Mellbro Sugar Plans to set up 5000 TCD Sugar Plant, 60 KLD Distillery & 30 MW Co-Gen Power Plant......,,,.......
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Mellbro Sugar Plans to set up
5000 TCD Sugar Plant, 60 KLD Distillery & 30 MW Co-Gen Power Plant
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First Info: July 2017 Update : June 2018 & January 2019
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Mellbro Sugar Ltd. Pvt. Ltd. plans for a Sugar Plant of 5000 TCD, a Molasses Based Distillery of 60 KLD and Co-generation Power Plant of 30 MW at Shirur Village in Bagalkot District, Karnataka....
Sugar Plant : 5000 TCD
Distillery : 60 KLPD
Co-Gen Power Plant : 30 MW
Location : Shirur Village in Bagalkot District, Karnataka.......
As on May 25, 2019: The Project is in planning stage.
The proposed buildings & utilities would be spread over an area of 3.19 Hectares (7.9 acres) includes Proposed sugar & cogeneration plant along with distillery shall be located. Around 14.16 Hectares (35 acres) is being developed as green belt. The balance area of 23.06 Hectares (57 acres) shall be vacant land.
IMPORTANT: As per the discussion we had on 21.05.2019 with
Mellbro Sugar Pvt. Ltd... the Project is in planning stage.
The Project is Scheduled to be Completed in 18-24 Months from the date of commencement of project work.
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The Main Scope of Supply includes:
Boiler : 125 TPH - 1 No. Fuel : Bagasse
Boiler : 22 TPH - 1 No. Fuel : (Spent Wash)
Heat
Exchangers, Air Pre-heater/Economiser)
Wet Scrubber for arresting fly ash
Air Pollution Control Equipment :
Electrostatic Precipitators are proposed for the plant steam generator, to contain the dust emission from plant to a level less than 150 Mg/Ncum during bagasse firing..
In this regard ESP will be followed by chimney of 72 meter height will be installed
to bring down SPM values to < 100 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 : 30 MW
BAGASSE Handling System
1.1800 mm wide belt conveyor to receive bagasse from last Mill.
2. Bagasse Belt elevator of Troughed belt type, Size: 1800 mm wide x suitable length to convey bagasse.
3. 1800 mm wide, 200 mm pitch Rake type conveyor with suitable drive. Length suitable to accommodate additional boiler in future.
4. Bagasse Belt Conveyor of Troughed belt type, Size: 1600 mm x suitable length to convey bagasse to Bagasse yard.
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
Cane Weighing ---> Cane Unloading--->Cane Preparation--->
Milling --->Juice Weighing---> Receiver--->Juice Heating --->
Juice Sulphitor---> Juice Heating --->Clarifier--->Juice Heating --->
Evaporator --->Syrup Sulphitor --->Syrup --->Syrup + Seed --->
Pan ---> Crystallizer >>
(White Sugar Cooling grading, weighing, bag stitching & Godown)
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 : : 1000 KVA : 1 No. ( Fuel : HSD)
Clarifier
:
Vacuum Filter
Injection pumps
POWER HOUSE CRANE
EOT type, three motion, power house crane
having capacity 35 Ton / 5 Ton and with suitable span
Sugar Receiving Gross Hopper
AUTO CANE FEED CONTROL
Automatic cane feed control system for sensing current of preparatory devices, mill drive power and donnelly chure level.Overfeeding of any Donnelly chute shall override all signals and trip all preceding rake and cane carriers.
Sugar Belt Conveyor
PLANETARY GEARBOX
Planetary gearbox input power 550 kW x 1000 rpm , speed ratio 1000 : 4.25 rpm
Service factor 2.00 on continuous rating.
Fluidised Bed Sugar Dryer
JUICE TREATMENT PLANT
Bottling
Plant
Dryer
MAGNETIC TRAMP IRON SEPARATOR
Multiple
Effect Evaporators
Centrifugal Machines
CO2 Recovery Plant (In future)
Water storage tanks
Piping works
CANE WEIGHING SCALE
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
Total water requirement for the Plant
activity will be 3720 m3/day for Sugar & Co-Generation Plant and 776 m3/day for Distillery.
DM PLANT /RO PLANT
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Effluent Treatment System and Scheme
Effluent Deneration : 881 KLD (from Sugar & Co-Gen Plant) & 983 KLD ( from Distillery)
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 :
Mellbro Sugar Ltd. Pvt. Ltd.
Melligeri Complex, Kaladagi Road,Bagalkot - 587 101, Karnataka, India
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Tel : +91-8354-221408 Fax : +91-8354-221408 Email : mel...@rediffmail.com
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