cap. 90T
0924
Vertical crystallizer for C'
Massecuite 1 set
Install 1 # 300 t mono vertical
crystallizer for C massecuite
0925 Liquidation pump for vert.Cry 1
Roto type, 8" x 8", Cap : 35 t/h, 30 m
head
0926 Cooler for hot water 1 Install 1# parallel heater
0927 Cold water surge tank
0928 Cold water circulation pumps 2 Cap : 36 cum/hr, 55 m head
0929 Hot water surge tank by gravity
0930 Hot water circulation pumps by gravity
0931
Hot & Cold water overhead
tank 3
1 # 7500 x 3750 x 2500 for hot
water
2 # 7500 x 4500 x 2500 for cold
water
E.I.D. - Parry (India) Limited (Bagalkot)
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0932 Service water tank 1
Concrete 40000 x 20000 x 2500, net
capacity 2000 cum
0933 Service water pump 3 1 # Cap : 450 cum/h, 22 m lead
2 # Cap : 300 cum/h, 40 m head
1000 Centrifugals
1001
A Massecuite centrifugal pug
mill 2
U shaped 5600 long x 1000 wide.
Each catering to 3
Machines
1002 A Massecutie Centrifugals 4
Install 4 # 1750 kg/charge fully
automatic DC drive
Centrifugal machines.
1003 AH molasses receiving tank 1 Dia 1900 x 1250 height
1004 AH molasses pump 2
Screw type pump of 30 t/h capacity,
25 m WC
1005 AL Molasses receiving tank 1 Dia 1900 x 1250 height
1006 AL Molasses pump 1 Screw type, Cap : 30 t/h, 25mWC
1007
Superheated wash water
system Set Suitable for 7 batch machines
1008 Superheated wash water pump 2 Cap : 20 cum/h, 55m head
1009 Air Compressor 2 Discharge pressure 6 kg/sq.cm(g)
1010 B Centrifugal pug mill 2
1 # U Shaped, 4600 long x 1000
wide, for batch machine
1 # U shaped, 6100 long x 1000
wide, for continuous m/c
1011 B Centrifugals 3
1 # Batch machines of 1250
kg/charge
2 # WK 1500, Cap : 15-18 t/h
continuous machines
1012 B-Magma mixer 2
1 # U shaped, 6000 long x 1000
wide for batch machine
1 # U shaped, 4900 long x 1000
wide for continuous m/c
1013 B Magma pump 2
1# Rota type, Cap : 20 t/h, 30 m
head
1 # Rota type, Cap : 20 t/h, 30 m
head
1014 B Molasses receiving tank 2
Dia 1500 x 1200 height, 1 # BL & 1 #
BH
1015 B Molasses pump 2
Screw type pump of 20 cum /h
capacity, 25 mWC
1016 CAW centrifugal pug mill 1 U shaped, 4600 long x 1000 wide
1017 C after Centrifugals 2
WK 1500, Cap : 10-12 t/h. 1 # B
curing machine is common
standby for CAW
1018 C After Magma mixer 1
U Shaped, 4900 long x 1000 wide
for B & CAW continuous
Machine
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1019 C-After magma pump 1 Common for B & CAW
1020 CL Molasses receiving tank 1 Dia 1500 x 1200 height
1021 CL Molasses pump 2
Screw type pump of 20 cum /h
capacity, 25 mWC
1022 CF centrifugal pug mill 1 6800+1000 long x 800 dia
1023 C Fore worker Centrifugals 3
wk - 1500 or equivalent machine for
C Fore curing
1024 C-Fore magma mixer 1 U Shaped
1 # 6000 long x 1000 wide, with
planetary
