DETAILED PROJECT REPORT FOR MODERNIZATION...
Transcript of DETAILED PROJECT REPORT FOR MODERNIZATION...
DETAILED PROJECT REPORT FOR MODERNIZATION OF SUGAR PLANT TO INCREASE ENERGY EFFICIENCY AND
CAPACITY FROM 2500 TCD TO 4800 TCD.
FOR
M/S GM SUGAR & ENERGY LIMITED SANGUR-581148
DISRICT: HAVERI, KARNATAKA
PREPARED BY
NATIONAL SUGAR INSTITUTE GOVT. OF INDIA
MINISTRY OF CONSUMER AFFAIRS, FOOD AND PUBLIC DISTRIBUTION DEPT OF FOOD AND PUBLIC DISTRIBUTION
KALYANPUR, KANPUR-208017 UTTAR PRADESH, INDIA.
The 28th Day of FEBRUARY-2017
Phone: 0512-2570541-3 Fax: 0512-2570247
Email : [email protected], [email protected] Web site: nsi.gov.in
CONTENTS
Sl No Particulars Page No
1.0 Project in General 1
2.0 Introduction 3
3.0 Project Promoters 7
4.0 Executive Summery 9
5.0 Project Cost 11
6.0 Means of Finance 12
7.0 Site Information 13
8.0 Project justification / Purpose of the project 14
9.0 Resource Availability 16
9.1 Land
9.2 Material
9.3 Raw Water
9.4 Power
10.0 Process Description 18
11.0 Plant and Machinery 29
12.0 Working Parameters for the Major Equipments 49
13.0 Fuel Balance 53
14.0 Steam Balance 54
15.0 Power Balance 58
16.0 VAPOUR BLEEDING SYSTEM 60
17.0 HMBD for the Plant 62
18.0 MATERIAL BALANCE 63
19.0 Technical Feasibility 72
20.0 Organizational Set-up 73
21.0 Manpower Requirement 77
22.0 Project Implementation and Schedule 79
23.0 SWOT Analysis 80
24.0 Codes and Standards 83
25.0 Abbreviations 94
26.0 Financial Workings 100
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
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1. Project in General
Project in General
1 Name of the
Project
M/s.G.M.Sugar and Energy Ltd.
2 Location / Site SANGUR VILLAGE, HAVERI, KARNATAKA STATE
– 581 148
3 Other Details
Phone No +91-8375-284425
Fax No +91-8375-284426
Email ID [email protected]
Web Site -
Corporate Office 22, 2nd floor, Pamadi Towers,
Gandhi Nagar, Bangalore - 9
Phone No +91-80-22203171
Fax No +91-80-22203172
Email ID [email protected]
Web Site
4 The Project Expansion cum Modernization of Sugar Factory
from 2500 TCD to 4800 TCD
5 Raw Material Sugar Cane
6 Product Sugar
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
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Co-products Power
Byproducts Molasses and Press mud
7 Capacity
Sugar Plant
Existing (TCD)
2500
Proposed (
TCD)
4800
Cogeneration
Existing ( MW) 14 MW (Season)
Proposed (MW) 18 MW (Season)
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
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2.0 INTRODUCTION
On the request of M/S GM Sugars and Energy Ltd., National Sugar
Institute, Kanpur took the preparation of this Detailed Project Report on
Bagasse Based Cogeneration.
National Sugar Institute, Kanpur is
An institution dedicated to Research, Training and Advisory Services.
Associated with sugar & allied industry since 1936.
Providing trained man power, newer technologies and technical
assistance.
Trained over 4800 national and international candidates.
Over 75 years of contribution to the welfare of sugar & allied industries.
The main functions of the Institute are to:
Provide technical education and training in research in all branches of
sugar chemistry, sugar technology, sugar engineering and allied fields.
Provide technical education and training in research in all branches of
sugar chemistry, sugar technology, sugar engineering and allied fields.
Undertake research on -
Problems pertaining to sugar technology, sugar and sugarcane chemistry
and sugar engineering in general and those of sugar factories in particular
Utilization of byproducts of sugar industry.
Provides technical advice and assistance to sugar factories with a view to
improve their efficiency and to assist them in their day-to-day problems.
Assistance is also provided to Central and State Governments in matters
relating to sugar and allied industries.
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
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M/s.G.M.Sugar and Energy Ltd.
The Karnataka Sahakari Sakkare Karkhane Ltd., Sangur, Haveri District
was established during the year 1983, under the Co-Operative Sector. The
rated capacity of the factory was 1250 TCD where as it was capable of
crushing @1800 TCD. The Factory was operating under Co-op Sector. May
be for obvious reasons it was not working consistently & economically in
spite of availability of sugarcane in the area of operation resulting in
dwindling in the cane area and hence it was leased out to M/s.G.M.Sugar
and Energy Ltd.(GMSEL), for a period of 30 years on a long term lease basis.
The present management has already expanded its crushing capacity from
1800 to 2500 TCD with 16 MW Cogeneration and now intends to expand the
crushing capacity further and also proposes to enhance the cogeneration
facility.
The minimum economical size of a sugar plant is shifting towards 4800
TCD, considering mainly the cost of production and economical and self-
sufficient downstream industries. Now the Indian Sugar industries are
expanding their capacities and modernizing the plants. Further, they are also
setting up Co-generation project as an integral part to reduce the production
cost.
M/s. GMSEL is proposing to modernize its Sugar plant for increasing
efficiency and simultaneously enhance its Capacity facility at Sangur Village
and Haveri District in Karnataka State. At proposed modernization and
capacity enhancement to 4800 TCD, the plant has sufficient cane
availability, in its command area. Hence mill operations or co-gen plant
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
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operations do not face any risk of low cane, except in adverse agro climate
conditions. Karnataka State has been at the forefront of promoting
renewable energy in the state. Several sugar mills have already expanded
their capacity and built-up the grid connected Co-gen plants in the state and
many projects are in the pipe line.
Considering the demand and potential for the sugar plant, M/s.GMSEL,
have decided to modernize its Sugar plant and enhancing crushing capacity
from 2500 TCD to4800 TCD. and prolonged operation of cogeneration of
18MW Cogeneration plant. It is proposed to Commission the Sugar Plant
modernization by 2017-18 season.
Project at M/s.GMSEL will integrate sugar mill operations with enhanced
energy efficiency measures and optimum usage of Bagasse. Greater
urbanization and rising standard of living have sparked of a rising trend in
usage of Sugar. Industrial consumption for sugar is also growing rapidly
particularly from the food processing sector and sugar based bulk
consumers such as soft drink and ice cream manufacturers. Our
consumption of sugar is significantly higher and compares favorably with
developed countries such as USA and countries of the European Union. In
fact, in urban areas of comparatively affluent Indian states like Punjab,
Haryana etc., per capita consumption of sugar is substantially high than
even in developed countries.
During season, the Co-gen Plant will operate on generated bagasse only;
no other fuels are going to be used. All excess available power is exported
to the KPTCL grid. During off-season, surplus Bagasse from the season will
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
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be used in the Co-gen plant and power generated, less auxiliary
consumption will be pumped to the KPTCL grid. KPTCL has an attractive
policy on the guidelines of MNES, to buy power from sugar cogenerations.
Further, the integrated Sugar modernization project will improve the
overall profitability of M/s.GMSEL, through its additional revenue
generation. This will enable M/s.GMSEL to give higher dividend to
promoters & higher price per ton of cane to its cane growers. Also the
project will help to improve Karnataka State’s power situation.
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
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3.0 PROJECT PROMOTERS
M/S G. MALLIKARJUNAPPA AND SONS, was established during the year 1999
as a registered partnership Firm under the Partnership Act. 1932, with the
object to do the business of trading in Arecanut and to act as a commission
agent and other related activities at Bheemasamudra. The firm is one of the
concern under the flagship group of “GM GROUP” founded by Late Sri. G.
Mallikarjunappa, a great visionary and nationalist. Now, the firm is
managed by Sri. G.M. Prasanna Kumar, Sri. G.M. Lingaraju and Sri. G.S.
Anithkumar. The group companies are reputed in the field of Agro,
Software, Trading, Education, Health Care like Hospitals, etc. and other
infrastructure activities. The motto of the group “Serve with Quality”
reflects the paramount importance given by the group companies in
delivering quality products to their customers.
The following are the existing Group companies under the flagship of “GM
Group”:
G. Mallikarjunappa & Sons Agro Based Industry
GEM Laboratories Pvt. Ltd. Trading and Holding
Company
GM Software Pvt. Ltd. Software Industry
GEM International (P) Ltd. Hospitality & Realty
Industry
Sri Prasanna Traders Commerce
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
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Shrishyla Farms (P) Ltd. Trading
G.M. Institute of Technology Technical Education
G. M. H. Pu. College Education
Shrishyla Educational Trust Education
Turnover – GM Sugar & Energy Ltd., has been incorporated in the
month of November 2007, and started manufacturing operations on
18/2/2008, form the leased sugar mill at Sangur, Haveri District. The
turnover of the company for the year 2007-08 stands at over Rs. 8.00
Crores (unaudited figures)
No. of employees - 640
It may be worth mentioning that M/s. GMSEL group companies
are financially very sound and have very good support from Financial
Institutions / Banks. They can easily organize financial support to
establish a green field project of value around Rupees three hundred
crores with their own equity to the extent required.
Establishment of the Sugar Complex with Co-gen plant will contribute
much for the rural area development. After the establishment of the
factory, the standard of living of the entire area will improve and will
provide employment directly and indirectly for 2000 and 3000 persons.
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
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4.0 Executive Summary
1. Company Name : M/s.GMSEL.
2. Owner : Sri. G. M. Lingaraju
3. Corporate office address : 22, 2nd floor, Pamadi
Towers, Gandhi
Nagar, Bangalore - 9
4. Site Location : Sangur Village, Haveri
District,
Karnataka State.
5. Project Proposed : Modernization of sugar
plant and
Enhancing crushing capacity
2500 TCD to 4800 TCD
6. Nearest Railway station : Haveri (12 Kms)
7. Nearest Airport : Hubli (85Km)
8. Nearest Sea Port : Karwar (250 KM)
9. Expanding to Capacity (22 Hrs) : 4800 TCD
10.Cane Crushing Season days : 180
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
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11.Total Cane crushing per season : 9.0 lakh metric tone
12.Sugar Recovery : 10.5 % Cane
13.Sugar Losses : 1.8 % Cane
14.Sugar Production : 9.45 lakh quintals
15.Average bagasse % Cane : 30.88%
16.Process steam percentage on Cane : 32 %
17.Power unit per Tonne of Cane : 22 KWH
18.Cogeneration plant capacity : 18 MW
19.Cogeneration plant Operation days : 310 Days Average
20.Capacity of the Boiler (MCR) : 100 TPH
21.Boiler Outlet Steam Parameters : 86 Kg/Sq. Cm(g) , 515 + 5 Deg.C
22.Turbo-generator type and Capacity : DEC & 18 MW
23.Captive Consumption
During Cane Crushing season : 7348 KW
During Off-Season : 2070 KW
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
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24.Power Factor (lagging) : 0.9
25.Generation Voltage (KV) : 11
26.Ambient temperature for Electrical : 55
Equipment Design (Deg.C)
27.Parallel operation : at 110 KV
28.System Frequency : 50 ± 5%
29.The economical steam rate required : 80-100
at Percentage load (%)
30.The minimum continuous load at : 15
which the TG is expected to operate
as a percentage of the ratio load (%)
31.Commissioning by : Dec. 2017-18
32.Project cost and means of finance :
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
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PROJECT COST
S.No Particulars Rs.In.Lakhs
1 Civil Cost 400
2 P & M Cost 7030
3 Tax and Transportation 1050
4 Pre Operative Expenditure 150
5 Working Capital Margin 400
6 Interest During Construction 200
TOTAL PROJECT COST 9230
MEANS OF FINANCE
Particulars % Amount in lakh Rs 1. Promoters Contribution 10 923 2. SDF Loan 40 3692 3. TERM LOAN 50 4615 TOTAL 100 9230
33. Pay back period (Years) 5 Years
34. Average DSCR 5.53
35. IRR % 8.63
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
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5. Site Information
1. Rain fall : 752.8 mm
2. Ambient temperature : Max 38oC & Min 24oC
3. Relative humidity : 60 - 70
4. Plant Elevation above Sea level : 552.9 M
5. Wind Direction : North West to South East
6. Soil Bearing Capacity : 15 – 20 Tons
7. Atmospheric Conditions : Dusty
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
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6. Project justification / Purpose of the project
6.1. Last 5 Years performance of the Plant:
The plant at its rated capacity of 2500 TCD has given outstanding
performance since the year 2012-13
Season No of Season Days
Cane crushed
In Tons
Sugar Produced in quintals
Recovery %
Units of Elect. Exported
2016-
17
90 247907 205063 8.27 22092000
2015-
16
157 450671 428416 9.51 40929000
2014-
15
200 537360 513528 9.56 53005500
2013-
14
152 395252 381417 9.65 39922500
2012-
13
135 278054 266344 9.58 76225500
Considering the demand and potential for the sugar plant, M/s.GMSEL, have
decided to modernise its Sugar plant for increasing efficiency and to enhance
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 18 of 118
crushing capacity from 2500 TCD to 4800 TCD during season. The other
reasons for this expansion project are:
1. Increasing domestic consumption of sugar in India with a CAGR of about
3.5 to 4 as compared to 2.0 to 2.5 globally.
