PRE-FEASIBILITY REPORT NEW 19.0 MW COGENERATION UNIT OF BHIMASHANKAR SAHAKARI SAKHAR KARKHANA LTD 1.

0 INTRODUCTION

M/s. Bhimashankar Sahakari Sakhar Karkhana Limited, at Dattatryanagar, P.O. Pargaon via Awasari, Taluka: Ambegaon, Dist. Pune.410 406 is engaged in the manufacture of sugar and is registered under the Co-operative Society Act, 1961 on 31.03.1994 vide registration No.PAN/AGN/A/S-47/ 1994. In Nov. 1999, the first elected board of directors took charge of the industry from government nominated director board under the chairmanship honorable founder Shri Diliprao Walse Patil, speaker, legislative assembly, (Govt. of Maharashtra). The initial installed crushing capacity of the factory was 2,500 TCD. Because of increasing availability of sugarcane in the area of operation, the factory expanded its crushing capacity to 4,000 TCD. The management now plans to establish a 19.0 MW cogeneration plant to fulfill their need of power and sell the surplus power to Maharashtra State Electricity Distribution Corporation Limited (MSEDCL). 2.0 PROJECT SETTING

The sugar factory has a plan to set up a 19.0 MW co-generation project within its premises. The plant is located off Pune-Nashik national highway No.50 just a 15.5 Km towards west. The geographical coordinates of the site are 18058N. and.74005E. During 2009-10 the crushing was 5,88,909 MT with average recovery of sugar of 12.0%. In Season 2009-10 the bagasse production for these season 1, 55,471 MT. Bhimashankar SSK Ltd., is now planning to balance the sugar plant and increase the saving of bagasse by using biogas. Further efforts will be made to procure surplus bagasse from the neighboring sugar units. 3.0 HIGHLIGHTS OF THE PROJECT

Name of the Industry Location of the project

Bhimashankar Sahakari Sakhar Karkhana Ltd. Dattatrayanagar, P.O. Pargaon via Awasari, Taluka: Ambegaon, Dist. Pune 410 406 State- Maharashtra Email : bhimashankar_sugar@vsnl.com Ph no: 02133-284231/32/41/46 Fax : 02133 - 284381

Prefeasibility Report: Proposed 19MW Cogeneration Project Bhimashankar SSKL

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Land Project Product Running Days Main Raw Material Water Requirement Fuel Production equipment and machinery

18 acres built up area, 6 acres provided for green belt development 19.0 MW Cogeneration (Power) plant Electricity Generation -18.0 MW 236 Days Water as main raw material for steam generation. Bagasse as a raw material for fuel. 900 m3/day Ghod River, Kathatpur KT Weir. (Permission available) Bagasse For season - 1074 MT/day During Off season: 305 MT/day Steam generators (Boilers), Condensate system, Turbo-generator sets, Cooling tower, Fire protection system, Bagasse and Ash handling system.

Boiler and Steam Presently the factoryis having one boiler of 37 TPH capacity Turbo Alternator working at 45 ata pressure and 445oC 50 C steam temperature. (STG Set) For a new boiler is of 80 TPH capacities at 88 Ata pressure and 515OC 50C steam temperature is planned to install. Operating load of the new boiler is estimate to be about 71.50 TPH during normal crushing season including the extraction of steam for process requirement, HP heater and de-aerator heating steam Manpower Project Cost EMP cost 4.0 Total staff around 35 Rs. 4461.25 Lakhs Rs.300.00 Lakhs

SITE SPECIFICATION The site is located off Pune-Nashik National highway No. 50, Distance- 15 km from factory site. Pune is the nearest railway station 55 from the site. Pune is the nearest airport -55 km from the site

