Swaraj India Agro Plans For Sugar, Distillery & Co-Gen Power Plant
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RELEASED : ISSUE JUNE 01 /14
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Swaraj India Agro Plans For
Sugar, Distillery & Co-Gen Power Plant
Swaraj India Agro Limited plans for a New Sugar Plant having Capacity of 4400 TCD, a Molasses Based Distillery having Capacity of 60 KLPD along with a Bagasse Based Co-generation Power Plant of 22.5 MW at Upalve Village, Taluka: Phaltan in Satara District, Maharashtra.
Capacity:
Sugar Plant : 4400 TCD
Distillery : 60 KLPD
Co-Gen Power Plant : 22.5 MW
Co-Gen Power 19.5 MW + Back Pressure Steam 3 MW = 22.5 MW)
Location :
Upalve Village, Taluka: Phaltan
Satara District, Maharashtra
As on June 04, 2014: The Project is in planning stage.
Total site area is 63 Acres.
An area of about 33% of the total project area will be developed with green belt.
IMPORTANT: As per the discussion we had on 21.05.2014 with
Swaraj India Agro Limited the Project is in planning stage.
The Project is Scheduled to be Completed in Two years from the date of commencement of project work.
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The Main Scope of Supply includes:
Boiler : 30 TPH - 1 No.
Fuel : Bagasse : During Cane crushing season : 1,62,355 Ton (160 Days) During Off-Season season : 42,926 Ton (55 Days)
Note : Concentrated spent wash (120 KL/Day) will be used in 30 TPH Slop Fired Boiler for steam generation and
it will be used for processing in distillery & power generation of 3 MW.
Heat Exchangers, Air Pre-heater/Economiser)
Wet Scrubber for arresting fly ash
Air Pollution Control Equipment :
The sources of emissions from the proposed sugar & cogen plant
shall be boiler of 30 TPH (1 No.) based .
Adequate air pollution control equipment in
the form of Electro static
Precipitator shall be provided for the proposed boilers of 30 TPH capacity (01 Nos.).
In this regard State-of-the-art ESP’s will be installed to boiler to bring down the SPM to < 50 mg/Nm3.
Unloading areas will be provided with water sprinklers to prevent the fugitive dust. All conveyors will be completely covered with GI sheets. Ash will be stored in silo and sold directly to brick & Cement manufacturer
Steam Turbine : 20 MW
Coal handling system
Ash handling system
Ash handling system collecting ash from furnace, Combustion chamber ,Economiser, air heater and wet scrubber shall be transported by
Belt Conveyors to a Silo to be provided.
Turbo Alternator :
Air Cooled Condenser
Power plant stack
Single Chimney
Fuel system
Manufacturing Process : Sugar Plant
The process of manufacturing process:
1. Extraction of juice (Crushing)
2. Clarification of juice
3. Concentration of juice (juice to syrup) by evaporation
4. Boiling of Syrup to grain (crystallization)
5. Separation of crystals from mother liquor (Centrifuging)
Cane receiving
Sugarcane Weighment
Sugarcane Unloading: The cart cane will be manually unloaded directly to the cane carrier.
The cane from the trucks and tractor- trailers will be unloaded with the help of cane un-loader crane. The cane will be unloaded on to the feeder table.
Sugarcane Conveying:
The cane from the feeder table will be then dumped to the main cane carrier, which conveys the cane to the cane preparatory devices.
Electronic devices, depending on the cane-crushing
rate control the speed of the cane carrier, and level in the cane carrier etc.
Sugarcane preparation:
The sugar cane will be passed through the cane preparatory devices called leveller, cutter and fibriser where in the cane is cut into small pieces to expose the juice cells for extraction. The preparatory index is about 85-90 %.
Milling:
The prepared cane will then be passing through the milling tandem having
4 mills of three rollers and necessary feeding device.
The mills will be running at about 4.5 to 6.0 RPM driven through hydraulic motors or DC variable speed drives.
The mills loaded hydraulically extract juice from the cane and is subjected for the extraction of juice aided by maceration water and compound imbibition.
The cane will be conveyed between mills with the help of rake type mechanical Conveyors.
Screens then will filter the extracted juice and filtered juice is pumped for further processing.
The fibrous residue after juice extraction known as bagasse will be withdrawn from the last mill and conveyed through drag type steel conveyors to boiler for steam generation. Surplus bagasse will be withdrawn from the conveyor and stored for reuse when necessary.
The bagasse conveyor also has return conveyor to feed the stored bagasse.
DISTILLERY–Alcohol Manufacturing Process
1. Dilution - Preparation of molasses for fermentation
2. Fermentation - Production of alcohol from fermentable
sugars in molasses solution
3. Distillation - Product Recover
All the Conveyors will be covered with GI sheets to prevent the fugitive dust emission into the atmosphere.
Cooling Tower
Storage Tanks
within the distillery premises.
