Sadashiva Sugars Plans For Expansion Of Sugar,Co-Gen Power & New Distillery..
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Sadashiva Sugars Plans For Expansion
Of Sugar,Co-Gen Power & New Distillery
Sadashiva Sugars Limited, a Subsidiary of EID Parry India Limited, plans for expansion of its Sugar Plant from 3500 TCD to 7500 TCD, Cogeneration Power Plant from 15 MW to 34 MW and to set up a New Molasses Based Distillery of 60 KLD along with a New 3 MW Power Plant from Spent wash Incineration Boilers at Nagaral & Nainigali Village in Bagalkot District, Karnataka..
Capacity:
Expansion:
Sugar Plant : 3500 TCD to 7500 TCD
Co-Gen Power Plant : from 15 MW to 34 MW
New Plant:
Distillery : 60 KLD
Generation of 3 MW Power from Spent
Wash Incineration Boilers.
Location :
Nagaral & Nainigali Village
Bagalkot District, Karnataka
As on January 10, 2013: The Project is in planning stage.
Proposed expansio of the sugar Cane crushing capacity from 3500 TCD to 75000 TCD, expansion of Co-generation of power from 15 MW to
34 MW & New Molasses based Distillery of 60 KLD shall be located in an area of 177.2 Acres within the vacant area of the existing premises.
premises.IMPORTANT: As per the discussion we had on 03.01.2013 with Sadashiva Sugars Limited the project is under planning stage.
The company is wating for Environmental clerances.
The Project is Scheduled to be Completed in
Two Years from the date of commencement of the project.
So, this is the RIGHT TIME to contact and Follow Up Contractor at following address obtain the detailed Enquiry of each product in time and to submit your quotation subsequently.
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The Main Scope of Supply includes:
1. Boiler : 110 TPH - 1 No.
Fuel : Bagasse- 1050 MT/day /
Coal - 495 MT/day
2. Boiler : 25 TPH - 1 No.
for Distillery
(3 MW Power will be generated from Spent wash
Incineration Boilers)
Heat Exchangers, Air Pre-heater/Economiser)
Wet Scrubber for arresting fly ash
Existing Status of Heating Equipment:
The company is operating 1 No. Boiler of capacity 85 TPH to meet the steam requirements of sugar plant of 3500 TCD & cogeneration plant of 15 MW.
Air Pollution Control Equipment :
The sources of emissions from the proposed expansion of sugar & cogen plant
shall be boilers of 110 TPH (01 No.) based on bagasse & coal.
In the co-gen power plant high efficiency Electro Static Precipitators (ESP) will be installed to bring down the particulate matter in the exhaust gas to less than 50 mg/Nm 3 to comply with CREP recommendations and will be let out into
atmosphere through adequate height of RCC Chimney
The sources of emissions from the distillery shall be incineration boilers of
25 TPH (01 No.) due to burning of spentwash slops along
with coal. High efficiency Bag filters will be installed in the proposed 25 TPH boiler to bring down the particulate matter in the flue gas to less than 50 mg/Nm3
to comply with KSPCB norms. The treated flue gases will be discharged into atmosphere through stack of RCC Chimney, which
will be attached with the 25 TPH boiler
Adequate air pollution control equipment in the form of cyclone dust
collectors shall be provided for the proposed incineration boilers of
20 TPH capacity (01 No.).
Apart from the boilers, standby DG sets shall be the stationary sources.
However, the usage of the same shall be for very limited periods. DG sets shall be provided with stacks of adequate height & noise control measures.
Steam turbine : 19 MW – 1 No.
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
Bagasse Handling system : 90 TPH
Coal Handling System : 45 TPH
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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:
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 the cane cells are extracted by the mills. The juice obtained from milling is sent for process, fibre that comes out from 4thmill is termed as bagasse and it is used as fuel in boilers.
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.
Crystallisation:
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.
Curing:
The above massecuites are centrifuged in centrifugals, where crystals are separated from the mother liquor. Separated mother liquor of massecuites is 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.
***********************************
Conveyors.
Cush - Cush conveyor :
Double scroll type 410 mm dia x 7000
The bagasse conveyor also has return conveyor to feed the stored bagasse
Screens : Rotary screen with 0.35 slit opening.
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.
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 : 375 Cu.m. / hr. - 2 Nos
(For DistillerY)
Cooling System : For Power Plant
No. of cells : 4 - 1600 Cum.Mtr/Hr
Mud Belt Conveyor : 1 No.
650 mm width troughed, 36000 mm long –1No
Gross Hopper Conveyor : 1 No
Single tray type, 2.0 m width, 12 m long –1No
Fluidized Bed Dryer : 1 No
40 Ton/h fluidized bed dryer along with all accessories –1No
Vibratory Screen : 2 Nos
80 mesh screen vibratory type with rectangular –1No
Screen of 1075 x 1000 x 30
------------------------------
Circular, 60 mesh size, 3.7 KW, 1.5 m dia–1No
Cane Weighbridges : 2 Nos.
60 Ton –1No. & 10 Ton –1No
Mills : 2 Nos
Mills 42" x 84" with pressure feeding system
JUICE PUMPS : 9 Nos
Unscreened juice pump :350 cu.m/hr,12 m head 960 rpm –2 Nos.