4.1 Connectivity

4.2 Land use pattern Since the project is going to be commissioned within the existing sugar factory premises and no additional land is required, hence the project is not causing any land use change in the area. 4.3 Ecologically sensitive attributes: There is no tropical forest/ biosphere reserve/ national park /wildlife sanctuary /wetland/Tiger reserve/area with threatened/reserved forest etc
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under wildlife protection act (1972)within radius 10 km study area. The nearest sanctuary to the site is Bhimashankar Wildlife Sanctuary located at a distance of 60km. 4.4 Social and Existing Infrastructure in the study area As explained earlier this area is covered in Ambegaon taluka. The study area is decided as an area within 10 km radius from the proposed unit. Altogether there are 36 villages in the study area. The infrastructure such as school, college, medical centers, roads, electricity and supply of drinking water is available to the local people. The factory is actively involved in several socioeconomic developmental activities of the region, finance for cane development, housing facility to its workers, helping the member farmers for various purposes such as educational, social, health, and cultural. Education Facilities: 24 primary schools, 4 middle schools, within study area. Health Services: The overall health facilities such as public health center, private clinics, dispensaries and nursing homes, etc. availability in the study area are adequate to serve the localities . Veterinary Center: The study area contains sizable cattle population consisting of cows, buffaloes, bullocks, goats, sheep, poultry etc. The bullocks are used for ploughing, harrowing, sowing and intercultural operations whereas buffalo, cows, sheep, goats and hens are kept as subsidiary source of income. Drinking Water: Drinking water supply for most of the villages is made available by Maharashtra Jivan Pradhikaran Communication: There are 19 Post offices and Telegraph within study zone Electricity: All villages have power supply from Maharashtra State Electricity Board. Road and transport: Asphalted roads are present throughout the study area, those connects to each of the village. There is a regular service of State Road Transport Corporation (MSRTC) bus available in the region. 5.0 CLIMATIC INFORMATION INCLUDING BASE LINE ENVIRONMENTAL CONDITION Climate Ambegaon taluka falling in the moderate rainfall intensity zone. Average rainfall is around 800.44mm. The annual average temperature is varies from 19-33oC Relative humidity - Early summer (January to March)42-55% o In monsoon it ranges 75-81% Wind The predominant wind direction observed during the study period was west direction; with 22 % of the 0-7 kmph Calm conditions constituted about 27.78

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% of the total time observed. Geology The district forms part of Western Ghat and Deccan Plateau. This Taluka falls to the foothill of Sahyadri Mountain range. The study area largely falls in the Basin of Bhima- Ghod River. Hydrology The district has three major drainage system namely, Bhima Ghod. River system in the northern, north eastern and eastern part, of which Bhima River has a total length of about 355 km. and Ghod River has a drainage of about 196 km. River Ghod approx 2 km away from the factory site in North direction. Soil The type of soil in the area is black to calcarious soil. Deep black soils have good water holding capacity due to rich humus content. Excepts certain packers, the soil have good drainage. These soils contain less 'Humus' Organic Matter. The pH of the soil is 8.0 to 8.9. Land-use Pattern It is observed from the available data that, the project surrounding land is mainly used for agricultural purposes, followed by residential purpose agricultural activities, partly for the pasture and other uses. Ecology The wild vegetation in the study area consists of semi-aired with significant thorny species. Mainly agricultural (cultivated) vegetation is dominant in the study zone. There is no wildlife sanctuary or national park or biosphere reserve exists in the 10 km radius area. Also, there are no rare or endangered floral or faunal species recorded in the 10 km radius zone. ScioEconomic Environme nt The infrastructure such as school, college, medical centers, roads, electricity and supply of drinking water is available to the local people. The Karkhana is actively involved in several socio-economic developmental activities of the region, finance for cane development, housing facility to its workers, helping the member farmers for various purposes such as educational, social, health, and cultural. Historical Sites 6.0 No historically important sites are present in the study zone of the proposed site BENEFITS OF BAGASSE BASED COGENERATION

Cogeneration offers energy, environmental, and economic benefits, including: Saving money

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 By improving efficiency, cogeneration systems can reduce fuel costs associated with providing heat and electricity to a facility. It saves the fossil fuel consumption by using the as well as and related foreign exchange. It does not increase the foreign exchange cut flow, as the plant and machinery are indigenously available It has lower installation and operating cost compared to the thermal power plant. The profit made by incomes through exportable power improve financial position of the sugar factory Improving power reliability

In cogeneration systems, it is located at the point of energy use. It provide high-quality and reliable power and heat locally to the energy user. It helps by reducing congestion on the electric grid by removing load. In this way, cogeneration systems effectively assist or support the electric grid, providing enhanced reliability in electricity transmission and distribution. Reducing environmental impact