1025 C-Fore magma pump 3 Rota type, Cap : 20 t/h, 30 m head
1026
FM receiving tank (below
machines) 1 Dia 1500 x 1200 height
1027 FM Pump below machines 2
Screw type pump of 10 cum /h
capacity, 25 mWC
1028 Final Molasses weighing scale 1
1029 Weighed FM Receiving tank 1 Rectangular type
1030 FM Pump below weighing scale 2
Screw type pump of 20 cum /h
capacity, 25 mWC
1031 Final molasses storage tank 2
Cap : 7500 T each, 28 m dia x 9.50
m Ht
1032 Final molasses transfer pump 2
Screw type pump of 20 cum /h
capacity, 25 mWC
1033 Sugar Melter 2 Cap :: 35 t/h vertical
1034 Melt pump 3
2 # Centrifugal, Cap 40 cum/hr, 30
m head
1 # screw type, Cap : 30 t/h, 25mWC
1100 Sugar Handling & Bagging
1101 Gross Hopper Conveyor 1
Single tray type, 2.0 m width, 12 m
long
1102 Fluidized bed dryer 1
1 # 40 t/h fluidized bed dryer along
with all accessories
1103
Sugar elevator from FBD to
grader 2 Cap : 40 t/h
1104
Sugar grader
2
1 # Cap : 35 t/h
1 # Cap : 35 t/h
1105
Sugar elevator from grader to
bin 2 Cap : 25 t/h
1106 Sugar Bins 3 125 t sugar bin
1107 Slat Conveyor 2 Width 400 mm, 1.5 KW
1108 Bag stitching machine 3 Cap : 300 bags/h
1109 Dry seed magma mixer 1 U Shape, Cap : 5 t
1110 Dry seed transfer pump 1
Rota type, 8" x 8", Cap : 300 t/h, 30
m head
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Dust collector system Set
1111 Dust collector tank 2 1 # Dia 3.0m x 3.7m Ht
1 # Rectangular wet scrubber, 2.5 x
1.5 x 2.0m
1112 Dust melt pump 2 Cap : 35 cum/h, 25 m head
1113 Sugar bag belt conveyor 6 Width 600 mm
1114
Sugar bags mobile belt
conveyor 10 Width 600 mm
1115 Sugar Godowns 4
2 # 100m x 40m x 10m, Cap :
400000 bags
1200 Condensing Plant
1201 Evaporator condenser 1
1 #Single entry Vapor inlet dia :
1100 mm with automation
1202 Batch Pan condensers 5
4 #Single entry Vapor inlet dia :
1300 mm with automation
1 #Single entry Vapor inlet dia :
1100 mm with automation
1023 Continuous Pan condensers 2
1 #Single entry Vapor inlet dia :
1100 mm with automation
1024
Ejector for pans & vacuum
crystallizer 1
Same system is to be followed for
new condensers also
1025 Automation Set
1026 Injection pump 4 1600 cum/h, 22 m head pumps
1027 Priming pump 1 Cap : 25 cum/h, 3.75 KW
1028 Cooling tower 3 Cap : 1600 cum/h, each cell
1029 Cooling tower water pump
1210 Priming pump 1 Cap : 25 cum/h, 3.75 KW
1400 Electricals
1401 Distribution transformers 3 2.5 MVA distribution transformer
1402 Bus ducts 4 4000 Amps,
1403 Power control centre (PCC) 3 4000 Amps,
1404 Motor Control Center (MCC) 12
1405 Distribution boards Lot
1406 Push button stations Lot
1407 Lighting Lot
1408 Earthing LOt
1409 APFC panel 2
1410 LT power and control cables Lot
1411
Miscellaneous work (cable tray,
danger baords, Lot
rail for transformer, gravel
spreading etc.)