Screened Juice pump: 400 cu.m/hr, 12 m head 960 rpm –3 Nos.
Imbibition juice pump: 350 cu.m/hr,12 m head, 960 rpm - 2 nos
Imbibition water pump: 200 cu.m/hr, 50 m head, 1440 rpm –2Nos
Mill House Crane : 1 No.
40 t EOT crane –1No.
Air Compressor : 4 Nos.
1000 cum/h air compressor
Plate Heat Exchangers : 4 Nos
Wash Pre-heating PHE(SS316) –2Nos.
Recycle Wash Cooler (Recycle) PHE (SS316) –1No.
Spent Wash Cooler PHE (SS316) –1Nos
Propagation Vessel : - 3 Nos
(For DistillerY)
Capacity - 2000 L (SS 304) –1No.
Capacity - 100,000 L : MS (epoxy lined)–1No..
Capacity - 180 L (SS 304) –1No.
PROCESS PUMPS : - 15 Nos
(For DistillerY)
Molasses feed pump : 1 + 1 stand by..
Fermenter Cooling Pump : 2 + 1 stand by.
Fermenter Discharge Pump : 1 + 1 stand by
Wash Transfer Pump : 1 + 1 stand by
Sludge Pump : 1 + 1 stand by
Recycle Pump : 1 + 1 stand by
Propagation II Cooling Pump : 1 No
Defoaming oil dosing Pump : 1 No.
Fire fighting system for complete complex:
Fire water pump motor driven : 100 TPH at 10 KSC- 1 No.
Fire water pump diesel set driven : 100 TPH at 10 KSC- 1 No
Jacky pump : 30 TPH at 10KSC - 2 Nos
Storage Tanks: 24 Nos ( for expansion)
For various purposes in Sugar, Power & Disttillery Plants.
DG set : 1500 KVA - 1 No
One Additial Dg Set of 1500 KVA willbe installed for stand by arrangement..
Silencer (Acoustic enclosures) to be provided to D.G.)
Clarifier :
Vacuum Filter
Injection pumps
Water Treatment Plant, Effluent Treatment Plant,
Oxidisation Chamber,Filter, DM. Plant, Softener.
Pumps Valves, Custom Pipeline Work
---------------------------------------------
The existing water consumption in the Sugar Plant including Power Generation is 400 m3 /day..
The water required for the proposed expansion will be 1510 m3 /day.
After the expansion, water consumption in the sugar plant including power generation shall be 1910 m3 /day.
The water required for the proposed expansion project will be
met from the Krishna River.
Total Water Balance For Sugar & Power Plant
( After Expansion )
I. Domestic : 40 M3/Day
II. Process water : 37 M3/Day
Boiler feed : 504 M3/Day
DM plant regeneration : 70 M3/Day
Cooling water make up : 189 M3/Day
Service water : 20 M3/Day
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Water Input 860 M3/Day
Total Water Balance For New Distillery &
3 MW CO-GEN. POWER PLANT
I. Domestic : 10 M3/Day
II. Process water : 560 M3/Day
Boiler feed : 40 M3/Day
DM water for RS dilution :190 M3/Day
Cooling water make up : 220 M3/Day
DM plant regeneration : 30 M3/Day
Service water : 20 M3/Day
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Water Input 1050 M3/Day
Water requirement for Sugar (Existing) : 27M3/Day
Water requirement for Sugar (Expansion) : 30 M3/Day
Water requirement for Co-gen power (existing) : 373 M3/Day
Water requirement for Co-gen power (expansion) : 430 M3/Day
Water requirement for Distillery : : 1050 M3/Day
Total water requirement for after proposed expansion will be :
1910 m3/day
Total Waste Water Balance For Sugar & Power Plant
( After Expansion )
I. Domestic : 32 M3/Day
II. Process water & Washing : 130 M3/Day
Boiler Blow Down 52 M3/Day
Tube cleaning 340 M3/Day
DM plant regeneration : 70 M3/Day
Cooling tower Blow Down : 365 M3/Day
Service water : 20 M3/Day
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Water Output 1009 M3/Day
Total Waste Water Balance For New Distillery &
3 MW CO-GEN. POWER PLANT
I. Domestic : 8 M3/Day
II. Spent wash : 600 M3/Day
Boiler Blow Down : 9 M3/Day
Cooling water Blow Down : 23 M3/Day
DM plant regeneration : 30 M3/Day
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Water Output 670 M3/Day
Waste water generation from Sugar (Existing) : 358.00 m3 /day
Waste water generation from Sugar (Expansion) : 408.00 m3/day
Waste water generation from Co-gen (existing) : 112.00 m3/day
Waste water generation from Co-gen r (expansion) :131.00 m3/day
Waste water generation from Distillery : 670.00 m3 /day
Total waste water generation for after proposed expansion will be :
1679 m3/day
:
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Effluent Treatment System and Scheme
The Sugar ETP will be 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.
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.
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 :
Sadashiva Sugars Limited(A Subsidiary of EID Parry India Limited ),
1/2, 3rd Floor, Venus Building' Kalayanamantapa Road, Jakkasandra,
Koramangala Extension, Bangalore - 560034, Karnataka, India
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Tel : + 91- 80- 49006666
Fax : + 91- 80 – 49006600
Email : admini...@murugappa.co.in/
Website : www.parrysugar.in /www.eidparry.com
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