PRE-FEASIBILITY REPORT

OF

INTEGRATED SUGAR 5000 TCD, COGEN 18 MW AND

NEW 30 KLPD DISTILLERY

AT

GAT NO.10, 11/1, 11/2, 15/3(PART), KAVATHE

MALKAPUR, TAL. SANGAMNER, DIST. AHMEDNAGAR,

MAHARASHTRA

BY

M/S. UTECH SUGAR LIMITED, 2055, ANANT

RESIDENCY, SADASHIV PETH, TILAK ROAD,

PUNE 411030
 INDEX
Page
Sr.No. Particular
No.
1.0 Executive Summary 1
2.0 Promoters Background and Profile 2
Need of project and its importance to the country and
2.1 2
region
2.1.1 Demand and Supply Gap 2
3.0 Brief Description of the Project 3
3.1 Land and Site Development 6
3.2 Employment Potential 6
3.3 Details of alternate site 7
4.0 Raw Material and its Suitability 7
4.1 Manufacturing Process 9
4.2 Production Details 12
4.3 Water Requirement 13
4.4 Power Requirement 13
4.5 Soil Classification 13
5.0 Waste Management 13
5.1 Air Pollution Management 15
5.2 Solid Waste Generation and Management 15
6.0 Rehabilitation and Resettlement 16
7.0 Cost of Project 16
 LIST OF FIGURES
Fig. No. Particular Page No.
3.1 Site Location 3
3.2 Google Image of Project 6
4.1 Sugar Manufacturing Process 9
4.2 Process Flow Diagram of Cogen Power Plant 10
4.3 Ethanol production process flow chart 12
5.1 ETP of sugar cogen complex 14
5.2 Spent Wash Treatment 15
8.0 Master Layout 17

LIST OF TABLES
Table No. Particular Page No.
3.1 Salient Features 3
3.2 Site Connectivity and environmental Sensitivity 5
4.1 Steam Balance 10
4.2 Ethanol Plant Details 11
4.3 Production Quantities 12
7.1 Budget Allocation 16
1.0 EXECUTIVE SUMMARY

M/s Utech Sugar Ltd. (USL) has set up 3800 TCD sugar and 14 MW cogen power plant at
Kavathe Malkapur, Tal. Sangamner, Dist. Ahmednagar.
USL has undertaken 1st trial crushing season in 2017-18 and crushed about 3.01 lakh MT
of cane and produced 3.32 lakh MT of sugar with an average recovery of 11.04% on cane.
USL has exported surplus power of 1.58 Million Units to MSEDCL.
USL is now planning to increase the cane crushing capacity from present 3800 TCD to
5000 TCD (net addition of 1200 TCD). The company also proposes to increase its cogen
power capacity from existing 14.0 MW to 18.0 MW for export of surplus power to grid
and set up New 30 KLPD Ethanol plant.
USL decided to go for the expansion for the above-mentioned capacities along with
ethanol plant considering the existing sugarcane availability and future potential for
sugarcane cultivation in the area of operation in the coming years due to excellent
rainfall.
The integrated project comprises of a sugar mill for the manufacture of high quality sugar,
thereby making available bagasse that is required for the cogen power plant operation
and molasses for producing ethanol. The area of operation for the sugar mill has good
rainfall of about 474 mm. This gives huge availability and potential for sustained
sugarcane supply to the sugar mill and thereby making sustained supply of bagasse and
molasses for cogen power and ethanol plant respectively.
USL already has 45.81 acres land in possession for the sugar factory and is sufficient for
the proposed expansion project. The water required is made available from the back
water of Mula Dam which has huge amount of water for supply of required water
throughout year for operation of the proposed project. The company has already lifted
water from Mula River and constructed water supply scheme of 7 Km.
The surplus power from cogen plant will be transmitted to 220 kV MSETCL Electrical
Sub-station through LILO arrangement at Darewadi about 5 Km from site.
The aggregate fund requirement for the integrated expansion project has been estimated
at Rs.8630.00 lakh.