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Co-generation Plant:
Machinery Details:
Equipment name Qty. Capacity
Boiler Capacity 1 110 T
Turbine Capacity 1 19 MW
Electro Static Precipitator 3 Fields
FD Fans 2
ID Fans 2
Air heaters 1
Feed water system 2 HP heater-1 with 16 ata extraction steam
HP heater-2 with 8 ata extraction steam
Feed water pumps 3 80tph capacity,110kg discharge pressure
HP LP dosing system 2 HP dosing pumps for steam drum dosing
2 LP dosing pumps for derator dosing
Dearator 1
Bagasse Handling system 1 90 TPH
Coal Handling System 1 45 TPH
Biomass preparatory system 1
Feed regulation station 1 Control valve station with manual by pass
station
Atemperation system 1 Spray between primary super heater and
secondary super heater
D M plants 2 each 400 OBR at 30TPH
Water clarifier 1 200 TPH
Cooling tower system
No. of cells 4 1600 Cum.Mtr/Hr
Cooling tower pumps 4 1600 Cum.Mtr/Hr, Discharge pressure -
3.25 KSC
Two pass surface condenser with
cooling water flow 4200 Cum.mtr/Hr
Condensate extraction system
Pumps 3 50TPH each at 6kg pressure
Gland steam condenser 1 100 TPH
Steam ejectors 2 Main
1 Hogging
Turbine lub oil system/control oil
system
1
package
ST switch gear- 11kv
Generator transformer - 36MVA-
11/110kv
Distribution transformers 3 2.50mva each, 11kv/415volt
1 3.15mva, 11kv/415v
Diesel generator set 1 1500 kva
PRDS system 1 75 tph,87/8 ata
1 80tph,8/2.5ata
E.I.D. - Parry (India) Limited (Bagalkot)
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Pumping station at Kali river & Piping
Pumps 3 100 tph each, Pressure-4kg
Priming pump 2 20 tph
Infiltration pump 3 100 tph
Electrical substation at Kali pump
hose with 11kv/415 v transformer,
MCC and 250 kva diesel set
Switch Yard
110kva breaker 2
11kv breaker 1
100kv Isolators 3
CTs and PTs as per the requirement
Double circuit 110kv line to Haliyal
substation
Bio mass storage yard area 20 acres with all Fire fighting system
Fire fighting system for complete
complex
Fire water pump motor driven 1 100 TPH at 10 KSC
Fire water pump diesel set driven 1 100 TPH at 10 KSC
Jacky pump 2 30 TPH at 10KSC
Distillery Plant:
SECTION I : FERMENTATION HOUSE :
MOLASSES WEIGHING SECTION :
1] Weighscale / Loadcell for Check : 1 No.
weighment. Capacity : 3 MT
2] Molasses feed tank : 1 No.
Material of construction : M.S
Capacity : 50 MT
- FERMENTATION EQUIPMENTS
1. PROCESS TANKS
A] Fermenter : 2 Nos
Material of construction : MS
Capacity : 500m3
Equipped with roof manholes, air sparger in stainless steel construction, sight and light
glass assemblies, level indicator, defoaming oil sensor, pressure relief device and required
nozzles and fittings.
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All internal surface will be sand blasted and epoxy coated ( 1 primer coat followed by 2
finish coats - min. DFT (150 micron ).
B] Propagation Vessel I
Design code : ASME VIII, Div. 1
Material of construction : SS 304
Capacity : 180 L
Equipped with sight glass, air sparger, cooling jacket, relief valve and necessary nozzles and
fittings.
C] Propagation Vessel II
Design code : ASME VIII, Div. 1
Material of construction : SS 304
Capacity : 2000 L
Equipped with sight glass, manhole, air sparger, relief valve and necessary nozzle and
fittings.
D] Propagation Vessel III
Geometric Capacity : 100,000 L
Design code : IS 803
Material of construction : MS (epoxy lined)
Equipped with shell and roof manholes, air sparger, sight and light glass assembly and
necessary nozzles and fittings.
All internal surfaces will be sand blasted and epoxy coated (1 primer coat followed by 2
finish coats - min. DFT 150 micron).
E] Defoaming Oil Day Tank.
Capacity : 1000 L
Material of construction : MS
2. PROCESS PUMPS :
A] Molasses feed pump : 1 + 1 standby.
Type : Positive displacement
Material of construction : CI with SS wetted parts.
Shaft sealing. : Gland packing.
Drive : Variable speed
-Molasses storage to feed : 1+1
-Weighing to diluter : 1+1
B] Fermenter Cooling Pump : 2 + 1 standby
Type : Centrifugal
Material of construction : SS 316
C] Fermenter Discharge Pump : 1 + 1 standby
Type : Centrifugal
E.I.D. - Parry (India) Limited (Bagalkot)
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Material of construction : SS 316
D] Wash Transfer Pump : 1 + 1 No.