2. Increasing demand of eco friendly power in India leading to
subsidies of several types.
3. Availability of plenty of sugar cane in the vicinity of the factory
in its command area to meet out the raw material requirement
at expanded capacity.
4. More capacity will help to reduce the overhead cost of the plant
as a whole leading to reduced cost of production per unit of
finished product.
5. Attitude of Karnataka Govt. to promote nonconventional
energy.
6. Successful working of so many sugar plants in the state of
Karnataka at this rate of crush.
7. More profits from the units may help for the upliftment of the
society.
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
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7.0 Resource Availability
7.1 Land:
GMSEL is already having sufficient land (110 Acres) in its
acquisition with the existing plant which is sufficient for the
modernization of sugar plant and enhancing its capacity from 2500 TCD
to 4800TCD.
7.2 Raw Material
Sugar cane requirement for the expanded capacity of 4800 TCD for
180 days of season operation is 8.64 lakh metric tonnes. Assuming a
yield of 85 tonnes per hectare and a drawl percentage of 80 % the cane
area requirement for this capacity shall be 12706 hectares. As per
records available with the factory, within the cultivated area allocated
for the factory, the present cane area available is 14400 hectares which
is sufficient for supply of adequate cane for the expanded capacity.
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 20 of 118
7.3 Water
The process adopted for the plant includes recycling of water in
the plant hence there is no need for extra water for the extended
capacity. The existing tube wells will be sufficient for the make up water
required for the process. It is also kept in the mind that in future, a
water softening and recovery plant shall be installed for converting the
excess of 10 % of water from the process for drinking purpose.
7.4 Power
Since there is cogeneration of power to the tune of 18 MW during the
season, the captive requirement of power shall be taken from this
unit. During Off season, the power shall be taken from Karnataka state
grid through LILO connection.
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
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8. PROCESS DESCRIPTION
8.1 Sugar manufacturing process involves mainly seven stages as
mentioned below.
� Weighing of sugar cane
� Crushing of sugarcane
� Juice clarification (double sulphitation)
� Evaporation & boiling
� Crystallization
� Curing
� Grading and bagging
8.2 Cane weighment and unloading system
Harvested sugarcane is brought to the factory by trucks trailers and
bullock carts. The factory will purchase the sugar cane only at the
factory gate. The factory will be provided with suitable platform type
computerized electronic weigh bridges to weigh the cane.
Trucks and trailer canes will be bound by steel wire sling ropes in two
or three layers with the weight of each layer not exceeding five tones
for easy unloading at the factory onto the cane feeder tables by
means of hooks attached to the three motion crane in the cane yard.
The cane form bullocks carts will be manually dumped into the carrier,
after weighment in the appropriate computerized electronic weigh
bridges at the factory gate.
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
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There will be three (3) unloading cranes of 15.0 T, one 10 T and one 7
T capacities. Two feeder tables of 7 m x 6m sizes and one 7 m x 8 m
size with 3 deg. negative slope are provided for unloading the cane
from the cranes.
8.3 Cane preparatory system & milling system.
The cane carrier is a slat type conveyor of 2000 mm width dragged by
three strands of roller chains of sturdy construction moving on well-
aligned flat rails. The system will be driven by suitable variable speed
drive motors to adjust the speed between 3m/min. to 10m/min.
The main cane carrier will be of 45 m horizontal length and 20 m
inclined length of 12 Deg. And 7 deg. Slope with a loading depth of 1.5
m at the horizontal length. The preparatory systems of kicker,
chopper, leveler and fibrizer will be placed on the inclined position of
the carrier with the fibrizer at the end of the carrier.
A disc type kicker rotating at 60 rpm will level the cane mat in the cane
carrier before they reach the knives for cutting.
The chopper will have 56 knives directly coupled to a 560 kW slip ring
induction, motor of 600 rpm. The clearance between the chopper
knives and the cane carrier slat will be 300 mm. A flywheel will be
provided at the outer end of the drive shaft.
There will be no cutter/ leveler and the existing one will be removed.
An equalizer shaft of toothed design will even out the cut cane level
in the carrier after the chopper.
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
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A heavy duty swing hammer type fibrizer with 136 hammers and box
type anvils driven by 2 nos. 1000 kw HTmotor 750 rpm is considered
as a cane preparatory equipment. The fibrizer will be placed at the
head end of the carrier with a clearance of 20 mm between the
hammer tip and the carrier slat. The fibrizer provided will be capable
of giving a preparatory index of 87% to 90%. The preparatory systems
open up the juice cells in the sugarcane and make it suitable for the
mills to extract maximum juice from the cane. The fibrized cane will
be conveyed to the milling station through a RTCC and an inclined
belt conveyor at a height of minimum 3m above the mills. A suitably
sized magnetic separator will be installed to trap the ferrous foreign
materials in order to save the mills from damage.
8.4 Milling system
The prepared cane is crushed in a milling tandem. Present tandem
consisting of Four (4) mills of three rollers each of size 910 mm dia (36
inches) and 1700 mm (67inches) length with similar size grooved
under feeder roller. The mills are driven by ACVFD motors of 373 kw
connected to the rollers through planetary type speed reduction
gears to enable the rollers to run at 2 rpm to 4.5 rpm speed.
The following changes will be done in the milling tandem:
1. one zero mill of 1000 X 2000 mm with heavy duty GRPF with 5%
higher size UFR will be added.
2. All other mills' UFR to be made 100%.
3. GRPF with 105 % UFR for the last mill will be added.
4. All the donnalley chutes' height are to be increased to 3m.
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
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The mills will be operated at a speed of 2.5 rpm to 3.5 rpm of the
rollers to achieve an RME of plus 96%, imbibitions % fibre of 250%
and bagasse moisture of 49%. All the mills will have a provision for
adding the GRPF/TRPF system during further expansion. The
fibrized cane will be fed to the crusher through a Donnelly chute
and under feed rollers and the extracted juice is screened through
a rotary screen to remove fine bagasse particles. The bagasse after
extraction of juice wills pass through successive mills through rake
type elevators and Donnelly chutes to enable maximum extraction
of juice from the cane. Imbibition water at 80 Deg. C will be added
after the penultimate mill to extract the last traces of juice in the
bagasse. The juice extracted in the last mill will be recycled to the
penultimate mill and the juice extracted in the penultimate mil will
be recycled to the third mill and the juice from the third mill will be
recycled to the second mill and the juice from the first and second
mills are passed on to the process after screening the fine bagasse
particles in a rotary screen. The water addition and juice flow are
measured by mass flow meters. The entire operation form cane
unloading to milling will be automatically controlled.
8.5 Co-generation
The bagasse coming out of the Fourth mill will be used as fuel for
generation of steam, which in turn will be used, for production of
electrical power and supply of process steam. The existing boiler of 80
TPH capacity, to produce steam at 87 ata and 510 Deg, C steam and
has been installed along with a 18 MW double extraction cum
condensing turbo-generator. From this plant, appx 10,500 kW of
power will be exported to the KPTCL grid after meeting with the
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
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inhouse power requirement during cane crushing season. The surplus
bagasse after production of steam in boilers will be stored for use
during non-crushing season. The cogeneration of power besides
effecting energy conservation of process and reducing costs will also
help to improve the viability of the project by sale of power to the
KPTCL grid. The exhaust steam at 2.5 ata from the turbines after
production of power will be used for process in subsequent stages.
8.6 Juice clarification (double sulphitaion)
The juice extracted from the first two mills after screening through
Decanters and measured through mass flow meter is passed through
juice heaters heated by vapour from evaporator bodies where the
temperature is raised to about 70 Deg. C. The juice after
primary heating is treated with milk of lime and sulphur dioxide gas in
a simultaneous and continuous liming and sulphitation vessel to
achieve a pH level of about 7.4.
Suitable automatic continuous sulphur burners with dried
compressed air admission for pure sulphur-di-oxide production and
stable lime slacker with classifier for removal of grit from milk of lime
and milk of lime storage vessel with pumps will be provided for
producing milk of lime and sulphur-dioxide gas. Automatic juice
stabilization provision and auto pH control provisions will be installed
for precise and continuous control of clarification process to ensure
efficiency. The dissolved mineral salts in juice and the colloids will get
coagulated as precipitates thus eliminating the impurities present in
juice. The treated juice will be further heated to 102 Deg.C in another
set of juice heaters by bled vapors from evaporators and exhaust
steam, if required. This is to enable efficient coagulation of
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
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precipitates and faster settling. The heated juice at 102 Deg.c is sent
to two parallel continuous settlers of sedimentation vessel known as
clarifier of 30 ft dia each divided into four equal compartments
superimposed one over the other. Gravity separation of the juice and
the precipitates takes place in the clarifier in a counter current
direction resulting in sparkling clear juice at the top and thick
precipitate settling at bottom of the compartments. Clear juice and
thick precipitate known as muddy juice continuously flow out of the
top and bottom respectively of all the four compartments. While the
clear juice will be taken to the evaporators through clears juice
heater, after heating to about 110 deg, c. The muddy juice will be
taken to the rotary drum vacuum filter. The muddy juice is mixed with
fine bagacillo particles obtained by screening from the bagasse
elevator to give the required porosity to the muddy juice and the
entrapped juice is filtered through screens of the vacuum filter and
the collected juice is treated separately. The solid that sticks to the
external surface of the filter drum is also washed be hot water spray
and drips to minimize the loss of sugar through the cake. The cake
sticking to the external surface of the drum will be scrapped and taken
out through a belt conveyor which will be used for the production of
bio-compost manure, which is a valuable nutrient to the soil as it
returns all the mineral salts that were taken up from the soil by the
cane during its growth.
8.7 Evaporation, Boiling &Crystallization.
Clear juice at a pH level of 7 from the clarifier passes to the first effect
of the quintuple effect evaporator at about 110 Deg.c through a juice
heater of DCH type. There will be a quintuple effect evaporator set
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
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with all the bodies as falling film type. All the evaporator bodies will
be provided with efficient internal and external catch all designs,
automation controls with flow measurement of exhaust and
condensates. Suitable desuperheating system for exhaust steam and
pressure reducing desuperheating provision for live steam bleeding
into exhaust will also be provided. The targeted evaporation in the
quintuple effect will be about 80%. Flash evaporation recovery system
will be provided for the condensates from all the evaporator bodies.
Efficient single entry multi condensing system will be provided at the
vapour exit of the last body of the quintuple after the vapour line juice
heater for creation of vacuum in the system. All other normal
provisions like juice syphon interconnection, level indicators, and auto
flow & level controllers, juice, etc. will also be provided. The steam
consumption at the evaporator station will be 32.5% for a continuous
capacity crush of 4800 TCD and above.
The syrup coming out of the evaporator will be maintained between
55 Brix to 60. Brix. A continuous syrup sulphitation vessel of 180 HL
will be provided for sulphating the syrup fitted with an auto pH-
indicating device. The sulphited syrup will be stored in syrup storage
vessels in the pan station.
8.8 Vacuum pan boiling
The design of the critically important pan boiling operations will
follow the following concepts.
Total automation of the boiling operations.
Efficient low head calendria vacuum pans with auto control
and pneumatic discharge for a – boiling A, B& C boiling.
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and Energy Ltd Prepared by National Sugar Institute, Kanpur.
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Totally automatic continuous pans for B&C boiling.
Molasses conditioners for A.H. (A heavy), B.H. (B Heavy), C.L.
(C Light) A L (A Light) & melt.
Vacuum crystallizer for storage of B-grain, C-grain and A-
footing.
Open seed crystallizer for dry seed and B-seed.
Conventional water-cooled crystalisers for B massecuite storage
and air-cooled for A-massecuite. B-crystallizer will be of
continuous cooling type. C-crystallizer will be of mono vertical
type.
Slurry graining for B&C.