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2.0 PROMOTER’S BACKGROUND & PROFILE
Mr. Ravindra Purshottam Birole, age 50 is the chief promoter and the Managing Director
of USL. He passed D.M.E in the year 1987. He started Utech Engineering Consultancy
Services and in 1991 Utech Engineering Works (I) Pvt. Ltd. was established to provide
services in the field of Design, Manufacturer, supply, erection & commissioning of Mill
House, Boiling House, Sugar refineries, Material handling on Turnkey basis.
Utech also entered into the field of supply of equipment for distillery manufacturing
rectified spirit and fuel grade ethanol manufacturing form rectified spirit.
Mr. Birole started with another company named “Rama Agro Foods Pvt. Ltd.” which
undertakes activities of procuring, processing and marketing the good quality
agricultural processed food products in domestic and International market to Customer
Satisfaction.
The suitability of the soil, increased irrigation facilities and previous experience of the
farmers in cane growing will be helpful in developing the required area for cane
plantation

2.1 NEED OF PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND REGION
India is one of the largest producers of sugarcane as well as sugar in the world. The
sugarcane is a cash crop for farmers. There are about 564 installed sugar factories in
India. Most of the sugar industries are located in rural areas providing employment to
rural masses. Sugar factories from Maharashtra are the backbone of rural economy.
These factories have contributed for the development of economy as well as
infrastructure in rural areas, generated ample of employment opportunity to local
people. The project proponent is one of a private sugar factory from the region of
Maharashtra. The cultivation of sugarcane is increasing every year in the command area
of the factory and it is anticipated to grow gradually for next few seasons. In addition, the
sugar factory is having plans to promote and support the cane development programme,
in its command area.

2.1.1 DEMANDS-SUPPLY GAP

The project is envisaged to meet the demand supply gap in both domestic and export
market demand is increasing day by day. The policy of Central Government is to increase
percentage of ethanol blending with petrol from the present 10% to 20% by the year

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2017. Therefore, it is important to all distilleries in the country to increase its ethanol
production to meet the demand & supply.
3.0 BRIEF DESCRIPTION OF THE PROJECT
The proposed scheme envisages for enhancing the sugarcane crushing capacity by
addition of 1200 TCD to its 3800 TCD sugar plant (total capacity of 5000 TCD)
considering the huge potential raw material available from the nearby villages.
This expansion program shall be met by addition of equipments in milling and boiling
house sections and necessary modifications in cogen power plant.
The company also proposes to set up new 30 KLPD ethanol plant along with captive cogen
power plant. The spent wash generated will be mixed with press mud and sold to the
farmers which will help in achieving zero discharge. The power requirements of the
distillery unit shall be met from the separate captive cogen power plant of 2 MW.

Table No. 3.1 Salient Features

Sr.no. Description Details

1 Name of the Company & M/s Utech Sugar Ltd. 2055, Sadashiv Peth,
Address Anant Residency, Tilak Road, Near Girija
Hotel, Pune-411030
2 Factory Site At Gat no 10,11/1,11/2, 15/3 (Part)
Kavathe Malkapur, Tal. Sangamner, Dist.
Ahmednagar, Maharashtra
3 Constitution & Type Limited Company
4 Products & By Products 1. Sugar
2. Cogeneration power
3. Ethanol
5 Existing Capacity of the Project Sugar Plant: 3800 TCD
Cogen Power Plant (14 MW: DEC type)
6 Proposed Expansion Capacities Proposed Sugar Plant: 1200 TCD
of the Project Total installed capacity: 5000 TCD
Proposed Cogen Power : 4 MW
Total installed capacity: 18 MW
New Ethanol Plant : 30 KLPD

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7 Commercial Operation Date- October, 2019
(C.O.D)
8 Working Days 160 days of sugar plant
160 days of cogen plant (Season) 66 days
of cogen plant (Off-Season) 270 days of
ethanol plant
9 Basic Raw material 8.00 lakh MT of Sugarcane
requirement per annum
10 Bagasse, Molasses & Press mud Bagasse - 220000 MT per Annum
Available from sugarcane Molasses – 34000 MT/Annum
crushing Press mud – 34000 MT / Annum
11 Steam requirement per hour 86.36 MT for sugar process, 8.00 MT for
Ethanol process
12 Power Generation per hour 17860 kW (10470 kW export) Generation
(Export)-Season @ Steam to Power Ratio of 5.60 kg/kWh)
13 Power Captive use per hour 5786 kW for sugar & colony, 800 kW for
ethanol, 1610 kW for Cogen Auxiliaries
14 Power Generation per hour 18000 kW (15950 kW)
(Export)-Off- season (Generation @ Steam to Power Ratio of
4.20 kg/kWh)
15 Power Captive use per hour 250 kW for sugar & colony, 800 kW for
ethanol, 1800 kW for Cogen Auxiliaries
16 Water requirement per day 500 m3/day for sugar
(Incremental capacity) 120 m3/day for cogen
150 m3/day for ethanol
17 Purchase cost of Sugarcane Rs 3000 per MT
18 Selling price of Sugar Rs 30,000 per MT
19 Power Tariff 6.27 Rs/kWh
20 Selling price of Ethanol Rs 40.85 per litre
21 Bio-Compost Selling Price Rs. 750/MT
22 Project Cost Rs.8630.00 lakh.

