MRN Cane Power (India) Plans For Sugar, Distillery & Co-Gen Power Plant
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MRN Cane Power (India) Plans For
Sugar, Distillery & Co-Gen Power Plant
MRN Cane Power (India) Ltd. plans for a Sugar Plant having Capacity of 5,000 TCCPD, Molasses Based Distillery having Capacity of 65 KLPD along with a Co-Generation Power Plant of 65 MW at Kallapur Village, Kulageri Hobli, Badami Taluka in Bagalkot District, Karnataka.
Capacity:
Sugar Plant : 5,000 TCCPD
Distillery : 65 KLPD
Co-Gen Power Plant : 65 MW
Location :
Kallapur Village, Kulageri Hobli, Badami Taluka
Bagalkot District, Karnataka
As on February 03, 2015: The Project is under planning stage.
Total site area is 233 Acres.
Out of this Area allotted for
1. Built up area : 50 Acres
2. Green belt : 81 Acres
3. Open area for future : 70 Acres
development
4..Cultivated area for : 32 Acres
utilization treated effluent
==============================
Total : 233 Acres
IMPORTANT: As per the the discussion we had
on 27.01.2015 with MRN Cane Power (India) Ltd.
the Project is under Panning Stage.
The company is waiting for Environmental Clearance.
The Project is Scheduled to be Completed
in 2 Years from the date of the commencement
of the project work.
*****************************
The Main Scope of Supply includes:
1. Boiler : 150 TPH - 1 No.
Fuel : Bagasse (Main Fuel -During Cane crushing season)/
Coal (Auxiliary fuel -During off season)
2. Boiler : 16 TPH - 1 No.
Fuel : Spent Wash will be concentrated in Multieffect evaporator ( MEE). The concentrate is then burnt as fuel admixed with coal or agrowaste bio-mass as fuel.
for Distillery
Heat Exchangers, Air Pre-heater/Economiser)
Wet Scrubber for arresting fly ash
Air Pollution Control Equipment :
The sources of emissions from the proposed expansion of sugar & cogen plant
shall be boilers of 150 TPH (1 No.) based on bagasse & coal.
The sources of emissions from the distillery shall be incineration boiler of
16 TPH (1 No.) due to burning of spent wash slops along
with coal.
Adequate air pollution control equipment in the form of Electro static
Precipitator/Bag Filter shall be provided for the proposed boilers of
150 TPH capacity (1 No.).
Adequate air pollution control equipment in the form of cyclone dust
collectors shall be provided for the proposed incineration boilers.
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.
CO-GEN POWER PLANT
Boiler Plant
The Unit shall be provided with a high pressure boiler with a capacity of 150 TPH
at 125 kg/cm2 pressure and 540 Deg C temperature.
The steam is required for both Power and Sugar plants. The Boiler will be fired with Bagasse alone
or with bagasse mixed with 15 % coal. Bagasse is available from sugar plant as captive source.
The flue gas from the boiler will be passed through ESP/Bag filter to free it from suspended particles
and then vented through a chimney of adequate height. The boiler ash will be quenched
and sent to bin through Belt Conveyor. Bagasse from mills or storage yard is to be sent to
boiler through Mechanical Conveyor.
Electricity Generation (Steam turbine and Alternator)
The high pressure steam from the boiler will be passed through the Double Extraction Cum
Condensing type of Turbine of 35 MW capacity. The turbine will be run by the high
pressure steam which in turn rotates alternator. The electric power produced will be used
to meet the captive power requirement of the sugar industry and co-gen plant.
Surplus power from the industry is exported to KPTCL through distribution grid.
The steam extracted at reduced pressure from turbine is used in sugar plant to meet its
process requirement.
Steam Turbine : 35 MW
Type : Double extraction - cum condensing
Distillery Unit
Distillery power plant will include medium pressure Boiler of 16 TPH capacity with 34 kg/cm2 pressure and 360 Deg C temperature.
The 16 TPH Boiler will be fired with Concentrated Spent Wash (CSW) admixed with bagasse and/or cane thrash as support fuel. Spent wash generated as effluent in distillation plant will be concentrated in evaporator. CSW has a heat value of 1800 kcal/kg. Coal will be used as support fuel in the event of Agro waste shortage. Bagasse will be available from captive source or will be bought from nearby sugar industries. Agro waste such as cane thrash is available from farmers in the region.
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.
========================
BULK STORAGE FACILITIES
1. Storage yards for storage of 30000 Ton Bagasse, 6000 Ton coal and 4000 Ton mud
and 200 Ton Boiler Ash.
2. Sugars go down for storage of 60000 T of sugar.
3. Molasses storage tanks 2 No’s, each of 10000 T capacity.
4. Ethanol storage tanks 12 Nos. Total : 6000 m3 capacity.
5. Spent wash storage tanks (2 Nos). Total capacity: 6000 m3
6. Water reservoir : 3000 m3
========================
Cooling Tower
Storage Tanks
within the distillery premises.
DG set : 1000 KVA - 1 No.
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. Plant.
Pumps Valves, Custom Pipeline Work
---------------------------------------------
Water Treatment plant : 2000 m3 /Day
The water consumption in the Sugar Plant including Power Generation and Distillery Plant :
Fresh Water Fresh water from Malaprabha River :
1.Co-Gen & Sugar Unit : 1020 m3 /Day
1.Distillery : 650 m3 /Day
===========================
Total : 1670 m3 /Day
Recycle water obtained as condensate
from juice evaporator in case of sugar
unit and spent wash evaporator in case
of distillery unit :
1.Co-Gen & Sugar Unit : 3950 m3 /Day
1.Distillery : 424 m3 /Day
===========================
Total : 4374 m3 /Day
FRESH WATER TREATMENT
The water has to be treated in a suitable water treatment plant.
The extent of water treatment required for different applications is given below.
Boiler feed : DM Plant
Cooling water : Soft water
Domestic use : Clarified, filtered and chlorinated
Gardening : Raw water
Process in sugar Plant & distillery : Soft water
===================
Effluent Treatment System and Scheme
An ETP plant of 1000 m3/Day will be designed for the treatment of plant effluents & ETP
plant of 1500 m3/Day will be designed for condensate water..
1. Domestic Effluent : Stream A- : 50 m3/Day
Domestic effluent will be generated at different locations in the industry. This will be stabilized in
septic tanks located near the sources. The over flow from septic tank is lead to sugar
plant ETP for further treatment.
Total quantity of domestic effluent will be 50 m3/Day.
Septic tanks are designed as per BIS specifications.
2. Plant Effluent : Stream A- : 734 m3/Day
Effluents to be treated in Sugar plant ETP consists of,
Plant effluents from sugar unit : 370 m3/Day
Plant effluents from Distillery unit : 364 m3/Day
-------------------------------------------------------
Total : 734 m3/Day
The effluent plant will be designed with 15 % higher capacity to accommodate peak
load and eventualities.
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.
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 :
MRN Cane Power (India) Ltd.
Prop: Nirani Sugars Limited.
World Trade Centre
Dr. Rajkumar Road , 9th Floor,Malleshwaram West
Bangalore- 560055, Karnataka, India
--------------------------------
Tel : + 91-80-23256500/ 550, 23565521
Email : nirani...@yahoo.co.in/ mrn...@gmail.com
Website : www.niranigroups.com
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