DG set :
One Additial Dg Set will be installed for stand by arrangement..
Silencer (Acoustic enclosures) to be provided to D.G.)
Clarifier :
Vacuum Filter
Injection pumps
Sugar Receiving Gross Hopper
Sugar Belt Conveyor
Fluidised Bed Sugar Dryer.
Bottling Plant
Dryer
Multiple Effect Evaporators
Centrifugal Machines
CO2 Recovery Plant (In future)
Water storage tanks
Piping works
Weigh bridge
Air compressor
Water Treatment Plant, Effluent Treatment Plant,
Oxidisation Chamber,Filter, R.O. / D.M. Plant.
Pumps Valves, Custom Pipeline Work
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Water consumption
1. Sugar Plant
100 m3/day ( Season : 160 days)
2. Co-Gen Power Plant
1310 m3/day ( Season : 160 days)
1595 m3/day ( Off-Season: 55days)
3. Distillery
720 m3/day ( Total : 270 days)
Total water will be Sourced from Banganga Dam (Kuravali Village) in Satara District, Maharashtra.
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Effluent Treatment System and Scheme
Capacity : 400 m3/Day
Industrial wastewater system from Cogeneration unit
shall be separated into two systems.
1.Plant Drain System
2. Neutralization and Chemical Drain system
Effluent from power plant such as boiler blow down, DM Plant, CT blow down will be treated in Effluent treatment Plant (ETP) having capacity 400 m3/day.
The plant drain system is collecting / shall collect and treat the wastewater from the floors, area wash downs, drainage from the turbine and boiler areas as well as equipment drains. Drains, which potentially could contain oil and grease, are / shall be routed to an oil/water separating system. The system shall divert oil or grease removed to a separate collection drum. The waste oil and grease collected shall be disposed of as via and approved waste oil scavenger service for recycling or disposal.
The neutralization and chemical drain system is collecting / shall collect & neutralize
regeneration waste from the boiler feed water blow down, if found necessary. It shall also collect and treat as it is and caustic waste from the de-mineralized water production plant and bulk chemical storage area drains, chemical feed area drains, along with wash down water collected from these areas.
The neutralization tank is / shall be sized from one and one half times the nominal volume of the demineralised regeneration waste of one demineralised train. The neutralization basin is / shall be internally coated with the computable with the acid and caustic waste.
A neutralization and chemical drain system is / shall be operated on automatic batch wise basis. After the neutralization tank reaches specified level, wastewater shall be neutralized by an automatic pH control system.
The wastewater generated from the Distillery plant will be segregated as process effluent and non process effluent to adopt separate treatment schemes.
Spent wash will be generated as process wastewater from the distillation column. The other wastewater from the plant include, cooling tower blow down, water treatment plant regeneration, floor washings and domestic wastewater.
Treated waste water will be used for gardening, dust suppression system, irrigation, manure making
process etc. to achieve zero effluent discharge. Bagasse based ash will be sold to brick & cement manufacturer.
Generated spent wash after following multistage evaporation process, incinerated in furnace (slope fire boiler) to achieve zero discharge.
Other Equipment
Material Handling Equipment : Conveyor, Hydraulic Equipment
DG Set, Air Compressor. DC/VFD Drive, Gear Box, Insulation, Valves, Pipes & Tubes, Cables, Automatic Weighing Machines for Bulk & Liquid Materials.
Straight Line Steam Tunnel
Pneumatic Piston Filler
Pressure Filler
Storage Tank, Hoses,Cables
Ventilation & Exhaust System
Complete Laboratory Equipments
Fire fighting System as per TAC norms,
Fire Fighting System shall be as per the TAC Norms and cover all areas where alcohol is produced, handled and stored.
Provision of Foam System for Fire Fighting to control fire from the alcohol storage tank.
Green Belt Development plan in 33% area and a scheme for Rainwater Harvesting have to be put in place.
Scope Of Entire Civil & Construction Work:
Construction of Office Building, Factory Shed- Boiler House, Substation-Control Panel- Electrical Work, Plumbing Work, Structural Steel fabrication and Erection Work, Fabrication Storage Tank, Vessels etc. etc.
Companies/ General Industries/ Contractors/ Sub Contractors/ Manufacturers of Boiler, Material Handling Equipment , Water Treatment Plant, Effluent Treatment Plant, Air Pollution Control Equipments, Cooling Tower, Blowers, Cranes, Hydraulic Equipments, Water line Valve, Pump, Pipeline etc. related to Distillery plant. may Contact for Specified Enquiry at :
Swaraj India Agro Limited
A/p. Nimbhore, Tal- Phaltan
Satara- 415523 Maharashtra, India
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Tel : + 91-2166- 262064/262164
Fax :+ 91-2166- 262164
Email : in...@swarajindia.co.in/purc...@swarajindia.co.in
Website : www.swarajindia.co.in
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