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Table No. 3.2 Site Connectivity and environmental Sensitivity

1 Nearest Village Kavthe Malkapur 310 meter

2 Nearest Town / City
3 State Highway
4 Nearest National Highway
5 Nearest Railway station
6 Nearest Airport
7 National Parks, Reserved
Forests (RF) / Protected
Forests (PF), Wildlife
Sanctuaries, Biosphere
Reserves, Tiger/ Elephant
Reserves, Wildlife
Corridors etc. within 10 km
Radius
8 River / Water Body
Sangamner 23.64 km
State Highway No. 49 is 50 Meter
NH 222 is 25.21 km
Rahuri railway station is 35.26 km
Shirdi airport is 33.67 km
Warwandi Reserve forest 3.5 km towards
north Direction, Chikaldhan Reserve forest
2.5 km towards East Direction and Reserve
forest 6.4 km towards South Direction.
Mula river is 5.02 km, towards South
Pravara river 14.93 km towards North

Fig. 3.1 Site Location

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 Fig. 3.2 Google Image of the Project

Project Implementation Schedule

The promoters have planned to complete the proposed integrated expansion by October
2019.

3.1 Land and site development

The sugar factory has already in possession land of about 45.81 acres and is sufficient for
the proposed expansion. Most of the land is plain with not much level difference and
strata of the land are quite hard. There is no need for site development work for sugar
and cogen project. However, site development expenses will be required for ethanol
plant.
The cost estimated for the site development component for ethanol plant is Rs 60 lakh.
This includes leveling of site, compound with fencing along with gate, internal roads,
culverts and drainage system for water and green belt development.

3.2 Employment Potential

The socio-economic benefits arising out of this project for the local population will
include creation of direct and indirect jobs and consequent rise in the income levels,
associated commercial and social infrastructure development in the areas, improved

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quality and availability of power due to grid benefits (in terms of deemed generation and
power factor improvement), better environment and higher returns for the cane crop due
to higher yield and cane price.
The captioned project will envisage additional employment for about 71 personnel of
various skills and categories mainly in ethanol plant. Apart from this, all associated
projects for efficiency improvement, fuel collection, storage, substitution, etc. will give
potential for employment in the rural masses, adjoining the USL location and improve
their economic status.

3.3 Details of the alternate sites

No alternate sites have been examined, as proposed project will be located in existing
factory
Premises.

4.0 Raw Material and its Sustainability

Sugar Plant
Ahmednagar district have good cane potential. Black soil available in the district is suited
for any kind of cultivation and the area is blessed with adequate irrigation facilities. This
district is famous for its rich agricultural production, as it is situated in near Godavari,
Mula & Pravara Rivers.
The total area under irrigation in the command area is about 103887 ha, mainly through
water available from the various projects on the Mula, Bhandardara & Pravara Projects.
Flood irrigation method is commonly used to irrigate the cane fields
The yields of the different varieties of the cane vary, depending on agro-climatic
conditions and water availability, from year to year. On an average the yield is expected
to be around 100 MT/Ha.
In order to get better sugar recovery the ideal ratio of Early, mid late and late maturing
varieties should be 40:40:20. In the proposed area of USL, this should be encouraged so
that farmers, who plant the late maturing varieties, are given necessary incentives.
It is always advisable for the promoters of the proposed sugar factory to have their own
cane fields. Also friends and supporters should also be made to grow cane. This will
induce confidence in other farmers for cane growing, as it will show that the management
can prove that cane growing is commercially more viable than other crops and that it will
fetch the farmers a good price.

