INTRODUCTION

Ghodganga Sahakari Sakhar Karkhana Ltd ( Godhganga co-operative Sugar factory) is a Sugar manufacturing

factory of Pune. It is renamed after its founder as Raosaheb Dada Pawar Ghodganga Sahakari Sakhar Karkhana

Ltd (RPGSSKL). This project turned out to be the best achievement of Cooperative sugar factories and rural

development. This set up is being conducive as sugar production is prime business for region. The project

brings employment and social development. Sugarcane grower/farmers in the region are really encouraged by

the establishment. The project started with capital share of local farmers.
 Industrial Juice
sugarcane processing

Molasses Baggase
Pressmud

Power
Biocomposting Distillery generation
 120 KG Sugar

300 kg 1 MT CANE CRUSHED 40 KG

Baggase Pressmud

40 kg
Molasses
 CHEMICALS REQUIRED
FERMENTATION CHEMICALS DISTILLATION CHEMICALS
 Caustic soda
 Urea
 Sulphuric acid
 DAP
 Nitric acid
 Enzymes
 MgSO4 BIOGAS CHEMICALS
 TRO (Turkey red oil)
 Urea
 Common H2SO4
 DAP
 HCL
 PRODUCTION COST PER LIT. WASH TO ETHANOL

Capacity-30000 lit/day
SR. PARTICULARS QUANTITY COST PER B.L.
1. Steam cost 100 MT ( RS- 3.33/BL
1000/MT)
2. Chemical cost - 0.25/BL
3. Water -- 0.08/BL
4. ETP & Compost Bio-gas -- 0.50/BL
5. Salary & wages -- 0.62/BL
6. Repair & maintainance -- 0.25/BL
7. Office exp -- 0.02/BL
8. Excise exp -- 0.06/BL
9. Electricity -- 1.30/BL
10. Raw material( molasses) Mol. (RS-8500/MT) 32.69/BL
11. Total TOTAL COST= RS
39.10/BL
 Yeast propagation

Developed in laboratory from single cell yeast culture.

Propagated in a test tube of 10 ml and transfer to bigger flask of 500 ml

Transfer to a 5 litre flask containing sterilized molasses media and p H is adjusted to 4.5 to 5.0

Nutrients such as urea diammonium phosphate etc. are used

Fermentation

The media is poured in the pre-fermentor, it is transferred to the fermentor tank until the gravity falls to 20 from 50

The process of fermentation of molasses takes 24 to 30 hours

Average efficiency conversion of sugar from molasses to alcohol is 80-85%

A set of four fermenters is used in the process

 The wash coming out from the last fermentor goes to the yeast settling tank

Yeast cream is separated by gravity settling from the wash and returned to the first fermentor by acidic treatment to avoid
contamination
Sludge is settled at the bottom while top supernatant wash over flow to the wash charger

After fermentation the next stage in the manufacture of alcohol is to separate alcohol from
fermented wash and to concentrate it to 95 % alcohol called as rectified spirit
Wash column is divided into two sections i) Vaporizer ii) stripper

The wash is preheated by plate heat exchanger and outgoing stillage

About 90% of the ethanol is removed from the top through vapour pipe of the column

The concentration of the alcohol in the vapour is approx. 50% V/V.

After fermentation the next stage in the manufacture of alcohol is to separate alcohol from
fermented wash and to concentrate it to 95 % alcohol called as rectified spirit

For this purpose, the method of distillation is employed.

 Multi-pressure distillation system for production of Rectified Spirit consists of distillation columns namely
• Degasifying cum analyser column
• Rectification Column
• Fusel Oil Concentration column

For ENA mode

• Degasifying cum analyzer column
• Pre-rectifier column
• Extractive Distillation column
• Rectification Column
• Refining /simmering column
• Fusel Oil Concentration column

Top vapours of analyser column are sent to pre rectifier column. Rest of the fermented wash flows down and is taken as
spent wash from analyser column bottom
 Pre-rectifier bottom liquid is preheated with spent-less and fed to rectifier cum exhaust column.

Low boiling impurities are concentrated in the pre-rectifier column.

A top draw is taken out as impure alcohol from the top of the pre-rectifier column.

The bottom of pre-rectifier column is sent to rectifier feed tank.

Rectifier exhaust is operated under pressure and heats analyzer column through re-boiler

Alcohol is enriched towards the top and is drawn out as Rectified spirit.

Fusel oil build-up is avoided in the Rectifier column by withdrawing outside streams of fusel oil.

These are sent to fusel oil concentration column from where the fusel oil is sent to decanter for further separation. The
fusel oil wash water is recycled back to the column.

A top draw is taken out as impure alcohol from the top of fusel oil column & pre-rectifier column.
Justification of Project

• India Needs Electric power

• Consumes Bagasse, which otherwise is an environmental risk

Various Government Departments will also be examining Justification and propriety of this
venture and permissions will be obtained to establish this unit. Many are already in hand.
- Certificate of incorporation of the company
- Industrial Entrepreneurs Memorandum (IEM), New Delhi for Co-gen Power
- NOC from Local body
- Land Registration, NA permission and Industrial purpose
- Water drawl permission
- On site emergency plan approval
- Central Excise Registration
Inoculation of the culture
Co-Generation Power Plant
 Conclusions
• This industry will manufacture Power by using their own waste. Project will not disturb the present land use
because their total land majority is already under cultivation.
• Trees will be maintained and not razed down.
• No Rehabilitation is involved.
• There will be no problematic waste materials as all will be utilized.

• Water, power, Raw material, and market is assured and found available with ease.
• Full precautions will be taken for Pollution Control, Resource Conservation and Environmental Protection.
• This is cost effective and Sustainable Development