B-seed of dry seed for A-footing as per needs.
External save all for all pans.
Automated injection and spray system to reduce power
consumption at this station to 2.0 kW /t/hr at peak crushing rates.
Sugar ICUMSA value 50-60 as per choice.
Final molasses purity around 30%
Efficient pan design will be chosen from the point of view of heat
transfer, rate of boiling, circulation, etc.
Automated operations will ensure uniformity of boiling as well as
steady steam, power and other operational conditions.
The capacities of the plant and machinery in the pan station is
given at Plant & Machineries Clause 9.
8.9 Curing, Drying, Grading and sugar bagging.
This is a very important step in sugar manufacture where the crystal
sugar developed in vacuum pans and nurtured in crystallisers is
separated as white from the A-heavy and A-light molasses will be
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 29 of 118
pumped to the pan floor for boiling with B-massecuite and A-
massecuite respectively.
The dried sugar after cooling in the hopper will be elevated by bucket
elevators to a vibrating screen assembly above the sugar bins known
as sugar graders and sieved according to sizes.
The factory proposes to make 90% and above of S-size crystals as per
ISS. M-size crystals 10%. The colour will be 31 plus which is the highest
as per ISS. The dry sugar below ISS. And part of S-sugar will be
returned to pan station as dry seed for further boiling of high quality
A-sugar.
The sieved sugar will be stored in the sugar bins according to the
grades and bagged in 50kg /100kg packing in automatic sugar net
weighing machines kept at the bottom of the sugar bins, stitched be
machines and conveyed to the warehouse through belt conveyors
where they are stacked.
The B-massecuite and C-massecuites are cured in continuous
centrifugals and with a purity of not less than 98% is taken back to the
pan station as seed for A-massecuite some times and excess will be
completely melted. When dry seed process is followed, this will be
completely melted. The B-molasses will be taken to the pans for
further boiling of C-massecuite.
The C-sugar coming out of C-continuous centrifugal machines is
magmised in a mingler beneath the machines and cured once again in
a subsequent continuous centrifugal machine know as C-after worker.
The molasses coming out of the C-centrifugal machine is known as
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 30 of 118
final molasses, which is weighted and pumped to the storage tank
outside the factory building.
The sugar from the C-after worker centrifugal, which will be of about
98% purity, is completely melted and taken to the pan floor for boiling
with A- massescuites. The molasses from the C-after worker machine
known as C-light molasses will be pumped to pan floor for boiling once
again with the C-massecuite. Thus, the desegregation of the syrup will
be continuously carried out by constant recirculation. Every stage of
operation will be automated and integrated through DCS control
system to ensure best process controls, efficient operations and
quality outputs.
9.0 Plant & Machinery
Details of plant and machinery which includes the existing and the proposed details
with their tentative cost is tabulated as below:
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and Energy Ltd Prepared by National Sugar
Institute, Kanpur.
Page 31 of 118
Machinery and Equipments Existing Proposed Final After Expansion
A
for 2500 TCD B
for 4800TCD Expansion C
4800TCD
Approx Cost (Lakhs)
S.No
Name of Machinery/Equipment DETAILS DETAILS DETAILS ©
1. CANE WEIGHING SCALE a) WEIGHING SCALE 01 No.Weighing
Scale.Capacity 100 Ton. 1 Nos.Weighing Scale.Capacity 100 Ton.
10.00
02 Nos.Weighing Scale.Capacity 60 Ton each.
02 Nos.Weighing Scale.Capacity 60 Ton each.
02 Nos.Weighing Scale.Capacity 40 Ton.
2 x 40 T bridges which are not in use now are to be upgraded by digitizing both the bridges and shall be used for tare weighment.
02 Nos.Weighing Scale.Capacity 40 Ton. Each
2 MILLING PLANT A CANE HANDLING a) CANE UNLOADER
01 No. 03 motion EOT crane with sling arrangment, 7.5 ton SWL Capacity.Lift-10 mtrs
03 No. 03 motion EOT crane with hydraulic operated sling arrangment, 15 ton SWL Capacity.Lift-10 mtrs.
03 Nos. 03 motion EOT crane with sling arrangment, 15 ton SWL Capacity.Lift-10 mtrs
100.00 1 Nos. 03 motion EOT crane with sling arrangment, 10 ton SWL Capacity.Lift-10 mtrs
01 No. 03 motion EOT crane with sling arrangment, 7.5 ton SWL Capacity.Lift-10 mtrs
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and Energy Ltd Prepared by National Sugar
Institute, Kanpur.
Page 32 of 118
01 No. 03 motion EOT crane with sling arrangment, 5.5 ton SWL Capacity.Lift-10 mtrs
Discarded: 01 No. 03 motion EOT crane with sling arrangment, 5.5 ton SWL Capacity.Lift-10 mtrs
1 Nos. 03 motion EOT crane with sling arrangment, 10 ton SWL Capacity.Lift-10 mtrs
Bridge span - 22 mtrs Bridge span - 22 mtrs Bridge long travel speed - 20 mtrs/min., Trolley cross travel speed- 20 mtrs/min.Hoisting speed-15 mtrs/min.
Bridge long travel speed - 20 mtrs/min., Trolley cross travel speed- 20 mtrs/min.Hoisting speed-15 mtrs/min.
Since the carrier length is to be increased the length of the bridge is also to be increased by same length.
b) FEEDER TABLE
2 Nos. Length - 7.0 mtrs, width-6 mtrs, loading capacity-15 Ton, chain pitch-152.4 mm, drive-11 kw with VFD, final rpm-1-1440 rpm.
1 No. Length - 8.0 mtrs, width-7 mtrs, loading capacity-15 Ton, chain pitch-152.4 mm, drive-15 kw with VFD, final rpm-1-1440 rpm.
2 Nos. Length - 7.0 mtrs, width-6 mtrs, loading capacity-15 Ton, chain pitch-152.4 mm, drive-11 kw with VFD, final rpm-1-1440 rpm. 1 No. Length - 8.0 mtrs, width-7 mtrs, loading capacity-15 Ton, chain pitch-152.4 mm, drive-15 kw with VFD, final rpm-1-1440 rpm.
20.00
c) CANE CARRIER Feed cane carrier-width-1700 m.m, total length-51 mtrs, No of slats - 630, chain pitch-152.4 mm
Feed cane carrier-width-2000 m.m, total length-65 mtrs, chain pitch-200 mm
Feed cane carrier-width-2000 m.m, total length-65 mtrs, chain pitch-200 mm
650.00
Drive-Planatery gear make Kavitsu with 55 kw VFD driven motor, final rpm-0-4.5 rpm
Drive-Planatery gear with 110 kw VFD driven motor, final rpm-0-4.5 rpm
Drive-Planatery gear with 110 kw VFD driven motor, final rpm-0-4.5 rpm
B CANE PREPARATION a) CANE CHOPPER No. of knives-32,Swing
Dia-1600 mm, clearance from cane carrier-700 mm, Bearing-23136cc3K,
shall be replaced by a kicker with 50 hp motor with suitable spikes A kicker with 50 hp motor with suitable spikes
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and Energy Ltd Prepared by National Sugar
Institute, Kanpur.
Page 33 of 118
Gear Box(Kirloskar)- power-110 Kw, final rpm-250 rpm
b) CANE LEVELLER No. of knives-42,Swing Dia-1450 mm, clearance from cane carrier-200 mm, Bearing-22234ckw
No. of knives-56,Swing Dia-1800 mm, No. of knives-56,Swing Dia-1800 mm,
Motor-03 Phase A.C Induction Motor 02 No X 180 Kw, rpm-560
Motor-03 Phase A.C Induction Motor 02 No X 560 Kw, rpm-560
Motor-HT, 03 Phase A.C Induction Motor 02 No X 560 Kw, rpm-560
c) CANE FIBRIZOR No. of hammers-96,Swing Dia-2130 mm, hammer tip size-80x80 mm, Bearing-23152cckw
No. of hammers-136,Swing Dia-2200 mm, hammer weight 22 kg with a suitable pusher
No. of hammers-136,Swing Dia-2200 mm, hammer weight 22 kg with a suitable pusher
Motor-HT motor Motor 02 No X 560 Kw, rpm-740
Motor-HT motor Motor 02 No X 1000 Kw, rpm-750
Motor-HT motor Motor 02 No X 1000 Kw, rpm-750
d) RTCC Carrier width-1460mm, length-22 mtrs, inclination-33 deg., chain pitch- 230 mm.
2000 mm width, pitch 250 mm, Length and slope as per the space availability
2000 mm width, pitch 250 mm, Length and slope as per the space availability
Drive- Planatery gear make make Kavitsu with 45 kw motor, Final rpm - 0-9.93 rpm.
Drive-45 kw motor with Planatery gear and vfd, Final rpm - 0-10 rpm.
Drive-45 kw motor with Planatery gear and vfd, Final rpm - 0-10 rpm.
belt conveyor 2000mm width, with provision of magnetic separator and equaliser Drive hp 25 kw. Slope and length as per the space availability.
2000mm width, with provision of magnetic separator and equaliser Drive hp 25 kw. Slope and length as per the space availability.
C MILLS a) MILLS
04 Mills with 90 % UFR and Donnelley Chute in all of them. Size: 910 X 1700 mm for all
1. one zero mill of 1000 X 2000 mm with heavy duty GRPF with 5% higher size UFR. 2. All other mills' UFR to be made 100%. 3. GRPF with 105 % UFR for the last mill 4. All the donnalley chutes' height are to be increased to 3m
1. one zero mill of 1000 X 2000 mm with heavy duty GRPF with 5% higher size UFR. 2. All other mills' UFR to be made 100%. 3. GRPF with 105 % UFR for the last mill 4. All the donnalley chutes' height are to be increased to 3m
650.00
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and Energy Ltd Prepared by National Sugar
Institute, Kanpur.
Page 34 of 118
b) INTER RAKE CARRIER 03 Nos, length-8 mtrs, Effective width-1910 mm inclination-36 deg. Chain pitch-230 mm
existing RTCC will be modified as 1st IRC existing RTCC will be modified as 1st IRC
Drive- Planatery gear with 22kw motor
c) DRIVE FOR MILLS AC VFD Motor ABB-CE, 373 kw, RPM-1000, Planatery gear box-ratio - 200:1, Premium Transmission Make.
1. AC VFD Motor, 250 kW, RPM-1000, Planatery gear box-ratio - 200:1, For 1st, 2nd and the 3rd mills' feed and under feed roller. 2. AC VFD Motor, 373 kW, RPM-1000, Planatery gear box-ratio - 200:1, For GRPF of Zero mill. 3. AC VFD Motor, 500 kW, RPM-1000, Planatery gear box-ratio - 200:1, For Zero mill. 4. AC VFD Motor, 250 kW, RPM-1000, Planatery gear box-ratio - 200:1, For GRPF of last mill. 3. AC VFD Motor, 500 kW, RPM-1000, Planatery gear box-ratio - 200:1, For last mill.
1. AC VFD Motor, 250 kW, RPM-1000, Planatery gear box-ratio - 200:1, For 1st, 2nd and the 3rd mills' feed and under feed roller. 2. AC VFD Motor, 373 kW, RPM-1000, Planatery gear box-ratio - 200:1, For GRPF of Zero mill. 3. AC VFD Motor, 500 kW, RPM-1000, Planatery gear box-ratio - 200:1, For Zero mill. 4. AC VFD Motor, 250 kW, RPM-1000, Planatery gear box-ratio - 200:1, For GRPF of last mill. 3. AC VFD Motor, 500 kW, RPM-1000, Planatery gear box-ratio - 200:1, For last mill.
300.00
MILL Drive Coupling Multi- mis alignment polyster sling-Saisidha Make.
Plannetary Gear Box suitable for the drives as mentioned aove
Plannetary Gear Box suitable for the drives as mentioned aove
d) ROTARY SCREEN 01 No-Cap-190 M3/Hr, Size-18x24, Aparture- 0.5 mm, Make- Suviron
01 No-Cap-190 M3/Hr, Size-18x24, Aparture- 0.5 mm, 02 No-Cap-190 M3/Hr, Size-18x24, Aparture-
0.5 mm, 100.00 e) IMBIBITION 01 No. Electro Magnetic
Flow Meter 0-75 M3/hr 01 No. Electro Magnetic Flow Meter 0-150 M3/hr in replacement to the existing one
01 No. Electro Magnetic Flow Meter 0-150 M3/hr in replacement to the existing one
f) MILL HOUSE CRANE 01 set EOT crane, 25 Ton SWL cap with independent Trolly, Building span 22 mtrs make- KBE
One additional EOT crane of 40 T and suitable upliftment of the roof top is required for the extended portion if the mill house building for Zero mill and fibrizer.