Cogeneration reduces the amount of fuel burned for a given energy output and reduces the corresponding emissions of pollutants and greenhouse gases. Conserving limited resources of fossil fuels Cogeneration requires less fuel for a given energy output, the use of cogeneration reduces the demand on our limited natural resourcesincluding coal, natural gas, and oiland improves our nation's energy security. 7.0 RAW MATERIALS Bagasse and water will be main raw material. The total requirement for the unit (including domestic and other.) 900m3/day .The bagasse is fuel material for this plant will be made available from the attached sugar factory. Bagasse requirement for cogeneration plant will be 1074.0 MT/day during season and 305 MT /day during non-crushing season. 8.0 WATER REQUIREMENT The water for sugar/cogeneration plants will be drawn from existing overhead service water tanks and will be recycled after cooling separately. Water from the reservoirs will be used for all plant and fire-fighting purposes. To achieve better efficiency and to maintain the plant and machinery in good condition, it is necessary to have proper water treatment system. Process water will be treated in a water treatment unit as well as a water-softening unit. By having

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proper water supply system such as clear water pumps etc, the distillery can have good water supply arrangement. Table 1: Water Consumption Details Cogeneration Water Consumed for Domestic Use (Drinking, Toilet, etc.) Gardening Industrial purpose 1. Process* 2. Washings* 3. Boiler feed** 4. Cooling tower make -up water ** 5. Others (Pump gland sealing) Total * Treated water from ETP will be utilized for gardening purpose **One time startup - requirement for boilers and cooling towers = 20,808 m3 Table 2: Water budget for 19 MW proposed cogeneration plant Sr. No 1. 2. Station Boiler Cooling Tower/ Spray Pond 3. Domestics Total 9.0 STEAM During cane crushing season, the steam will be generated from two boilers, one is of 80TPH capacity, 88 Ata pressure and 515oC 50 C temperature; second is of 37 TPH capacity with 46 ata Pressure and Temperature 445 50C. Produced steam will be supplied to a new TG set of 13 5 900 2 847 3 53 Septic Tank Soak pit Nil 50 810 810 00 Sugar ETP 00 Input m3/day 85 Loss m3/day 35 Effluent m3/day 50 Sent to Sugar ETP Recycle m3/day 50 Nil Nil 80.0 810.0 5.0 900 m3/day Consumption M3 /day 5.0 Nil

Prefeasibility Report: Proposed 19MW Cogeneration Project Bhimashankar SSKL

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MW and existing 6 MW. The exhaust steam from cogeneration unit will be utilized in sugar factory, distillery, and other subunits. Table 3: Steam Balance For season Total steam generation Steam required for Sugar process @2.5ata 106.53 TPH 72.73TPH Off season 28.25TPH -6TPH 3.0 TPH -19.25TPH 28.25 TPH

Steam for distillery and ENA units @ 2.5 ata 6 TPH Steam to De-aerator Steam to H.P .Heater @7ata Condensing flow steam Total steam consumption 10.0 BOILER 7.0 TPH 7.8TPH 13TPH 106.53 TPH

The factoryis having one boiler of 37 TPH capacities working at 45 ata pressure and 445oC 50 C steam temperature. For new boiler 80 TPH capacities at 88 Ata pressure and 515oC 50C steam temperature is planned. Operating load of the new boiler is estimate to be about 71.50 TPH during normal crushing season including the extraction of steam for process requirement, HP heater and de-aerator heating steam. Table 4: The boiler details Sr. no. 1 Boiler New 80 TPH @ 88 ATA Pressure and temperature 515 50C Existing 37 TPH @ 46 ATA Pressure and temperature 445 50C Pollution Control Equipment Electrostatic precipitator Multi cyclone dust collector Steam generation 71.1 TPH

2.

35.4 TPH 106.5 TPH

Total Steam generation during crushing season Table 5: Steam Turbine Generator (STG) Sr. No. 1. Steam Turbine Generator 13 MW (New)

Power generation (MW) 12.100

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2.

6 MW (Old)

5.900 18.000

Total power generation

11.0 BAGASSE HANDLING SYSTEM There will be provision for handling excess bagasse which will not be used in the boiler (during season) to a storage area. The Bagasse will be supplied to boiler from elevated carriers and belt conveyors. For the non-crushing season the fuel handling system will also used to handle alternative fuels such as cane trash. 12.0 ASH HANDLING SYSTEM Ash generated in the Boiler consists of bottom ash and fly ash. Fly ash handling system shall consist of dense phase handling system. Fly ash collected at various generation points will be collected and conveyed to a fly ash silo. 13.0 PROCESS The proposed cogeneration, aims at significantly improving the energy efficiency of the sugar factory, enabling the plant to generate surplus power from its cane cursing operation. This surplus power could be exported to the state electricity grid. The proposed co-generation system is designed to utilize the present boilers & T.G. sets for steam generation and surplus electrical power generation.