Type : Centrifugal
Material of construction : SS 316
E] Sludge Pump : 1 + 1 No.
Type : Centrifugal
Material of construction : SS 316
F] Recycle Pump : 1 + 1 standby
Type : Centrifugal
Material of construction : SS 316
G] Propagation II Cooling Pump : 1 Nos.
Type : Centrifugal
Material of construction : SS 316
H] Defoaming oil dosing Pump : 1
Type : Positive displacement.
Material of construction : GI
3. PLATE HEAT EXCHANGERS. [ Alfa Laval make ]
M.O.C of Qty
Plates Nos.
a] Prop II Temp. Control PHE SS 316 1
b] Fermenter Cooling PHE SS 316 2
(Min.AK 20 FMI 168 plates each with back flushing arrangement)
4. MISCELLANEOUS :
A] Positive Displacement Blowers : 1 + 1 standby
Type : Twin lobe
Material of construction : CI body, cast steel.
Braided with suction/discharge silencers, relief valve, non-return valve & suction filter.( water
cooled) OR
Alternatively Vacuum Pump may be considered for same duty.
Capacity : 1700nm3/hr+900nm3/hr
Head : 9 MWC
B] Carbon-di-oxide Scrubber : 2 Nos.
Type : Sieve plate column
Material of construction : SS 304
Plate material : SS 304
E.I.D. - Parry (India) Limited (Bagalkot)
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Diameter : 600mm
With water spraying arrangement in AISI 304, sight glass and packing support grid.
C] Strainers - : 3 Nos.
For : 1) Fermented wash
2) Recycle.
3) Diluted Molasses
Type : Basket
Material of construction : AISI 304
Hole size : 0.6 mm
D] Sterile Air filters : 2 Nos.
Capacity : 20 M3/Hr. & 120 M3/Hr
E] Water molasses static mixer in AISI 304 : 1 No.
F] Air Compressor for Instrumentation Air : 1No+1No (Common for entire
plant including Mol. Sieve plant)
5. YEAST RECYCLING SYSTEM :
A] Yeast Separator [Alfa Laval make] 2 + 1 Nos.
Indigenous model DX 409
B] Chain Pulley block with travelling trolley : 1 No.
Capacity 1 MT
C] Cleaning table for separator in MS : 1 No.
D] Yeast Cream Funnel : 3 Nos.
Material of construction : SS304
E] Hydrocyclones : 1 Set.
Material of construction :
- Body : AISI 304
- Cone : Ceramic
6. CIP SYSTEM :
I CIP tank/Hot water tank : 1 No each.
Capacity : 2000 L
Material of Construction : AISI 304
II CIP Pump : 1 No.
Type : Centrifugal
Material of construction : SS 316
7. Cooling Tower : 2 Nos. 400 Cu.m./ hr.
E.I.D. - Parry (India) Limited (Bagalkot)
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SECTION II : Distillation
1 Analysing Column (Vacuum) Material of Construction : SS304
Type of Trays : Sieve
No. of trays : 50
Tray spacing : 750mm
Diameter : 1698mm / 2195mm
(min. diameters mentioned)
2 Rectifying Column (Under pressure) Material of Construction : SS304
Type of Trays : Sieve
No. of trays : 144
Tray spacing : 300
Diameter : 1790mm
(min. diameters mentioned)
3 Aldehyde Column Material of Construction : SS304
Type of Trays : Sieve
No. of Trays : 60
Tray spacing : 250mm
Diameter : 710mm
(min. diameters mentioned)
7 Beer Pre-heater : Shell & Tube type
Material of Construction : SS 304
Tube length : 3000mm
Tube thickness : 1.25mm
8 Analysing coloumn Reboiler : Shell & Tube type
Material of Construction : Shell: 304Tubes: SS316
Tube length : 3000mm
Tube thickness : 1.25mm
Qty : 1+1
9 Stripper Rectifier Column Reboiler
Type: Shell & Tube
MOC: Tubes : SS304 Shell : CS, Ends : CS
Qty : 1 Nos.
