Satish Sugars Plans For Expansion Of Sugar,Distillery & Co-Gen Power Plant
Industrial Directory Of India
“New Projects This Week"
RELEASED : ISSUE NOVEMBER 18 /12
Comprising of Total 81 New Project Enquiries
with Company's Name/ Address/ Phone/ Fax/ Contact person/E-mail
(Published Every Week
:Electronic Issue)
http://www.industrialdirectoryofindia.com/download
FREQUENTLY ASKED QUESTIONS ABOUT PROJECT ENQUERIES
Visit : http://industrialdirectoryofindia.com/FAQ
(Helpline : +91-900 7158 600)
Satish Sugars Plans For Expansion
Of Sugar,Distillery & Co-Gen Power Plant
Satish Sugars Limited plans for expansion of its Sugar Plant from 10000 TCD to 15000 TCD, Molasses Based Distillery from 60 KLD to 120 KLD, Cogeneration Power Plant from 45 MW to 80 MW along with setting up of a New 4 MW Power Plant from Spent wash Incineration Boilers in Beerangaddi & Hunshyal P.G. Villages, Sangankeri - Yadwad Road, Gokak Taluk, Belgaum District, Karnataka.
Capacity:
Expansion:
Sugar Plant : from 10000 TCD to 15000 TCD
Distillery : from 60 KLD to 120 KLD
Co-Gen Power : from 45 MW to 80 MW
New Plant:
Generation of 4 MW power from Spent
Wash Incineration Boilers.
Location :
Beerangaddi & Hunshyal P.G. Villages,
Sangankeri - Yadwad Road, Gokak Taluk,
Belgaum District, Karnataka
As on November 20, 2012: The Project is in planning stage.
Proposed upgradation of the sugar Cane crushing capacity from 10000 to 15000 TCD, expansion of Cogeneration of power from 45 MW to 80 MW &
expansion of molasses based distillery from 60 KLD to 120 KLD shall be located in an area of 4.203 Acres within the vacant area of the existing premises.
[The existing buildings of Sugar, Cogeneration & distillery units are spread over an area of 48.66 acres (19.70 hectares).
This includes the composting facilities of distillery, ETP for sugar & cogeneration units and utilities.
Existing Green Belt area is being developed over an area of 49.90 acres (20.22 hectares). An area of 9.97 acres (4.036 hectares) is covered by road & pavements Vacant area available with the unit is 50.733 acres (20.54 hectares)]
premises.IMPORTANT: As per the discussion we had on 16.11.2012 with Satish Sugars Limited the project is under planning stage.
The company is waiting for Environmental clearances.
The Project is Scheduled to be Completed in
Two & Half Years from the date of commencement of the project work.
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.
*****************************
The Main Scope of Supply includes:
1. Boiler : 100 TPH - 2 Nos
Fuel : Bagasse (Main Fuel -During Cane crushing season)/
Coal (Auxiliary fuel -During off season)
2. Boiler : 20 TPH - 2 Nos
for Distillery
(4 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 2 Nos. Boilers of capacities
90 TPH & 130 TPH to meet the steam requirements of sugar plant of 10000 TCD & cogeneration plant of 45 MW.
During cane crushing season bagasse is used as main fuel (100% heat input)
(2400 MT per day).
During the off season, coal is used as an auxiliary fuel (15% heat input) (270 MT per day) along with bagasse (85% heat input) (1530 MT per day).
The present power requirement of the sugar, cogeneration & distillery plants
is 15 MW. This requirement is met from the cogeneration plant and around 30 MW is being exported to the grid in the crushing season.
Apart from the above high pressure boilers, the company is operating a
14 TPH boiler to meet the steam requirements of distillery.
Bagasse consumption of 14 TPH Boiler is 153 MT per day.
Air Pollution Control Equipment :
The sources of emissions from the proposed expansion of sugar & cogen plant
shall be boilers of 100 TPH (02 Nos.) based on bagasse & coal.