01 set EOT crane, 25 Ton SWL cap with independent Trolly, Building span 22 mtrs make- KBE
50.00
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and Energy Ltd Prepared by National Sugar
Institute, Kanpur.
Page 35 of 118
One additional EOT crane of 40 T and suitable upliftment of the roof top is required for the extended portion if the mill house building for Zero mill and fibrizer.
g) MILL ROLLER LATHE Capacity suitable for 42" x 84" mill roller. No Change
h) MILL PUMPS Capacity (M3/Hr) Head (Mtr) Size Make Motor(KW) Qty
Capacity (M3/Hr) Head (Mtr) Size Make Motor(KW) Qty
50.00
i) Zero Mill (1W+ 1SB) 250 15 150/320 PSP 18.5 1 250 15
150/320 18.5 1
250 20 6 nk 125 Kirloskar 18.5 1 250 20 6
nk 125 18.5 1 ii) 1st Mill (1W+ 1SB) 150 15
150/320 PSP 18.5 1
250 15 150/320 PSP 18.5 1
250 15 150/320 18.5 1
150 20 6 nk 125 Kirloskar 18.5 1
250 20 6 nk 125 Kirloskar 18.5 1
250 20 6 nk 125 18.5 1
iii) 2nd, 3rd & 4th Mill (1W + 1SB)
60 15 100/320 PSP 11 4
150 15 100/320 PSP 11 4
150 15 100/320 11 4
iv) Imbibition Water Pump (1W + 1SB)
60 50 65/430 PSP 22 2
150 50 65/430 PSP 22 2
150 50 65/430 22 2
v) Rotary wash pump (1W + 1SB)
25 60 40/200 KSB 7.5 2
25 60 40/200 KSB 7.5 2
25 60 40/200 7.5 4
3 CLARIFICATION PLANT
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and Energy Ltd Prepared by National Sugar
Institute, Kanpur.
Page 36 of 118
a) MEASURMENT OF RAW JUICE
Electronic mass flow meter cap-0-200 MT/hr. Electronic mass flow meter cap-0-300 MT/hr Electronic mass flow meter cap-0-300 MT/hr 10.00
Raw Juice Pump 01 no. PSP make pump Cap-150 M3/Hr, Head 60 mtr, Motor-45 KW
02 no. PSP make pump Cap-300 M3/Hr, Head 60 mtr, Motor-60 KW
02 no. PSP make pump Cap-300 M3/Hr, Head 60 mtr, Motor-60 KW 10.00
01 no. Gita make pump Cap-200 M3/Hr, Head 80 mtr, Motor-90 KW
b) JUICE HEATERS J.H. Nos H.S.A. No. of passes Tube/pas No. of tube Tube length Id/Od mm
DCH for all the type of juice heating suitably sized for different stages
DCH for all the type of juice heating suitably sized for different stages
125.00
VLJH. 01 200M2 22 17 374 4000mm 42/45 VLJH. 01 240M2 20 23 460 4000mm 42/45 R,J,H. 03 200M2 22 17 374 4000mm 42/45 (2 nos vapour and 1 no. cond heater) S.J.H 03 200M2 22 17 374 4000mm 42/45 Cl.J.H. 01 200M2 22 17 374 4000mm 42/45 DCH 02 nos for S.J. Heating
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and Energy Ltd Prepared by National Sugar
Institute, Kanpur.
Page 37 of 118
c) JUICE SULPHITOR 01 NOs-Con. J.S having Dia 3.0 Meter & working Height 2.1 mtrs. Drive- Planatery drive with 5.5 HP,1480 rpm, Sulphited Juice Receiving Tank-18 M3.
1 X 300 HL Continuous Juice Sulphitor with suitable juice receiving tank
1 X 300 HL Continuous Juice Sulphitor with suitable juice receiving tank
Cap-150 M3/Hr, Head 60 mtr, Motor-45 KW
02 nos. pump Cap-300 M3/Hr, Head 60 mtr, Motor-60 KW
02 nos. pump Cap-300 M3/Hr, Head 60 mtr, Motor-60 KW
01 no. Gita make pump Cap-200 M3/Hr, Head 80 mtr, Motor-90 KW
d) SULPHUR GAS PLANT
25.00
i) No.of Sulphur Furnaces & Capacity
02 Nos,Film Type Furnace Cap-150 Kg/Hr 01No,Film Type Furnace Cap-150 Kg/Hr
02 Nos,Film Type Furnace Cap-150 Kg/Hr 01 Nos,Film Type Furnace Cap-150 Kg/Hr
02 Nos,Batch Type Furnace Cap-0.6 m2 tray area Port type.
ii) AIR BLOWER 01 No. Ingersol make size 9x7, RPM-650 01 No. Ingersol make size 9x7, RPM-650
01 No. Ingersol make size 9.5x5, RPM-675 01 No. Ingersol make size 9.5x5, RPM-675
01 No. Ingersol make size 1/285x1/2x4, RPM-560
01 No. Ingersol make size 1/285x1/2x4, RPM-560
e) MILK OF LIME PLANT
i) LIME SLACKER
01 No, Rotary Type size- 2.0x4.0 mtr, fitted with Rake Type Classifier
01 No, Rotary Type size- 2.0x4.0 mtr, fitted with Rake Type Classifier
20.00 ii) M.O.L STORAGE TANKS
02 Nos,Dia-2.8 Mtrs,Height 2.1 Mtrs 1 x 400 hl
02 Nos,Dia-2.8 Mtrs,Height 2.1 Mtrs 1 x 400 hl
iii) M.O.L PUMPS 02 Nos,Cap-6 M3/Hr, Head-20 Mtrs 1 x 15 cub m
02 Nos,Cap-6 M3/Hr, Head-20 Mtrs 02 Nos,Cap- 15M3/Hr, Head-20 Mtrs
f) R.V.F
02 No, R.V.Filter, Size-8' X 16',UHEC make with all assessories 1 set of Decanter suitable for 4800 TCD 1 set of Decanter suitable for 4800 TCD
600.00
50.00 Sulp. Juice Pump 01 no. PSP make pump
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and Energy Ltd Prepared by National Sugar
Institute, Kanpur.
Page 38 of 118
g) CLARIFIER 01 No, Make- 444 type Make- KBE Dia- 30' 01 No, Make- 444 type Make- KBE Dia- 30' 01 No, Make- 444 type Make- KBE Dia- 30' 150.00
B EVAPORATOR SECTION
i)
EVAPORATOR 1st SET Evaporator Body No. Type Heating Surface (m2) No. of tubes Tube length Tube ID/OD
Quintuple FFE set suitable for 4800 TCD with stand by arrangement for all the bodies
Quintuple FFE set suitable for 4800 TCD with stand by arrangement for all the bodies
1st body Semikestner 1400 4300 4100 mm 35/38
2nd body Robert 1600 4840 2500 mm 42/45
3rd body Robert 750 2820 2000 mm 42/45
4th body Robert 560 2122 2000 mm 42/45
5th body Robert 440 1661 2000 mm 42/45
ii) Evaporatoe Spare Bodies Spare for 1st & 2nd body
Spare for 4th body
spare body Robert 440 1658 2000 mm 42/45
800.00
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and Energy Ltd Prepared by National Sugar
Institute, Kanpur.
Page 39 of 118
Spare for 5th body
spare body Robert 440 1658 2000 mm 42/45
iii) CLEAR JUICE BUFFER TANK
01 No,Cylidrical Tank, Cap-100HL, 01 No,Cylidrical Tank, Cap-500HL 01 No,Cylidrical Tank, Cap-500HL, 10.00
C SYRUP TREATMENT PLANT
a) SYRUP SULPHITOR
02 Nos, Cap-6 M3, Dia-2.5 Mtr,Working Height-1.5 Mtr 40.00
b) Unsulphired & sulphited Syrup pumps
04 nos, cap-80m3/hr, head-30mtr, motor-18kw
2 nos, cap-150m3/hr, head-30mtr, motor-40 kw
2 nos, cap-150m3/hr, head-30mtr, motor-40 kw
4 PAN SECTION
a) SYRUP & MOL STORAGE TANK
11 Nos ractangular Type Tanks for Syrup & Molasses Storage, Cap-200 HL each
11 Nos ractangular Type Tanks for Syrup & Molasses Storage, Cap-400 HL each
11 Nos ractangular Type Tanks for Syrup & Molasses Storage, Cap-400 HL each
500.00
Syrup-03 NoS,Melt-01 No,A.L-01 No,A.H-02 Nos,B.H-02 Nos,Cl-02 Nos
b) MOLASSES CONDITIONER
On line molasses conditioners 3 Nos No change No Change AH- 25 Ton/Hr, BH-15 Ton/Hr, CL- 10 Ton/Hr
c) SUGAR MELTER 01 No, Cap-25T/Hr No change No change d) RORI MELTER 01 No, Cap-10T/Hr No change No change e) VACCUM PANS f) State number of Pans,Cap
of each Pan 08 Nos Total Pans,06 Nos Batch Pans and 2 nos Cont. Pans
08 Nos Total Pans,06 Nos Batch Pans and 2 nos Cont. Pans
Pan No. Cap.(ton) H.S.A. m2 Tube length(mm) Id/Od mm Use for
Pan No. Cap.(ton) H.S.A. m2 Tube length(mm) Id/Od mm Use for
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and Energy Ltd Prepared by National Sugar
Institute, Kanpur.
Page 40 of 118
02 100 420 750 98/102 A- boiling
02 100 420 750 98/102 A- boiling
02 60 280 900 98/102 A- graining
02 60 280 900 98/102 A- graining
03 40 200 900 98/102 A-boiling
03 40 200 900 98/102 A-boiling
04 40 200 900 98/102 A-boiling
04 40 200 900 98/102 A-boiling
05 45 231 900 98/102 B-graining
05 45 231 900 98/102 B-graining
06 45 231 900 98/102 C-graining
06 45 231 900 98/102 C-graining
07 20ton/hr 900&1200 98/102 B-boiling Existing 15 TPH will be used for B
07 20ton/hr 900&1200 98/102 B-boiling
Existing 15 TPH will be used for B
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and Energy Ltd Prepared by National Sugar
Institute, Kanpur.
Page 41 of 118
08 15ton/hr 900&1200 98/102 C-boiling 1 x 20 TPH new for C
1 x 20 TPH new for C
g) CONDENSERS
100.00 i)
Pan No-1 Pan No-2 Pan No-3 Pan No-4 Pan No-5 Pan No6 CVP for B M/C CVP for C M/C Evaporator 1&2
As per requirement of Pans with complete automation
As per requirement of Pans with complete automation
Condensor Dia.(mm)
1350 1100 1100 1100 1100 1100 1100 1100 1050 x 2 nos.
ii)
INJECTION WATER PUMPS
02 Nos Injection Pumps (For Pan), Cap-2000 M3/Hr,Head-20 Mtr, VFD Drive-132 Kw 1 x 4000 cub m per hr
02 Nos Injection Pumps (For Pan), Cap-2000 M3/Hr,Head-20 Mtr, VFD Drive-132 Kw 1 x 4000 cub m per hr to be added
100.00
02 Nos Injection Pumps (For Pan), Cap-700 M3/Hr,Head-22 Mtr, Drive-60 Kw
02 Nos Injection Pumps (For Evaporator), Cap-450 M3/Hr,Head-20 Mtr, Drive-45 Kw
iii) SPRAY POND Mist Creating Spray pond having 360 Nos. Nozzles.
Mist Creating Spray pond having 500 Nos. additional Nozzles.
Mist Creating Spray pond having 360 Nos. Nozzles. Mist Creating Spray pond having 360 Nos. additional Nozzles.
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and Energy Ltd Prepared by National Sugar
Institute, Kanpur.
Page 42 of 118
iv) SPRAY PUMPS
02 Nos Pumps Cap-2500 M3/Hr, Head-15 mtr, Drive-150kw. 1 x 4000 cub m per hr
02 Nos Pumps Cap-2500 M3/Hr, Head-15 mtr, Drive-150kw. 1 x 4000 cub m per hr additional
h) CRYSTALLIZERS
150.00
10 Nos. air cooled, 02 Nos receiving, 02 nos mono vertical, 01 nos seed and 02 nos vavuum crystallizers
Apart from the existing crystallizers, the following are to be added
Type Nos Capacity Application 2X120 T for new A pans 2X120 T for new A pans
Horizontal air cooled 02 65 MT A- Massecuite
Existing Horizontal air cooled 01 45 MT A- Massecuite shall be used for new C cont receiving
Existing Horizontal air cooled 01 45 MT A- Massecuite shall be used for new C cont receiving
Horizontal air cooled 04 45 MT A- Massecuite
Horizontal air cooled 02 45 MT C- Grain
Horizontal air cooled 02 45 MT B- Massecuite
Horizontal air cooled 02 45 MT B&C cont pan receiver
Mono Vertical water cooled 01 200 MT B- Massecuite
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and Energy Ltd Prepared by National Sugar
Institute, Kanpur.