E.I.D. - Parry (India) Limited (Bagalkot)
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10 Final Condensor : Shell & Tube type
Material of Construction : Tube and tube sheet are in
SS 304, water side in CS
Tube length : 3000mm
Tube thickness : 1.25mm
11 Aldehyde Condensor : Shell & Tube type
Material of Construction : SS 304
Tube length : 3000mm
Tube thickness : 1.25mm
12 Aldehyde Vent Condensor : Shell & Tube type
Material of Construction : SS 304
Tube length : 3000mm
Tube thickness : 1.25mm
13 Final Product Cooler : PHE
Material of Construction : SS 304 plates
Area : Suitable
14 Fusel Oil / Heads Spirit Cooler : Vertical type
Material of Construction : SS 304
15 Fusel Oil washer decanter : Vertical type
Material of Construction : SS 304
16 Steam Chest : 1 No.
Material of Construction : MS
17 Hot water tank
Capacity : 1 M3
Material of Construction : MS
18 Reflux Tanks : 2 Nos.
19 Plate Heat Exchangers:
Sr. Description M.O.C. (Plates) Qty.
I Wash Pre-heating PHE SS316 2
II Recycle Wash Cooler (Recycle) PHE SS316 1
III Spent Wash Cooler PHE SS316 1
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20 Pumps : With flame proof motors, mechanical seals & back pull out rotor design.
Sr. Description M.O.C. Qty.
IV Rectifier Reflux Pump SS316 1+1
V Weak Alcohol feed pump SS316 1+1
21. Cooling Tower : 2 Nos. 375 Cu.m. / hr.
SECTION III: Molecular Sieve Dehydration:
1 Mol Sieve Superheater
Type: Shell & Tube
MOC: Tubes: SS304 Shell: CS Bonnets: CS
Qty : 1 Nos
2 Mol Sieve Unit
Type: Dished ends; with packed bed of Molecular Sieves
MOC: SS
Qty: 2 Nos
3 Mol Sieve Condenser
Type : Shell & Tube
MOC: Tubes: SS304 Shell: CS Bonnets: CS
Qty : 1 Nos.
4 Mol Sieve Product Cooler
Type: PHE
Qty : 1 Nos.
5 Mol Sieve Regenerant Condenser
Type: Shell & Tube
MOC: Tubes : SS304 Shell : CS Ends : CS
Qty : 1 Nos.
6 Mol Sieve Regenerant Drum
Type: Dished top & bottom
MOC : SS
Qty: 1 Nos
7 Mol Sieve Vacuum Pump Drum
Type: Dished top & bottom
MOC : SS
Qty: 1 Nos. 1
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8 Mol Sieve Recirculation Cooler
Type: PHE
Qty : 1 Nos.
9 Mol Sieve Regenerant Pump
Type: Centrifugal
MOC: Impeller:SS Casing: CI
Qty: 1 + 1 No.
10 Mol Sieve Vacuum Pump
Type: Liquid Ring
Qty : 1 No+1No
11 Rectified Spirit Day Tanks: 2 Nos. MS , Capacity : 100 KL Each.
Additional Columns for ENA Production.
Extractive Distillation Column
Recovery Column
Polishing Column
6.2 Residential Area (Non Processing area):
Facilities like canteen, rest room and indoor games facilities will be provided in the proposed
expansion project.
6.3 Green Belt:
Total 1/3rd of the total area including existing will be developed in the Plant premises.
Greenbelt development plan
Local DFO will be consulted in developing the green belt.
Greenbelt of 60 acres will be developed in the plant premises as per CPCB guidelines.
15 m wide greenbelt will be developed all around the plant.
The tree species to be selected for the plantation are pollutant tolerant, fast growing, wind
firm, deep rooted. A three tier plantation is proposed comprising of an outer most belt of
taller trees which will act as barrier, middle core acting as air cleaner and the innermost core
which may be termed as absorptive layer consisting of trees which are known to be
particularly tolerant to pollutants.
E.I.D. - Parry (India) Limited (Bagalkot)
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6.4 Social Infrastructure:
Social infrastructure will be developed as per need based in the nearby Villages.