The sources of emissions from the distillery shall be incineration boilers of
20 TPH (02 Nos.) due to burning of spentwash slops along
with coal.
Adequate air pollution control equipment in the form of Electro static
Precipitator shall be provided for the proposed boilers of
100 TPH capacity (02 Nos.).
Adequate air pollution control equipment in the form of cyclone dust
collectors shall be provided for the proposed incineration boilers of
20 TPH capacity (02 Nos.).
The air pollution control equipment proposed for all the boilers shall
ensure that the air emissions shall confirm to CPCB standards.
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 : 35 MW
1. 20 MW - 01 No.
2. 15 MW - 01 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
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: 2 Nos ( for expansion)
In the proposed expansion the company shall construct two storage tanks
of 500KL for storing rectified spirit within the distillery premises.
DG set : 1 No
One Additial Dg Set willbe installed for stand by arrangement..
Silencer (Acoustic enclosures) to be provided to D.G.)
Clarifier :
Vacuum Filter
Injection pumps
Sugar ReceivingGross Hopper
Sugar Belt Conveyor
Fluidised Bed Sugar Dryer.
Water Treatment Plant, Effluent Treatment Plant,
Oxidisation Chamber,Filter, R.O. Plant.
Pumps Valves, Custom Pipeline Work
---------------------------------------------
The existing water consumption in the Sugar Plant including Power Generation is 7927m3 /day.
Of this total water requirement of 7927 m3 /day, about 7000m3 /day is being met from the cane juice of sugar plant and the balance requirement of 927m3 /day is drawn from River Ghataprabha.
After the expansion, water consumption in the sugar plant including power generation shall be 11976m3 /day.
Of this total water requirement of 11976 m3 /day, about 10500 m3 /day shall be met from the cane juice of sugar plant and the balance requirement of 1476m3 /day shall be drawn from River Ghataprabha.
Total Water Balance For Sugar & Power Plant
( After Expansion )
Water Input
I. Fresh water from river source : 1476 M3/Day
II. Water intake from cane juice as : 10500 M3/Day
70% moisture content in sugar canel
---------------------------------------------------------------------------------------
Water Input 11976 M3/Day
Water Output
I. Domestic effluent : 58 M3/Day
II. Sugar Factory effluent 1500 M3/Day
III. Cooling tower Blow down : 282 M3/Day
IV. DM Plant drain water (Co-gen) 562 M3/Day
V. Boiler Blow down @ 1% of 420 TPH : 101 M3/Day
VI. Evaporation losses from cooling tower 1385 M3/Day
(Co-gen)
VII. Drift Losses from cooling tower 421 M3/Day
(Co-gen)
VIII Water loss in bagasse : 2250 M3/Day
IX Water loss with molasses : 60 M3/Day
X Water loss with press mud & others 420 M3/Day
XI Other Losses
a. Flash losses : 1500 M3/Day
b. Steam losses from boiler & TG : 202 M3/Day
c. Soot blowing, deaerator vent : 120 M3/Day
d. Losses Due to floor wiping etc. : 225 M3/Day
e. Domestic Losses : 10 M3/Day
f. Spray pond Evaporation : 1523 M3/Day
XII. Steam to sugar process : 540 M3/Day
XIII. Excess vapour condensate to : 817 M3/Day
condensate recycle
---------------------------------------------------------------------------------------
Water Output 11976 M3/Day
:
*********************************************
The existing water consumption in the Distillery is 1077m3 /day.
Of this total water requirement of 1077 m3 /day, about 94m3 /day is being met from
the treated spentlees and the balance requirement of 983m3/day is drawn from River Ghataprabha.
After the expansion, water consumption in the distillery shall be
2154 m3 /day.
Of this total water requirement of 2154 m3/day, about 188m3/day shall be met from the treated spentlees and the balance requirement of 1966m3/day shallbe drawn from River Ghataprabha.