Page 43 of 118
Mono Vertical water cooled 01 300 MT C- Massecuite
Mono Vertical water cooled 01 300 MT C- Massecuite
Mono Vertical water cooled 01 300 MT C- Massecuite
Horizontal 01 20 MT Dry Seed
Horizontal Vaccum 01 70 MT A Grain
Horizontal Vaccum 01 70 MT A Grain
Horizontal Vaccum 02 30 MT A&B- Grain
Existing Horizontal Vaccum 01 30 MT shall be used for C grain
Existing Horizontal Vaccum 01 30 MT shall be used for C grain
5 CENTRIFUGAL SECTION A a) CENTRIFUGAL MACHINE
i) BATCH C/F MACHINE
03 Nos KB-1250, Cap-1.25 Ton/Charge Machines for A-M/C,, Make- Thyssen Krupp
01 No. KB-2250, Cap-2.25 Ton/Charge Flat bottom C/F
01 No. KB-2250, Cap-2.25 Ton/Charge Flat bottom C/F additional
100.00
ii) CONTINUOUS C/F MACHINE
7 Nos - Continuous Machines.
200.00 02 Nos. KC-1500 & 01 no. SC-1100 Continuous Machines For CFW M/C, , 02 No NK-1100 for CAW
04 No KC-1500 For B M/C new and discard SC 1100 02 No KC-1500 For CFW M/C new
04 No KC-1500 For B M/C new and discard SC 1100 additional 02 No KC-1500 For CFW M/C new additional
b) MAGMA MIXTURE 02 Nos, Semi Open Double Stirrer Drive
c) MOLASSES RUN OF TANKS 06 Nos, Cap-5 M3
d) AIR COMPRESSOR
02 Nos, Size-EH-200, Cap-250 m3/Hr, RPM- 375, KW-30, Make-Kirloskar.
B SUGAR DRIER
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and Energy Ltd Prepared by National Sugar
Institute, Kanpur.
Page 44 of 118
a) HOPPER
Grass Hopper - before FBD,Width- 1.5 Mtr,Length-11.5 Mtr
Grass Hopper - before FBD,Width- 2.0 Mtr,Length-11.5 Mtr
Grass Hopper - before FBD,Width- 2.0 Mtr,Length-11.5 Mtr 20.00
Grass Hopper -after FBD,Width-1.2 Mtr,Length-12 Mtr
Grass Hopper -after FBD,Width-2.0 Mtr,Length-12 Mtr
Grass Hopper -after FBD,Width-2.0 Mtr,Length-12 Mtr
b) FLUIDISED BED DRIER (FBD) Cap-25 T/H, Cap-40 T/H, Cap-40 T/H, 80.00
c) SUGAR ELEVATOR
02 Nos, Cap-25 T/Hr each ,Type- Vertical rubber belt type
02 Nos Cap-40 T/Hr each,Type- Vertical rubber belt type
02 Nos Cap-40 T/Hr each,Type- Vertical rubber belt type
20.00
d) SUGAR GRADER
01 Nos, Cap-25 T/Hr, Make I.C. Type-Vibrating Sizer with 6 decks.
01 Nos, Cap-40 T/Hr, Type-Vibrating Sizer with 6 decks.
01 Nos, Cap-40 T/Hr, Type-Vibrating Sizer with 6 decks
40.00
e) SUGAR DISTRIBUTION BELTS
01 no. for Dry Seed-600x10000 mm
6 SUGAR BAGGING & HANDLING
a) SUGAR BINS 03 Nos,Cylendrical & Conical Type.
01 No-For M-Grade, Cap-100 T
01 Nos-For S1-Grade,Cap-150 T
01 No-For S2-Grade, Cap-150 T
b)
SUGAR WEIGHING & BAG FILLING
03 Nos Automatic weighing & bagging machines, Weighing Capacity-50 kg & 100 Kg, Bagging Capacity-300 Bags/Hr, Make- Prayas.
SYSTEM
c) SUGAR BAG HANDLING SYSTEM mannual
Under ground belt conveyor system from Drier House to Sugar Godown.
Under ground belt conveyor system from Drier House to Sugar Godown.
50.00
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and Energy Ltd Prepared by National Sugar
Institute, Kanpur.
Page 45 of 118
d) CHECK WEIGHMENT SYSTEM
02 Nos Electronic weighing scale, Capacity-100 +/- 0.02 Kg
e) SLAT CONVEYOR
03 Nos Stich Well Make, Capacity-600 Bags/Hr, Width-550 Speed-7.5 to 9.0 Mtr/Min.
f) STICHING MACHINE
03 Nos Stich Well Make, Capacity-100 Bags/Hr(Minimum), Type-Twin Head
7 GENERAL a) SUGAR GODOWN 03 nos, 02 nos x 74800
bags each and 01 no x 100000 bags stacking capacity. 1 X 248000 bags staking cap 1 X 248000 bags staking cap additional
500.00
b) MOLASSES STORAGE TANK
02 Nos Steel Tanks 3000 m3 capacity (4000 MT) for Final Molasses. 2 x 10000 MT
01 Nos Steel Tanks capacity 10000 MT for Final Molasses. 400.00
c) E.T.P 01 No Effluent Treatment Plant, Cap-1000 M3 /Day Make- Pure Water.
d) C.P.U.
01 No Condensate Polishing Unit, Cap-780 m3/Day, Make-Pure Water.
e) SERVICE WATER PUMP
2Nos, Cap. 250 m3/hr, Head-30 mtr, Drive- 37KW, 1450 rpm
f) SERVICE WATER PUMP (C.W.)
02Nos KPD 150/32 , Cap.-400 m3/hr, Head- 30 mtr , Drive- 45 KW , 1450 rpm
g) JACK WELL PUMP 02 nos VT pumps, Cap-317 m3/Hr, Head-52 mtrs
h) BORE WELL 04 nos KSB make pumps, drive- 7.5 HP
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and Energy Ltd Prepared by National Sugar
Institute, Kanpur.
Page 46 of 118
8 STEAM POWER PLANT
A BOILER i) BOILER 01 No. Boiler MAKE-IJT-
Yamunanagar,Cap-80 Ton/Hr. Working Pressure- 87 Kg/cm2, Total Heating Surface Area of Boiler-4312 M2- Type-Water Tube,Super Heater HS Area-894 ,Economiser HS Area-1230 , Air Heater HS Area-258 ,
Modification in Boiler to enhance the capacity by 20 TPH
Modification in Boiler to enhance the capacity by 20 TPH
400.00
ii) FURNACE Type-Spreader Stroke,Grate Area of Furance-1930.
iii) FD FAN 02 Nos. FD Fan Cap.-53388 M3/h,Make-Power build Ltd,Motor-55KW,RPM-984
iv) ID FAN 02 Nos. ID Fan,Make-Power build Ltd,Motor-180KW,RPM-730
v) S.A.FAN 02 Nos,Cap-35280 M3/h,Make-Power build Ltd,Motor-110 KW,RPM-984
vi) BOILER FEED PUMPS 03 Nos. Make-KSB, Capacity - 57.1 m3/h, RPM-2980,Head-1190m,power-280KW
vii) FEED TRANSFER PUMP 02 Nos. Make-KSB, Capacity - 95 m3/h, RPM-2950,Head-85m,power-37KW
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and Energy Ltd Prepared by National Sugar
Institute, Kanpur.
Page 47 of 118
viii) LP DOSING SYSTEMS Make-Reliance Industries,Tank Cap. 225 Liter,Pump Cap.-20LPH,Pump Dis. Pressure - 6.5 Kg/cm2, 37 KW
ix) 02 Nos. Make-Sri Rajeshwari Engg, LPH-20,SMP-200
x) HP DOSING SYSTEMS Make-Reliance Industries,Tank Cap. 225 Liter,Pump Cap.-20LPH,Pump Dis. Pressure 120 Kg/cm2 , 37 KW
02 Nos. Make-Sri Rajeshwari Engg, LPH-20,SMP-200, Pump Dis.Pressure - 120 Kg/cm2
xi) FEED WATER TANK 01 Nos. Cap.-60 m3,Design Pressure-2Kg/cm2,Design Temp.-105*C
xii) DEARATOR TANK 01 Nos. Cap.-102TPH,Operating pressure-1.0245Kg/cm2,Temp.-120*C
xiii) HP HEATER 01 Nos. Make-C.Doctor India,Feed water Qty-80 TPH,Tube side Pressure- 140 Kg/cm2
xiv) ELECTRO STATIC PRECIPITATOR Design Dust-Emission
xv) MAIN COOLING WATER PUMPS
04 Nos. Make-Mather+Platt,Cap.-1800
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and Energy Ltd Prepared by National Sugar
Institute, Kanpur.
Page 48 of 118
m3/h, Head-30 mtr,RPM-1490,200 KW
xvi) COOLING TOWER FAN'S 03 Nos. Make-Premium Transmission,RPM-1480,55 KW
xvii)
AUXILLARY COOLING WATER PUMPS
02 Nos. Make-KSB,Discharge-300 m3/h,RPM-1480,Head-35 mtr
B COAL HANDLING SYSTEMS
a) MAGNETIC SEPERATOR 01 Nos. Make-Magnetics Corporation of India,Model No. CBM-CP-25RF-2.5TR,RPM-1420,2.2 KW
b) CBC-1 01 Nos.Make-Top Gear Transmission,Gear box,RPM-1450,9.3KW
c) TRAMP METAL DETECTOR
01 Nos.Make-Electromag,Model No.-MS/08.85/SQTA
d) VIBRO SCEENER 01 Nos.Make-Ecoman,Circular type
e) BUCKET ELEVATOR 01 Nos.Make-Top Gear Transmission,Model No.-2260X
f) CRUSHER 01 Nos. Make-Ecoman,Size-800x600,Impactor type
g) BLOWER 01 Nos. Make-Ecoman,Capacity-16500 m3/h
h) CBC-2 01 Nos.Make-Top Gear Transmission,Gear box,RPM-1450,5.5 KW
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and Energy Ltd Prepared by National Sugar
Institute, Kanpur.
Page 49 of 118
i) CBC-3 01 Nos.Make-Top Gear Transmission,Gear box,RPM-1450,2.2 KW
j) CBC-4 01 Nos.Make-Top Gear Transmission,Gear box,RPM-1450,5.5 KW
k) SLOT CONVEYOR 01 Nos Make-Top Gear Transmission,Gear box,RPM-1450, 30 KW
C BAGASSE CONVEYOR 06 Nos Make-Top Gear Transmission,Gear box,RPM-1450, 7.5 KW
D ASH BELT CONVEYOR 01 Nos Make-Top Gear Transmission,Gear box,RPM-1450, 3.7 KW
ABC 03 Nos Make-Top Gear Transmission,Gear box,RPM-1450, 3.7 KW
E AIR COMPRESSOR 01 Nos. Kirloskar make,Model-TC50S,Pressure-7 Kg/cm2
01 Nos. Summits make,Model-SA0060DMN,Pressure-7 Kg/cm2
f) CHIMNEY RCC construction & suitable to accommondate one more Boiler, cap-125 ton/hr approx.Height-75 Meters,I.D-5.0 Meters
9 WATER TREATMENT PLANT
01 Nos.Thermax make RO cum mix bed Plant Cap.-10 m3/Hour followed by 01 No ION Exchange make DM Plant cap- 20 m3/hr.
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and Energy Ltd Prepared by National Sugar
Institute, Kanpur.
Page 50 of 118
Bagasse Drying System Complete Bagasse Drying system for handling 40T bagasse per hour
Complete Bagasse Drying system for handling 40T bagasse per hour
400
10 POWER PLANT A POWER TURBINE 01 Nos- Multistage
extraction Siemens MAKE-TURBINE- 18000 KW, Steam pressure-86 Kg/cm2, 6800 RPM
Steam Temp-5150 c +/- 5 , Gear Box Triveni
ALTERNATOR 11 KV HT Voltage , 3 Phase, 18743 KW, Alternator TDPS Make
CONDENSOR -01 Nos.Surface Condensor Make-GEL of Heating Suface 1333 mtr2, No. of tube-4683
-02 Nos Condensate Pumps Make-Sulzer,Head-80 mtr,RPM-2960,24.5 KW
C SWITCH YARD 01 no. Transformer cap-25 MVA, 110 KV, Make- Crompton Greaves, 03 nos. P.T., 03 nos C.T.