Surplus to Electricity grid Power Captive Power Bagass e Boiler Steam Turbo Generator

De-aerator HP Heater Sugar Process

Exhaust Steam

Figure 1: Schematic of Cogeneration Project

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14.0 COGENERATION SCHEME The co-generation schemes operations during crushing season (160 days) are designed to use bagasse as a biomass fuel, which is as per the guidelines and qualifying norms stipulated by MERC. Table 6: Power balance for crushing season is as follows Total Generation of power from T,G set of 13 MW and 6 MW Sugar Factory power consumption Distillery, cogeneration unit and administration, colony load. Total Captive consumption Surplus power to be exported to state grid 5.100 MW 0.900 MW 6.000 MW 12.000 MW 18.000 MW

Table 7: Power balance for off- season Captive consumption Distillery, Sugar factory administration, Cogeneration Plant auxiliaries Exportable Power Total Power generation 4.700 MW 5.950 MW 1.250 MW

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Bagasse as Fuel 29.95 T/hr

Bagasse as Fuel 14.80 T/Hr

Boiler 80TPH

Boiler 37 TPH

Total Steam 71.1TPH 45 kg/cm2(a) 485oC

Total Steam 35.4 TPH 45 kg/cm2(a) 485oC

13 MW T.G. Set

6MW T.G. Set

84 Ata pressure at - 505 o C

~
12100KW

~
5900 KW

43Ata pressure at 440 o C

18000 KW

Captive consumption 6000 KW

Export Power 12000 KW

Figure 2: Process flow chart for season

Prefeasibility Report: Proposed 19MW Cogeneration Project Bhimashankar SSKL

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Bagasse 12.7 TPH

Boiler 37TPH

Total Steam 28.7 TPH 6 MW T.G. Set

Power 5.95 MW

Captive consumption

Surplus power 4.7 MW exported

1.25MW
Figure 3: Process flow chart for off-season 15.0 ENVIRONMENT PROTECTION AND WASTE MANAGEMENT Environment protection and the control of solid, liquid, and gaseous effluent or emissions are key element in the design of all steam and power generating system. At present the most significant of these emissions are sulfur dioxide (SO2), Oxides of nitrogen (NOx) and fine airborne particulate matter (SPM) and gases. Bagasse being a biomass, a renewable fuel does not add any net CO2 to the atmosphere, because of the carbon recycling during the growth of cane. The same is applicable even for the other biomass fuel propos to be used in the plant during the off-season operation. 15.1 Air Environment Atmospheric emission arises primarily from the by-product of the combustion process SO2, NOx, particulate fly ash are exhausted from the stack. A second source of particulate matter and gases is fugitive dust from bagasse/Biomass/Ash handling equipment. A final source of air emission is the cooling tower and associated thermal rise plume, which contains heat and some trace materials along with the water vapor.
Prefeasibility Report: Proposed 19MW Cogeneration Project Bhimashankar SSKL
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The element polluting the air that are discharged from the proposed unit are,
q q

Dust particulate from fly ash in flue gas Sulfur-di-oxide in the flue gas (Very minor)

15.1.1 Control Measure 1. Electro Static Precipitator(ESP) for effective control of fly ash 2. The existing stack height is 60 m which is as per norms, considering the particulate matter emission. There is very little sulfur in biogas (1.5% of total volume). hence the criteria for fixing stack height based on SO2 emission is applicable. The temperature encountered in the steam generator while burning high moisture bagasse and biomass is low enough to minimize the NO2 production. 3. Moreover, the tender specification for stem generation will stipulate over fire air system with staged combustion, which will also ensure reduction in Nitrogen oxide emission. Hence, no separate measures are taken to nitrogen oxide pollutants. 4. Fly ash collected from the dust hoppers and the air heater hopper and the ash collected from the furnace bottom hoppers can be used for two purposes. 1) The high potash content in the bagasse ash makes the ash good manure. 2) It could be sold to brick manufacturing units as per their requirements. 15.2 Water Environment blowAqueous discharge arises from a number of sources. Theses include cooling tower and gas side water washing waste solution. 15.2.1 Effluents and Sewage Disposal Effluent: Wastewater from power plant does not have any significant BOD/COD level. All wastewater will be neutralized prior to discharging .An effluent treatment plant for sugar mill is already in operation for the wastewater and provided with aerators, to meet the norms prescribed by MPCB. The total waste water generated from various units is estimated to be about 50-55m3/day. The existing ETP of sugar factory (1000m3capacity) is adequate to treat the effluents from cogeneration unit. Sewage: Existing sewage system, which is connected to common septic tank and it discharges as per the normal accepted local practices. (Refer Figure 4) 15.3 Solid Waste Generation and Management The solid waste will be mainly, the ash generated in the boiler, which collected by electrostatic precipitator. Total ash generation during crushing season will be 21.48 MT per day. It will be 6.091MT per day during off season. The boiler ash is usually rich in Potash;
Prefeasibility Report: Proposed 19MW Cogeneration Project Bhimashankar SSKL
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down, sluice water from the bottom ash handling system, boiler chemical cleaning solution,