Total Water Balance For DISTILLERY
( After Expansion )
Water Input
I. Fresh water for Industry : 1890 M3/Day
II. Feed water content in Molasses : 100 M3/Day
III. Steam from boiler : 655 M3/Day
---------------------------------------------------------------------------------------
Water Input 2645 M3/Day
Water Output
I. Losses with Product : 120 M3/Day
II. Loss from Industrial use 855 M3/Day
III. Effluent sober nature (cooling purging 66 M3/Day
blow down) sent to garden
IV Effluent moderately polluted : 252 M3/Day
V Effluent highly polluted spent wash : 960 M3/Day
V! Recycled to boiler through reboiler 392 M3/Day
---------------------------------------------------------------------------------------
Water Output 2645 M3/Day
:
Effluent Treatment System and Scheme
After expansion the quantity of process effluent from the Sugar unit shall increase to 1500 m3/Day.
The additional process effluent of 500 m3 /Day shall be treated in an elaborate proposed ETP (Capacity 500 m3/Day) based on the activated sludge process.
Industrial wastewater system from Cogeneration unit
shall be separated into two systems.
1.Plant Drain System
2. Neutralization and Chemical Drain system
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.
Around 126 KLD of spentlees shall be generated from the proposed expansion.
This shall be treated by RO & 94 KLD shall be reused back.
RO reject of 32 KLD shall be sent to sugar ETP for further treatment.
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 :
Satish Sugars LimitedSangankeri , Yadwad Road, Hunshyal P.G., Gokak Taluk,
Dist: Belgaum, Karnataka - 591 224, India
-----------------------------------------------------------------
Tel : +91- 8332- 284550/1/2/3
Fax : +91- 8332- 284666
Email : in...@satishsugars.com
Website : www.satishsugars.com
FREQUENTLY ASKED QUESTIONS ABOUT PROJECT ENQUERIES
Visit : http://industrialdirectoryofindia.com/FAQ
GET NEW PROJECTS INFORMATIONS ONLINE
http://www.industrialdirectoryofindia.com/download
We provide information on NEW PROJECTS such as Automobiles,Aviation, Breweries & Distilleries, Biotech,Banking & Finance, Cement,Construction & Machineries,Chemicals,Coal,Dairy,Defence, Drugs & Pharmaceuticals, Engineering, Food Processing,Packaging,Fertilizers, Hospitality & Healthcare,HRD Hotels & Restaurant, Infrastructure, IT, ITES, BPO,KPO, Iron & Steel,Logistic. Metallurgy, Minerals, Mining,Material Handling & Warehousing, Oil & Natural Gas, Paper, Passenger Cars, Polymers, Petrolium,Ports,Pipelines, Power & Transmission, Real Estate,Resort & Tourism,Renewable Energy,Rural Development, Roads & Highways, SEZ, EPZ, Shopping Plazas, Storage & Distribution, Sugar, Textiles,Tyres, Refineries, Transport Equiments, Valves, Vegetable Oils, Water & Waste Water Treatment and many other Industries.
with all Contact Details:
Company's Name
Address/ Phone/ Fax
Contact person's Name
E-mail Id
We provide the information of Projects for various stages right from Land Acquisition, Starting Of Civil Work, Vendor Registration & Material Procurement etc. etc. to completion.
We make your Bidding/MARKETING/ Sub-contracting & Planning MORE EASY
GET YOUR COMPANY REGISTERED TODAY AND GET ALL PROJECTS INFORMATIONS DIRECTLY IN YOUR MAIL BOX .
Visit : http://www.industrialdirectoryofindia.com/registration
GET ALL BUYING LEADS FOR YOUR PRODUCT DIRECTLY IN YOUR MAIL BOX
------------------------------------------------------------------------------------------------------------
RELEASED ANNUAL ISSUE :
“NEW PROJECTS THIS WEEK”
Over 2250 Nos Projects Enquries Online