6.5 Connectivity:
Component Description
Road The site can be well approached by a NH # 13
Rail Nearest Railway station located at 27 Km South west
Air port Nearest Airport located at Belgaum which is at distance of 145 Kms
from the Plant site
Sea Port Goa port is at a distance of 230 Kms from the Plant site
6.6 Drinking water management:
Drinking water required for the workers will be met from ground water resources.
6.7 Sewerage system:
Domestic waste water generated will be treated in septic tank followed by soak pit.
6.8 Industrial waste management: 6.8.1 Waste water management
Waste water generated from the proposed Project will be treated in Effluent Treatment proposed
which is furnished under paragraph 3.10.2
6.8.2 Solid waste management:
Details of Solid waste generation and disposal is furnished under 3.11
6.9 Power requirement & Supply / Source:
The portion of power requirements will be met through KPTCL. Balance Power requirement will be
met through in house generation through turbine.
E.I.D. - Parry (India) Limited (Bagalkot)
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7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN
No rehabilitation or resettlement plan is proposed as there are no habitations in the in the Plant site.
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8.0 PROJECT SCHEDULE & COST ESTIMATES
The total cost of the project has been estimated at Rs. 351 Crores. The Project Cost estimates
include all expenses to be incurred towards the entire project development including Site
Development Expenses, Payments to EPC Contractor, Non EPC Expenses, Pre-Operating
Expenses, Start-Up Fuel & Commissioning Expenses, Contingency, Margin Money for Working
Capital and Financing Expenses including Interest During Construction (IDC).
Detailed breakup of the Cost is given below.
S.No. Particulars Cost in Crores
1. Land Development & Civil Works : 41.00
2. Plant & Machinery : 181.00
3. Packing, Forwarding and Taxes : 26.00
4. Erection, commissioning and structures 20.00
5.
Power connection, PCC, Cables, yard
lighting etc., : 30.00
6. Contingencies : 10.00
7. Preliminary & Pre-Operative Expenses : 3.00
8. Margin Money for Working Capital : 40.00
Total : 351.00
MEANS OF FINANCE
1 PROMOTERS (33%) : 115.83
2 TERM LOANS (67%) 235.17
Total : 351.00
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9.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)
With the implementation of the proposed expansion project, the socio-economic status of the local
people will improve substantially. The land rates in the area will improve in the nearby areas due to
the proposed activity. This will help in upliftment of the social status of the people in the area.
Educational institutions will also come-up and will lead to improvement of educational status of the
people in the area. Primary health centre will also come-up and the medical facilities will certainly
improve due to the proposed project.
EMPLOYMENT POTENTIAL
The man power required for the industry is 500 Nos. which is inclusive of 275 nos. on permanent
basis and rest all will on Temporary or contract basis.
S.No. Particulars No. Employees
1. Technical & Administrative Staff 150
2. Skilled & Semi Skilled 275
3. Unskilled & Helpers 75
Total 500
OTHER TANGIBLE BENEFITS
The following are the other benefits to the area due to the proposed project.
Educational status will improve in the area
Medical standards will improve due to the proposed project.
Overall economic up-liftment of socio-economic status of people in the area.
Ancillary developmental activities like CO2 plant, Cattle feed plants will be created due to the
establishment of the proposed unit.
SOCIO-ECONOMIC DEVELOPMENTAL ACTIVITIES
The management is committed to uplift the standards of living of the villagers by undertaking
following activities / responsibilities.
Health & hygiene
Drinking water
Education for poor
Village roads
Lighting
Creating harmonious relationships
E.I.D. - Parry (India) Limited (Bagalkot)
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Helping locals to conduct sports
Training to the unskilled manpower
HEALTH & HYGINE
1. Personal and domestic hygiene,
2. Maintaining clean neighborhood,
3. Weekly health camps offering free-check up & medicines
4. Ambulance services
5. Education & drug de-addiction, aids.
DRINKING WATER
Making drinking water available at centralized locations in the village,
SUPPORTING EDUCATION
1. Providing books to all poor children,
2. Conducting annual sports festival in the village schools,
3. Providing amenities like fans, lavatories,
4. Maintain play ground etc.
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