D COGEN AUXILLARY TRANSFORMER
02 nos cap- 1.75 KVA, 11000 V/415V make - Crompton Greaves.
Automation at mills and boiling house 200.00
Total of Plant and Machinery 7030.00
B D.G. SET 01 No,Make- Perkins, 1500 KVA, HZ-50,Voltage-11 KV AC, AMP-70 l
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and Energy Ltd Prepared by National Sugar
Institute, Kanpur.
Page 51 of 118
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and
Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 52 of 118
9. Working Parameters
PERFOFMANCE TARGETS
S. No.Parameters Unit Targets
1 Season Duration days 180.00
2 Sugarcane Yield t/hec. 75.00
3 Cane Crush Rate tch 230.00
4 Stoppages
1. Mechanical/ Electrical % available hrs. 1.00
2. Process % available hrs. 1.00
3. General Cleaning % available hrs. 1.00
4. Miscellaneous & festivals % available hrs. 1.00
5. Cane % available hrs. 1.00
Total % available hrs. 5.00
5 Sugar Loss
1. In Bagasse % cane 0.55
2. In Press Mud % cane 0.04
3. In Molasses % cane 1.15
4. Unknown % cane 0.06
Total % cane 1.80
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and
Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 53 of 118
6 Process Parameters
1. Pol in Cane 12.30
2. Fibre in Cane 14.50
3. Primary Juice
Bx % 19.00
Pol % 15.55
Purity % 81.84
4. Mixed Juice
Bx % 14.00
Pol % 11.25
Purity % 80.36
5. Last Mill Juice
Bx % 2.00
Pol % 1.40
Purity % 70.00
6. Bagasse
Quantity % Cane 29.97
Pol % Cane 1.83
Moisutre % Cane 49.00
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and
Energy Ltd Prepared by National Sugar Institute, Kanpur.
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7. Filter Cake
Quantity % Cane 3.40
Pol % Cane 1.20
8. Clear Juice
Bx % 13.52
Pol % 10.93
Purity % 80.86
7 Process Efficiency
a. Mill Extraction % 95.61
b. Reduced Mill Extraction % 96.31
c. Boiling House Recovery % 89.35
d. Reduced Boiling House recovery % 92.31
e. Virtual Putity of Molasses % 30.35
f. Purity Rise - MJ to CJ % 0.50
g. Final Molasses Purity % 29.00
h. Final Molasses Brix % 92.00
i. syrup Brix % 66.00
j. Imbibition % Fibre 250
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Energy Ltd Prepared by National Sugar Institute, Kanpur.
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8 Estimated Recovery % cane 10.50
9 sugar Production (Grade wise) % of toal
L- 30 0.00
M-30 10.00
S-30 90.00
10 Process Stores Consumption
1. Lime % cane 0.14
2. Sulphur % cane 0.04
11 Steam and Fuel Consumption
1. Steam consumption for process % cane 32.50
2. Steam /Fuel ratio kg/kg 2.51
3. Moisture in bagasse % 49.00
4. Bagasse consumption % cane 20.00
5. Extra fuel consumption % cane Nil
6. Bagasse consumption at vaccum filter % cane 0.50
7. Bagasse produced % cane 30.00
8. Power Export
i. During Season (180 days)
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and
Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 56 of 118
Total Power Generation MWhr 18.005
Power Consumption MWhr 7.348
Power Export MWhr 10.657
ii. During Off- Season (25 days saved bagasse)
Total Power Generation MWhr 17.996
Power Consumption MWhr 2.072
Power Export MWhr 15.924
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and
Energy Ltd Prepared by National Sugar Institute, Kanpur.
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10. Fuel Balance
BAGASSE /FUEL BALANCE (SEASON)
1 CANE CRUSH RATE TCD 4800.000
2 DAYS OF SEASON OPERATION DAYS 180.000
3 TOTAL CANE CRUSHED LMT 8.640
4 BAGASSE % CANE % 30.000
5 TOTAL BAGASSE PRODUCED LMT 2.592
6 BAGASILLO AND WINDAGE LOSSES % CANE 0.800
7 BAGASILLO AND WINDAGE LOSSES LMT 0.069
8 BAGASSE AVAILABLE FOR COGEN LMT 2.523
9 STEAM GENERATION TPH 100.000
10 STEAM FUEL RATIO 2.488
11 BAGASSE REQUIREMENT LMT 1.736
12 SURPLUS BAGASSE LMT 0.786
MT 78643.882
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and
Energy Ltd Prepared by National Sugar Institute, Kanpur.
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BAGASSE /FUEL BALANCE (OFF-SEASON)
1 CANE CRUSH RATE TCD 0.000
2 DAYS OF OPERATION DAYS 110.000
3 TOTAL CANE CRUSHED LMT 0.000
4 BAGASSE % CANE % 0.000
5 TOTAL BAGASSE PRODUCED LMT 0.000
6 BAGASILLO AND WINDAGE LOSSES % CANE
7 BAGASILLO AND WINDAGE LOSSES LMT 0.000
8 BAGASSE AVAILABLE FOR COGEN from season LMT 0.786
9 STEAM GENERATION TPH 72.000
10 STEAM FUEL RATIO 2.488
11 BAGASSE REQUIREMENT LMT 0.764
12 EXTRA BAGASSE TO BE PURCHASED LMT -0.022
MT -
2240.47
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and
Energy Ltd Prepared by National Sugar Institute, Kanpur.
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11. Steam Balance
STAEM BALANCE (SEASON)
1 STEAM GENERATION TPH 100.000
2 HP Steam for SJAE & GSC TPH 0.450
3 HP heater 1 TPH 0.000
4 MP Steam at 8 kg/cm2 TPH 9.800
5 Distillery/Ethanol Plant TPH 0.000
6 HP Heater 2 TPH 10.000
7 Desuperheating Water addition TPH 0.200
8 LP Steam at 2.5 kg/cm2 TPH 77.776
9 Sugar Process TPH 76.364
10 De-aerator TPH 3.000
11 Desuper heating water addition TPH 1.587
12 Condensing Steam TPH 11.974
Total Steam TPH 100.000
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and
Energy Ltd Prepared by National Sugar Institute, Kanpur.
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STAEM BALANCE (OFF-SEASON)
1 STEAM GENERATION TPH 72.000
2 HP Steam for SJAE & GSC TPH 0.360
3 HP heater 1 TPH 0.000
4 MP Steam at 8 kg/cm2 TPH 6.350
5 Distillery/Ethanol Plant TPH 0.000
6 HP Heater 2 TPH 6.480
7 Desuperheating Water addition TPH 0.130
8 LP Steam at 2.5 kg/cm2 TPH 2.117
9 Sugar Process TPH 0.000
10 De-aerator TPH 2.160
11 Desuper heating water addition TPH 0.043
12 Condensing Steam TPH 63.173
Total Steam TPH 72.000
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and
Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 61 of 118
12. Power Balance
POWER BALANCE (SEASON)
1 POWER GENERATED MW 18.100
2 CONSUMPTION IN SUGAR PLANT MW 5.018
3 FOR LIGHTING AND COLONIES MW 0.500
4 FOR CCOGEN AUXILIARY MW 1.629
5 DISTILLERY/ENA/ETHANOL PLANT MW 0.000
6 TOTAL CAPTIVE POWER CONSUMPTION MW 7.147
7 EXPORTABLE POWER MW 10.953
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and
Energy Ltd Prepared by National Sugar Institute, Kanpur.
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POWER BALANCE (OFF-SEASON)
1 POWER GENERATED MW 17.910
2 CONSUMPTION IN SUGAR PLANT MW 0.350
3 FOR LIGHTING AND COLONIES MW 0.100
4 FOR CCOGEN AUXILIARY MW 1.612
5 DISTILLERY/ENA/ETHANOL PLANT MW 0.000
6 TOTAL CAPTIVE POWER CONSUMPTION MW 2.062
7 EXPORTABLE POWER MW 15.848
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Page 63 of 118
Steam Balance for Boiling House Quintuple Effect FFE set 1 TCH 230 2 MJ Bx 12.61% 3 CJ Bx 11.13 4 Syrup Bx 67.9294003 5 Total Evaporation t/h 259.54 259.54 Exhaust I II III IV V Drop kPaa 32 32 32 32 35 6 Prs Cal kPaa 200 200 168 136 104 72 Vap kPaa 168 136 104 72 37 Drop oC 10.2 5 7.5 13.1 15.21 7 Temp Cal oC 125 125 114.8 109.8 102.3 89.2 Vap oC 114.8 109.8 102.3 89.2 73.99 sat oC 120.2 114.8 109.8 102.3 89.2 73.99 8 Qty t/h 30.13 69.307 64.6038 59.9147 49.29915 11.68909 9 Flash vapor t/h 0.72 1.01 2.16 3.5
10 Factor 0.9433 1.0473 1.047 1.046 1.044 11 Evaporation t/h 65.378 67.6596 62.7307 51.56691 12.20341 12 Heating surface sq m 2000 2000 2000 1800 1600 13 ER kg/sqm/hr 32.689 33.8298 31.3653 28.64828 7.627134 14 Total Heat kJ/kg 2716.6 2699.7 2691.5 2680.4 2663.4 2323.15 15 Bleeding 16 To Condenser 0 17 RJ1 t/h 12.20341 18 Rj2 t/h 7.05
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19 SJ1 t/h 4.153652 20 SJ2 t/h 11.77 21 CJ 1 t/h 3.82587 22 CJ 2 t/h 3.76 23 A Pan t/h 23 24 B Pan t/h 8.28 25 C Pan t/h 4.6 26 Bg Pan t/h 1.0626 27 Cg Pan t/h 0.4313 28 Molasses Cond t/h 0.897 29 B-C Melter t/h 0.391 30 Total 1.4939 8.75489 15.5915 43.37782 12.20341
31 Steam for losses and other miscllaneous uses
% Cane 1.93
32 Total Steam Consumption
% Cane 32.06
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Page 65 of 118
13.
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and Energy Ltd Prepared by National Sugar
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14. HMBD for the Plant
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Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and Energy Ltd Prepared by National Sugar
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Page 68 of 118
15. MATERIAL BALANCE:
GM SUGAR AND ENERGY LTD. SANGUR Material Balance
1 Basic parameter SUMMARY
Milling rate -TCD 4800.
00
-TCH 230.0
0 MATERIAL %
Cane t/h cu.mt/h
Cane - Pol% 11.58 Cane 100.0 230.0
Fibre % 13.00 Bagasse 35.7 82.1
First expressed Juice - bx 19.34 Imbibition 35.1 80.7 80.7
- Purity 80.51 Mixed Juice 99.4 228.6 215.7
Mixed Juice purity 78.29 Quick Lime 0.2 0.4 Last Mill juice Purity 71.43 Milk of lime 3.2 7.3 7.0
Imbibition % fibre 300.0
0 Sulphur 0.1 0.1 Sulphur di oxide 0.1 0.3 738.0 2 Bagasse Air for sulphur burner 989.0 Pol % 1.86 Filter Cake 4.0 9.2 Moisture % 50.56 Filter Cake wash water 6.0 13.8 13.8 Fibre % 46.84 Filtrate 15.0 34.5 32.2
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Bagasse % cane 35.70 Raw Juice 114.4 263.1 248.2 -t/hr. 82.11 Sulphured Juice 117.6 270.5 255.2 pol in Bagasse %cane 0.66 Clear Juice to evaporator 105.9 243.5 229.7 Syrup 17.3 39.9 30.7 3 Imbibition
% cane 35.09 Pan Floor Material Soild t/h Bx Pol Pty % on Cane
t/hr. 80.71
A Massecuite 26.68 61.36 94.52 81.30
86.01 28.23
4 Mixed Juice B Massecuite 11.49 26.41
59 96.92 66.77
68.89 11.85
DMF 71.30 C Massecuite 7.58 17.44 100.1
1 51.35
51.29 7.57
% cane (nett) 99.39 Pol in MJ% cane 11.36 Total Massecuite % Cane 45.75 47.65
Mixed Juice A Heavy Molasses 11.49 26.41
59 81.6 56.38
69.09 14.07
Pol % 11.43 A Light Molasses 1.78 4.1 74.66 67.12
89.90 2.38
-Bx % 12.61 B Heavy Molasses 6.75 15.53 84.12 41.98
49.9 8.03
Bx. In Mixed Juice % cane 12.53 C Light Molasses 1.60 3.67 72.6 48.85
67.29 2.20
N-S in MJ % cane 1.17 Final Molasses 4.72 10.8 87.29 27.16
31.11 5.40
B Magma 4.73 10.9 90 86.40 96 5.26
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5 Extraction CAfter Magma 1.27 2.9 90 86.40 96 1.41
C Fore Cured Sugar 2.87 6.6 90 72.00 80 3.18
Recorded extraction % 98.10 Product Sugar 9.67 22.24 99.96 99.95
99.99 9.68
Reduced extraction % (mittal) 98.31
20 C – Massecuite solids balance
6 Cao & Milk of Lime
CaO -%cane 0.17 B-molasses purity 49.9
-Kg/hr 391 B molasses solids in C m/c % cane 6.75
Quick Lime (80% purity) -%cane 0.19
- Kg/hr 437 21 B – Massecuite & B- Sugar
Milk Of Lime
-Beaume 6.00
- kg/hr 7261.