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To encourage farmers and assure continuous and assured supply of cane from them, it is
recommended that USL should supply all inputs like seed cane, fertilisers etc. to farmers
through bank loans, by issuing suitable guarantees for recovery of bank loans.
It is recommended that USL should also sponsor cane development schemes on its own
and / or with the help the farmers in its command area, for availing financial assistance.
This will help USL in ensuring assured availability of cane, on a long-term basis.
USL has already appointed skilled & experienced personnel within Agronomy
Department.
With these sustained efforts, USL is sure of getting the required sugarcane for its
expanded capacity, by the time plant is commissioned.
Cogen Power Plant
Bagasse is the main source of fuel that will be available from the sugarcane crushing of
8.00 lakh MT after expansion. This is purely green source of fuel and will not pose any
pollution to environment.
The cogen plant will be operated for 160 days to cater steam to sugar process during
season. The sugar plant will generate about 2,20,000 MT of bagasse. Cogen power plant
after expanding it to 18 MW, will use around 160000 MT of bagasse during season &
balance bagasse after consuming around 9785 MT for the distillery/ethanol plant boiler
for its operation will be used for off-season cogen plant operation.

Ethanol Plant

Molasses generated from the sugar mill is the main source for ethanol plant that will be available
from the sugarcane crushing.

After expansion to 5000 TCD and 8 lakh MT of cane crushing, the molasses will be
available from sugar mill is around 34000 MT. Hence, the own raw material availability
for the ethanol plant will be assured and will not face any difficulty for its operation for
270 days.

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4.1 Manufacturing process

Fig. 4.1 Sugar Manufacturing Process

Cogen Power Plant

The Cogen power plant of 14.0 MW will be upgraded to 18.0 MW by carrying out
modifications / upgradation in boiler, turbine & Air-Cooled Condenser. The boiler
capacity will be increased to 100 TPH from existing 90 TPH. Two more cells will be added
in Air Cooled Condenser for cooling additional steam extracted from turbine.

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Table No. 4.1 Steam Balance

RAW WATER ETP

REGENER
WASHI COOLIN
-ATION DM
NG G
WATER PLANT TOWER

COOLED WATER
SOFT WATER

FUEL BOILER STEAM STEAM

TURBINE 18
AGROWAS 1 X 100 TPH
TE GEN
GSC

CONDENSED STEAM
USED IN OTHER UNIT

ESP FLY

ASH

USED FOR BIO

STACK
COMPOSTING / BRICK
MANUFACTURING

CLEAN FLUE GAS

Fig. 4.2 Process Flow Diagram of Cogen Power Plant

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Table No. 4.2 Ethanol Plant Details

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 Molasses from Sugar unit

Molasses Weighing

Dilution of molasses
Addition yeast
culture
Fermentation

Distillation

Ethanol/ Anhydrous alcohol

Fig. 4.3 Ethanol production process flow chart

4.2 Production details

Table 4.3 Production Quantities

Description Crushing Year 2017-18

Sugar Cane (MT) 3.01

Bagasse (MT) 77542

Molasses (MT) 12696

Sugar Produced (MT) 33187

Sugar Recovery (%) 11.04

Molasses (% on cane) 4.22

Bagasse (% on cane) 25.80

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4.3 Water Requirement:

The water required is made available from the back water of Mula Dam which has huge
amount of water for supply of required water throughout year for operation of the
proposed project. The company has already lifted water from Mula River and constructed
water supply scheme of 7 Km.

4.4 Power Requirement

The surplus power from cogen plant will be transmitted to 220 kV MSETCL Electrical
Sub-station through LILO arrangement at Darewadi about 5 Km from site.
Company has already entered Power Purchase Agreement with MSEDCL.

4.5 Soil Classification

District has got rich Black soil, which is most fertile, heavy and useful for sugarcane
farming. Reddish and Coarse Grey soils are available in the district in which soyabean,
Sugarcane, Maize, Tur, Jowar, Wheat and various type of pulses has been mainly
produced

5.0 Wastewater Management

Sewerage system
Domestic waste water generated will be sent to septic tank and soak pit.