hence it could be directly applied into agriculture field or sold to the brick manufacturers as per their demand. Figure 4 15.4 Thermal Pollution The hot effluents are the spray pond overflow. The hot water will of about 420C temperature and the quantity will be in minor quantity around 4-5 m3/day. This hot water will be cooled down to normal temperature in cooling pond and then recycled. Hence, there will be no thermal pollution of any surface water body around the project site. 15.5 Noise Pollution The principal source of noise generation is the boiler and DG. However the noise generated in the boiler section will be localized and will not dissipate because of the enclosures provided. Additionally, transportation and handling of bagasse also could raise the levels of noise. The noise generated will be only temporary and during the period of operations. Considering these facts, the project will have minor negative impact on noise environment.

Bagasse feeding 19MW Electricity

Boiler feed water

Boiler/Furnac e

Steam

Turbine

Boiler blow down from power plant

Fly Ash and bottom ash (21.48 MT/day Sluice water from the bottom ash handling system, boiler chemical cleaning water

Neutralized

Reuse for cooling tower make up OR Mixed in sugar ETP

Sent to ETP of sugar factory

Ash is rich in potash, mixed with press mud and sell to farmer as manure Or Brick manufacturers

Figure 4: Schematic of waste management

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15.6 Hazardous Waste Spent oil from the gear boxes and automobile batteries will be disposed to the authorized vender as per the Hazardous waste (Management and handling) Amended Rules, 2003. 15.7 Rain Water Harvesting Scheme Rain water is one of the purest sources of water for improving the water table in the sub soil and also the quality of water. Rain water which is otherwise wasted has to be recharged in to the soil. This can be adopted either using traditional way or by modern technologies. The various types of rain harvesting schemes are, diverting rain water collection through proper channels to the nearest pond or open wells and run off from built in areas mainly roofs are diverted to storm water drains, which is again taken to the nearest lake / pond. Building up of recharge structures should be in scientific way. Recharge structures of size approx. 2x2 m and 3m depth can be dug and filled with pebbles/rubbles of sizes more than 2. At the center of this structure 6 or 8 pipe is driven to the depth of approx.10m, with perforation of 1or2. Such structures can be built at pre-defined places (minimum 4 or 5 places, depending up on the site situation) so that maximum quantity of rain water within the premises of sugar factory can be collected. The water diverted through channels, from roof tops and other means can be collected in this recharge structure, which will definitely improve the water table as well as quality of the water and feed water to the plant during drought season. The industry has planned to implement the rainwater-harvesting project. It will appoint a special consultant, under his guidance the project will be designed and implemented. 15.8 Fire protection system Fire protection system shall be provided in accordance to the LPA regulations. It consists of a network of hydrants One electric driven pump, one diesel engine driven pump, one jockey pump. Portable fire extinguishers shall be provided at strategic locations Fire alarms All safety devices such as lightening arresters, trippers, etc 15.9 Rehabilitation and Resettlement Proposed Cogeneration power plant located in existing sugar factory premises; therefore there is no rehabilitation and resettlement problem.

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16.0. Cost Estimates Financial Projection 1 2 Net Sales to MSEDCL Total cash cost of production without depreciation and interest: Variable Cost Profit before depreciation and interest Less: (Rs. lac) Depreciation : 3904.37 Interest on term loan:1385.41 Interest on SDF loan : 418.18 Profit after depreciation and interest Add back depreciation Total Cash Accruals Estimated Environment management cost Sr. No. 1 2 3 4 Total Category Investment(Rupees lakhs) in 32995.8 9765.18

3 4

23230.63 5707.95

5 6

17522.67 3904.37 21427.04

Rs. 300.00lakhs

Bagasse and Ash 250.00 handling Fire protection FD/ID fans Greenbelt 20.00 25.00 05.00 300.00

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