43 B massecuite purity 68.89
-Cu m /h 6.98 B- foresugar purity 96
-%cane 3.16 B-massecuite solids % cane 11.49
B- foresugar solids % cane 4.73
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7 Sulphur & sulphur Dioxide Pan dropping Bx. 96.92
Sulphur -%cane 0.06
Expected crystal content % Massecuite 38.33
-kg/hr 138.0
0 Expected exhaustion % 18.99 Commercial sulphur -purity 99.9
-%cane 0.06 22 A-Heavy molasses
-kg/hr 138.1
4
Sulphur di-oxide -%cane 0.12 A-H molasses purity 69.09
(60 deg C,1.0 bar(g)) -Kg/hr 276.0
0 AH molasses in B Massecuite %cane 11.49
-cu m/hr
737.968 Total 11.49
For Juice Sulphitation -Kg/hr 184.0
0 For Syrup Sulphitation -Kg/hr 92.00 23 MELT
B sugar solid for melting - % Cane 4.73
8 Compressed Air C sugar solid for melting - % Cane 1.27
Volume required -cu m/hr 989 B+C Sugar solids for melting
- % Cane 6.00
Juice Sulphitor -cu m/hr 593.4 B+C Sugar magma brix 90
Syrup Sulphitor -cu m/hr 395.6 B+C Sugar magma quantity
- % Cane 6.67
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Dust & Rori sugar for melting - % Cane 1.00
9 Bagacillo Dust & Rori sugar magma brix 90
Mill wet (50% moisture) - Kg/tch 12.5
Dust & Rori sugar magma quantity
- % Cane 1.11
-Kg/hr 2875 Total sugar solids for melting - % Cane 7.0
-% cane 1.25 Total Magma for melting
- % Cane 7.78
Dry basis -% cane 0.63 Avg magma brix for melting 90
Is clear juice used for melting Y/N 1/0 0
10 Filter Cake Clear Juice for melting
- % Cane 0
Mud solids % cane 0.65 Clear Juice solid in melt - % Cane 0
Total dry solids %cane 1.28 Total Melt solids - % Cane 7.0
Moisture %filter cake 70 Total Melt quantity - % Cane 10.00
filter cake %cane 4 - t/h 23.00
-t/h 9.20 - cu.m/h 17.04
Pol %filtercake 2.64 Pol in filter cake %cane 0.11 24 SYRUP SULPHITER 11 Filter wash water Syrup from Evaporator
- % Cane 17.34
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Qty % cane 6 - t/h 39.89 -t/h 13.80 12 Filterate 25 A LIGHT MOLASSES
Dry solids % in Sulphured juice 0.8
Dry solids % clarifier underflow 4.8 Reference purity A Sugar 99.9
Clarifier underflow -% cane 14.8 Purity A Light molasses 89.9
-t/h 34.04 A Light molasses solids % Cane 1.78
filterate -% cane 15
-t/h 34.50 26 A MASSECUITE 13 Raw Juice Input Material % Cane Sulphured syrup soilds 17.34 Mixed % cane 99.39 Melt Solids 7.0 Filterate %cane 15.00 A Light molasses soilds 1.78
Raw Juice -% Cane
114.39 Total soilds input 26.1
-t/h 263.0
97 Purity 86.01
-cu m/hr
248.20
Output material % Cane
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14 Sulphured Juice A Sugar 9.68
Raw juice % cane 114.3
9 AH Molasses 11.49 Milk Of Lime % Cane 3.16 AL Molasses 1.78
Sulphur dioxide % cane(55 % abs) 0.06 Total Soilds output 22.94
Sulphured Juice - % Cane
117.61
-t/h 270.5
0 27 EVAPORATION IN PANS %CANE
-cu m/hr
255.19
(a) A Massecuite Boiling
15 Clear Juice Dropping Brix 94.52 Mixed Juice % cane 99.39 Input Material : Milk of lime% Cane 3.16 Syrup @ 65 Bx 26.68 Sulphur di oxide % Cane 0.06 Seed Magma @ 70 Bx 10.00 Fresh Wash Water %cane 6 A Light Molasses @ 70 Bx 2.54 Bagacillo % Cane 1.25 Total input material 39.22 Filter cake % Cane ( less) 4
Clear Juice % Cane 105.8
6 Output Material : Pol in clear juice % Cane 9.22 A Massecuite @94 Bx 28.38 NS in clear juice % Cane 2.57 Evaporation 6.76
Clear Juice - pol% 8.7
Add Movement water @ 3% MC Soilds 0.851
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and Energy Ltd Prepared by National Sugar
Institute, Kanpur.
Page 75 of 118
- Bx% 11.13 Total Evaporation 7.61
- Purity 78.22
- t/h 243.4
7 (b) B Massecuite Boiling
For Melting - t/h 0 Dropping Brix 96.92
- % Cane 0 Input Material :
AH Molasses 16.41
To evaporator - t/h 243.4
7 Total input material 16.41
-cu m/hr
234.107
- % Cane
105.86 Output Material :
16 Syrup Bx% 67.93 B Massecuite @96 Bx 11.85 Total evaporation % cane 88.51 Evaporation 4.56
Syrup -%cane 17.34
Add Movement water @ 5% MC Soilds
0.57426
- t/h 39.89 Total Evaporation 5.13
- cu m /hr 30.69
( c) C Massecuite Boiling
17 Final molasses Dropping Brix 102
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and Energy Ltd Prepared by National Sugar
Institute, Kanpur.
Page 76 of 118
Purity product Sugar 99.9 Input Material : Purity final molasses 31.11 AH Molasses@80 0
Final molasses solids % cane 4.72 BH Molasses @80 8.44
Final molasses sugar % cane 1.28 CL Molasses @80 2.0
Final molasses NS % cane 3.44 Total input material 10.44 18
C-massecuite & C- foresugar Output Material :
C massecuite purity 51.29 C Massecuite @102 Bx 7.43 C- foresugar purity 80 Evaporation 1.60
C-massecuite solids % cane 7.58 Add Movement water @ 10% MC Soilds 0.74
C- foresugar solids % cane 2.87 Total Evaporation 2.35
Pan dropping Bx. 100.1
1
Expected crystal content % Massecuite 29.33
Total Pan Floor evaporation % Cane 15.09
Expected exhaustion % 20.18 Bled Vapour requirement for pans % Cane 15.09
19
C-After sugar & C-light molasses
C-after sugar purity 96 C-light molasses purity 67.29
C-after sugar solids 1.268
53 C-light molasses solids 1.60
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and Energy Ltd Prepared by National Sugar
Institute, Kanpur.
Page 77 of 118
C-magma Brix 90
Expected crystal content % magma 78.99
Expected exhaustion % 28.71
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and
Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 78 of 118
16. Technical Feasibility
Modernization cum Expansion of the plant has been proposed by alteration and additions of suitable plant and machinery. The project has been prepared by Experts from National Sugar Institute, Kanpur who is considered to be the best in this field. Detailed specifications of plant and machinery are given in para-9 of the report. This DPR shows:
1. Land availability is there for the expansion. Ref Para- 7.1 2. Raw material required for the project is sufficient. Ref Para-7.2 3. There is surplus of water available for the plant operation and
maintenance. Ref Para 7.3 4. Due to co-gen plant of the plant, there is enough of power available. 5. The process to be adopted, Ref papa 8; is a well proven process and is
followed by number of factories in India and worldwide. 6. The targets fixed for the working parameters are well within the reach. Ref
para-10 7. Availability of fuel for the project is sufficient. Ref para 11 8. Availability of steam for the project is sufficient. Ref para 12 9. Man power required for the project is sufficiently available. Ref para 16/17
Keeping in view the above points, which are the requirements for any project to be technically viable, it ascertained that the project is technically feasible.
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and
Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 79 of 118
17. Organizational Set-up
The present organizational set up of the plant is as follows:
Existing Streingth for Sugar Season 2016-17
S.N. Position Shift
A Shift B Shift C Shift R General Vacant Total Engineering
1 Chief Engineer 1 1 2 Dy C E 1 1 3 Drafts Man 1 1
Mill House 4 Shift Engr 1 1 1 1 4 5 Fore Man 1 1 6 Fitter 1 1 1 1 1 5 7 Fitter Helper 2 2 2 1 1 8 8 Oil Man 1 1 1 1 4 9 RTC Operator 1 1 1 1 4
10 Pump Attdr 1 1 1 3 11 Feeder Tb opr 1 1 1 3 12 Welder 1 1 1 1 4 13 Unloader opr 4 4 4 2 14 14 Regger 2 2 2 1 1 8 15 Attdr 1 1
Boiling House 16 Fore Man 1 1 17 Fitter 2 2 2 1 7 18 Fitter Helper 1 1 1 1 4 19 Oil Man 1 1 1 1 4 20 Pump Attdr 2 2 2 1 7 21 Welder 1 1 1 1 4
Work Shop 22 Engineer 1 1 23 Turner 1 1 1 1 4 24 Machinist 1 1 25 Carpenter 1 1
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and
Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 80 of 118
26 Fitter 1 1 27 Helper 2 2 28 Jackwell opr 1 1 1 3
Manufacturing 29 Chief Chemist 1 1 30 Dy C C 1 1 31 Shift Chemist 1 1 1 1 4 32 Juice Supervisor 1 1 1 3 33 Evap Mate 1 1 1 1 4 34 Juice Sul Mate 1 1 1 1 4 35 RVF mate 1 1 1 1 4 36 Dorr mate 1 1 1 3 37 SB Attdr 1 1 1 3 38 JH Attdr 1 1 1 3 39 Pan Incharge 1 1 1 1 4 40 Pan Man / Asst. P Man 5 5 5 2 17 41 Pan Helper 2 2 2 1 7 42 Centrifugal Mate 1 1 1 1 4 43 Centrifugal Opr 4 4 4 2 14 44 Crystallizer attdr 2 2 2 1 7 45 Melter Attdr 1 1 1 1 4 46 Magma mixer Attdr 2 2 2 1 7
ETP 47 ETP Opr 1 1 1 1 4 48 LAB 49 Lab I/C 1 1 50 Lab Chemist 1 1 1 1 1 5 51 Lab Boy 2 2 2 1 1 8
Materials 52 Material Manager 1 1 53 Godown Keeper 2 2 54 Clerk 2 2 55 Attdr 2 2 56 Store I/C 1 1 57 Store Keeper 1 1 58 Clerk 1 1 59 Asst Store Keeper 1 1 1 1 4 60 Attdr 2 2
Total 230
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and
Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 81 of 118
Casual Labour Enginnering Man Power for Engineering 102 Casual lab for CC 6 Man Power for Manufacturing 112
Casual lab for Mill & W/S 12 Man power for Store & Godown 16
Manufacturing Casual Labour 49 Hopper Attdr 3 Total 279 Syp/ Mol tank mazdur 6 RVF Helper 6 ETP Mazdur 8 Store Attdr 2 Cleaning Mazdur 6 Total 49
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and
Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 82 of 118
18. Manpower Requirement
The present strength of manpower is sufficient for the expanded capacity
because;
1. There is no increase of any section or station. There is only increase in
equipment capacities.
2. Due to implementation of automation, there will be saving in manpower
as no of batch equipments will be made continuous and automated.
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar and Energy Ltd Prepared by National
Sugar Institute, Kanpur.
Page 83 of 118
19. Project Implementation and Schedule
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 84 of 118
19.1 SWOT ANALYSIS
Strengths (S)
I. Excellent sugarcane availability in the area of operation to the tune
of about 12.5 lakh MT.