Effluent Treatment System

The spent wash of a distillery process is a serious problem by way of threat to the
environment. USL is adopting 4 stage zero discharge effluent treatment process to take
care of spent wash around 90 KL/day.
Due care will be taken in design, implementation and operation of the captioned project
for satisfactory disposal and effective utilization of plant effluents, waste water and
colony waste water. Scientific treatment will be given to ensure that waste water from all
sources needs the norms stipulated by the Maharashtra Pollution Control Board and
CPCB. The effluent / spent wash will be concentrated in evaporators after bio-
methanation followed by bio-composting.

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In order to fulfill the Pollution Norms and to achieve zero Discharge and at the same time
to operate ethanol plant for the period 270 days per annum, the company has proposed
to go for Bio-Compost after bio-gas and evaporation. The bio-compost will be sold to
farmers.

SUGAR UNIT EFFLUENT EFFLUENT OF COGEN

BAR SCREEN CHAMBER

OIL SKIMMER

EQUALIZATION TANK

Sludge
PRE CLARIFIER

BIO-AERATION TANK- I

Sludge
CLARIFIER

BIO-AERATION TANK- II

Sludge Return Sludge

CLARIFIER
CLARIFIER

Sludge
FILTERATION UNIT
FILTERATION UNIT
SLUDGE DRYING BED F

TREATED EFFLUENT COLLECTION TANK

GARDENING GREEN BELT DEVELOPMENT –R&D FARM

Fig. 5.1 ETP of sugar cogen complex

Page 14 of 17
 Fig. 5.2 Spent Wash Treatment

5. 1 Air Pollution management

Main air polluting elements discharged from the proposed Cogen Project include dust
particulate from fly ash, Nitrogen oxides and Sulphur-di-oxide in the flue gas
The ESP is already installed to maintain the particulate matter emission below 100
mg/Nm3. flowing through flue gases.
Bagasse contains minor quantity of sulphur. Hence, the chimney height is calculated as
per the designated formula the problem of Sulphur can be tackled. The temperatures
encountered in the boiler while burning high moisture bagasse are lower enough to
minimize the nitrogen-oxides production. Moreover, the tender specification for boiler
will stipulate over fire air system with staged combustion, to ensure reduction in
nitrogen-oxide emission. Hence, no separate measures are taken to contain the nitrogen
oxide pollutants.

5.2 Solid Waste Generation and Management

In this project only bagasse as fuel is considered and no coal will be used. Total bagasse
utilized during season will be 160000 MT and 60000 MT bagasse will be used in off-
season and distillery boiler for 270 days. Ash generated will be 3200 MT & 1200 MT (total
4400 MT).Total ash is generated as bottom ash which is collected at the bottom of the
boiler below grate (travelling grate or dumping grate) and fly ash which fly along with
exhaust gases.

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ESP is already installed to arrest the fly ash and same will be collected and sent to ash
silo. ESP will be designed to maintain the particulate matter emission below 100
mg/Nm3.
The ash generated will be initially stored in silos and suitably supplied to the brick
manufactures through trucks and also can be used to mix in the farms. As the ash
generated from the bagasse has high potash value, same can be used to mix with press
mud and use for bio-compost production and then sell it to farmers as fertilizer.
The sludge from primary clarifies, settling tank and secondary clarifier will be sent to
sludge drying beds. Sludge will be dried in natural heat of sunlight. The dried cakes will
be
scrapped off periodically and can be utilized as manure.

6.0 Rehabilitation and Resettlement

The project site is fully in possession over the years. The present proposal is only for
expansion Thus, no Rehabilitation or Resettlement issues are any more involved with no
human settlement.
7.0 Cost of the project
Table 7.1 Budget Allocations
Sr. Description Sugar Cogen Ethanol Total in
no INR Lakhs
1 Land 0.00 0.00 0.00 0.00
2 Site Development 0.00 0.00 60.00 60.00
3 Civil Works 180.00 30.00 1020.00 1230.00
4 Plant and Machinery 1593.00 974.00 3315.80 5882.80
5 Misc. Fixed Assets 295.00 0.00 542.80 837.80
6 Prelim& Pre op. 149.00 75.00 259.22 483.22
Expenses
7 Contingencies 23.00 11.00 51.93 85.93
8 Working capital 0.00 0.00 50.25 50.25
margin
Total 2240.00 1090.00 5300.00 8630.00

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Fig. 8.0 Master Layout

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