II. Required equity and bank loans are in place
III. Required land is in possession
IV. Professionally and efficiently managed organization by promoters
and technical team
V. Major NOCs are already secured
VI. Availability of basic infrastructure
VII. Crushing season starts from November to April, which is the
period, when the demand for the power is at peak level. Excess
power generated by the Project will help to meet peak demand of
the state utility.
VIII. Environment friendly power generation
IX. Close to demand/load centers
X. Low transmission cost
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 85 of 118
Weaknesses (W)
I. Delay in project implementation may increase capital cost
(GMSPL will take due care for commissioning of the plant within
the desired time & cost schedules)
Opportunities (O)
i. Expansion of sugar & cogen plant
ii. Levy sugar is removed
iii. Decontrol of Sugar Sector
iv. A Sugar Plant with grid connected Cogen Project is now well
proven in India, for techno - commercial viability
v. Ease in sale of sugar
vi. Keenness of Government of Karnataka to purchase power
vii. Availability of nearby KPTCL substation and grid to evacuate
exportable surplus
viii. Capital subsidies from MNRE & low cost funds from SDF
ix. Potential for trade of emission reductions in the international
market
x. Demand supply gap existing in the State. Potential for KSEDCL to
absorb the complete excess power generated due to demand
supply gap
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 86 of 118
xi. Opportunities for selling the sugar internationally owing to export
subsidy and power to any third party through a power trader as
allowed in Electricity Act 2003
xii. KERC’s Renewable Purchase Specification (RPS) to all distribution
licensees.
xiii. Most of the State Electricity Regulatory Commissions have come
up with RPS specifications. Therefore if the State utility is not in a
position to absorb the power generated, this can be sold to
utilities outside the state through open access
Threats (T)
I. Fluctuating prices of sugar
II. Over dependence on KSEDCL for revenue in the PPA.
Alternatively, third party buyers can be identified.
III. Cycle or climatic changes leading to low crushing. Cane
development in the nearby area to reduce shortage of
sugarcane
IV. Threats from diseases on sugarcane.
V. Delay in project implementation which may lead to project
overrun and cost overrun
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 87 of 118
20. Codes and Standards:
Systems and equipment will be designed in accordance with the
applicable sections of the following codes, standards and regulations
in effect at the date of the Contract. Applicable sections of codes,
standards and regulations will be defined in specifications.
Indian Standards (IS)
IS : 6 : Moderate heat duty fire clay refractories
Group-A
IS : 8 : High heat duty fire clay refractories
IS : 325 : Three phase induction motors
IS : 456 : RCC Structures
IS : 498 : Grading for Vacuum Pan Sugar
IS: 800 : Code of practice for Constructions in steel
IS: 807 : Code of practice for Design, Manufacture,
Erection and Testing (Structural Portion of
Cranes & Hoists)
IS : 875 : Code of practice for Design loads for
building
Structures
IS : 1162 : Cane Molasses
IS : 1554 : PVC insulated (heavy duty) electrical cables
IS : 1651 : Stationary cells and batteries, lead-acid type
(with Tubular positive plates)
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 88 of 118
IS : 1893 : Criteria for earthquake Resistant-Design of
Structures
IS : 1973 : Sugarcane Crushers
IS : 2026 : Power Transformer
IS : 1893 : Criteria for earthquake Resistant-Design of
Structures
IS :2309 : Practice for the protection of the buildings
and Allied Structures against lighting – code
of Practice
IS : 2429 : Round Steel Short link chain electric butt
welded Gr.30
IS : 2544 : Porcelain post-insulators for system with
Nominal voltage Greater than 1000V.
IS :2705 : Current Transformers
IS : 2825 : Code for unfired pressure vessels
IS : 3043 : Code for practice for earthing
IS : 3144 : “Methods of test for Mineral Wool Thermal
Insulation Material”
IS : 3156 : Voltage Transformer
IS : 3177 : Code practice for design of Electrical
OverheadTraveling Crane and Gantry Crane
IS : 3427 : Metal-enclosed switchgear and control gear
for Rated Voltages above 1kv and including
52 kv
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 89 of 118
IS : 3646 : Code of practice for interior illumination
IS : 3832 : Hand Operated Chain pulley blocks
IS : 3938 : Specification for Electric Wire Rope Hoists
IS : 4503 : Shell and Tube Heat Exchangers
IS : 4772 : Code of practice for Construction of Sugar
Godowns
IS : 4776 : Toughed Belt Conveyors
IS : 4903 : Guide for Treatment and disposal of
Effluents of cane Sugar Industry
IS : 5422 : Turbine type generators
IS : 5521 : Steel Tanks for Storage of Molasses
IS : 5527 : layout plant for Sugar Factory Laboratories
IS : 5982 : Plantation White Sugar for
Identification
IS : 6547 : Specification for Electrical Chain Hoists
IS : 6983 : Rollers and Axis for Sugarcane Crushers
IS : 6997 : Test code for sugar cane crushers
IS :7098 : Cross linked polyethylene insulated
PVC Sheathed cables
IS : 7155 : Code of recommended practice for Conveyor
Safety
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 90 of 118
IS : 7424 : Photoelectric Reflectance method
for Measurement of Whiteness of
Plantation White Sugar in Solid State
IS : 8183 : “specification for Bonded Mineral Wool”
IS : 8466 : Bagasse Carrier Chains
IS : 8531 : Pulleys for Belt Conveyors
IS : 8598 : Idlers and Idler Sets for Belt
Conveyors
IS 8623 : Low voltage switchgear and control Gear
assemblies
IS 9069 : Inter-Carrier Chains
IS 9921 : Alternating current disconnectors
(isolators) &
earthing switchers for voltage above 1000V
IS 9952 : Batch type Centrifugal Liners for Final
Massecuite for sugar industry
IS 10556 : Code of practice for storage and handling of
insulating Materials
IS 11102 : Glass Bottles for sugar standards
IS 11592 : Code of Practice for Selecting and Design of
Belt Conveyors
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 91 of 118
IS 12198 : Sprockets for Sugar Factories
IS 13118 : High voltage alternating current circuit
beakers
IS 13947 : LV switchgears and control gear
IS 13770 : Static wait hour meters, class 1 and 2
IS 14164 : Industrial application and finishing of
Thermal
insulating materials at Temperatures above
80OC and upto 700OC
IS 14350 : Code of Hygienic Conditions for Sugar
Factories
American Society of Mechanical Engineers ( ASME)
ASME Section I : Rules for construction of power boilers
ASME Section IX : Welding & Brazing Qualifications
ASME Section VIII : Unfired Pressure Vessels Code
ASME Section IX : Welding Qualification
ASME Performance Test Code
ASME PTC 4.1 : steam Generating Units
ASME PTC 4.3 : Air Heaters
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 92 of 118
ASME PTC 3.0 : Guide for evaluation of Measurement
Uncertainty in performance test of steam Turbine
ASMW PTC 10.11 : Water and Steam in the Power Cycle (Purity
and Quality , Leak detection and Measurement).
ASMW PTC 25.3 : Safety and Relief Valves
American National Standards Institute
ASME B 13.5 : Pipe flanges and flanged fittings
ASME B 13.9 : Butt welding fittings
ASME B 13.11 : Socket Welding and Threaded fittings
ASME B 31.1 : Code for Power piping
IEEE STANDARDS
IEEE :80 : Guide for safety in AC substation Grounding
IEEE: 141 : Recommended Practice for Electric Power
Distribution of Industrial and Commercial
Power Systems
IEEE: 142 : Recommended Practice for Grounding of
Industrial
and Commercial Power Systems
IEEE:241 : Recommended Practice for Electric Power
Systems.
in Commercial buildings
IEEE:242 : Recommended Practice for Protection and
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 93 of 118
Coordination of Industrial and Commercial
Power Systems
IEEE:399 : Recommended Practice for
Industrial and Commercial Power Systems
IEEE:446 : Recommended Practice for Emergency
And Standby Power for Industrial and
Commercial Power Systems
IEEE :493 : Recommended Practice for the Design of
Industrialand Commercial Power Systems
IEC Standards
IEC :34 : Rotating Electric machines
IEC :44 : Instrument Transformers
IEC : 56 : HVAC circuit breakers
IEC : 71 : Coordination of insulation
IEC : 76 : Power Transformers
IEC : 85 : Thermal evaluation and classification of
Electrical Insulations
IEC: 99 : Lighting Arrestors
IEC: 129 : Alternating current disconnectors
(Isolators) and Earthing Switches
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 94 of 118
IEC : 144 : Degrees of protection of enclosures for low
Voltage switchgear & control gear
IEC : 137 :Bushings for Alternating Voltages Above 1000 V
IEC : 183 : Guide for selection of HV cables
IEC : 185 : Current Transformers
IEC : 186 : Potential Transformers
IEC : 214 : On loan tap changers
IEC : 227 : PVC insulated electric cables
IEC : 255 : electrical relays
IEC : 269 : LV fuses
IEC : 270 : Partial discharge requirements
IEC : 296 : Insulating oils
IEC : 298 : AC metal enclosed switch gear and control gear for
rated voltages above 1 kV and upto and Including 52
kV.
IEC : 354 : Loading guide for oil immersed Power
Transformers
IEC : 376 : Specification and acceptance of new
sulphur
hexafluoride
IEC : 439 : LV switchgears and control gear assembly
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 95 of 118
IEC : 502 : Extruded solid dielectric insulated power for
Rated voltages from 1 kV upto 30 kV
IEC : 529 : Classification of degree of protection
IEC : 542 : Application guide for on load tap changers
IEC : 606 : Application guide for power transformers
IEC : 694 : Degrees of protection provided by enclosure
(IP code)
IEC : 885 : Electric test methods for electric cables
IEC : 909 : Short circuit current calculation in Three
phase AC systems
IEC : 947 : LV switchgears and control gear
IEC : 1036 : Static meters
Industry Standards (As determined to be applicable by Contractor)
Indian Boiler Regulations (IBR)
American Gear Manufacturers Association (AGMA)
American Petroleum Institute (AP1)
American Society for Heating, Refrigeration and Air-conditioning
Engineers (ASHRAE) Handbook
American Society for Testing and Materials (ASTM)
American Water works Association (AWWA)
American welding society (AWS) Structural Welding Code (AWS D1.1)
Conveyor Equipment Manufacturers Association (CEMA)
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 96 of 118
Cooling Tower Institute (CTI)
Heat Exchange Institute (HEI)
Hydraulic Institute (HI)
Institute of Electrical and Electronics Engineers (IEEE)
Instrument Society of America (ISA)
Manufacturers Standardization Society (MSS) of the Valve and Fitting
Industry
National Fire Protection Association (NFPA)
Pipe Fabrication Institute (PFI)
Tubular Exchanger Manufacturers Association (TEMA)
Turbine:
IEC Recommendation Publication No : 45CSN 080030DIN 1943
British Standards
BS 4592 : Industrial type metal floors, walkways and
Stair Treads
BS 5395 : Stairs, ladders and walkways
BS 2573 : Permissible Stresses in Cranes
BS:460 : EOT Cranes for general use in factories,
workshops & Warehouses
BS: 5316 : Performance Testing of Pumps Part-I Class C
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 97 of 118
RECOMMENDED MINIMUM THICKNESS FORTHERMAL INSULATION (MINERAL
WOOL)
NOMINAL
DIA IN MM OPERATING TEMPERATURE (Dec.C)
Below 101 - 151 - 201 - 251 - 301 - 351 - 401 - 451 -
100 150 200 250 300 350 400 450 500
65 & Below 25 30 30 35 40 45 45 50 60
80 30 35 40 40 45 50 55 60 70
100 35 35 50 45 50 60 65 70 75
125 35 40 45 50 55 65 70 75 80
150 35 40 50 55 60 70 75 80 90
200 35 45 66 60 65 70 80 95 100
250 40 50 60 65 70 80 85 100 110
300 40 55 60 75 80 90 100 110 120
350 45 55 60 75 80 90 100 110 120
400 45 60 70 75 80 80 8 90 105
450 50 60 75 90 - - - - -
500 50 60 75 90 90 105 115 125
135
550 55 60 80 90 95 105 115 125 135
600 55 65 80 95 95 110 120 130 140
Above 600
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 98 of 118
& Flat 55 65 80 95 100 110 120 130 140
Surfaces
Note The table is given only as a guideline and the thickness shall be
selected as per the calculations using IS Standard for conductivity.
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 99 of 118
21. ABBREVIATIONS
AC : Alternating Current
AGMA : American Gear Manufacturer’s Association
API : American Petroleum Institute
ASHRAE : American Society of Heating, Refrigeration and AC Engineers
ASME : American Society of mechanical Engineers
ASTM: American Society of Testing Materials
AWS : American Welding Society
AWWA : American Water Works Association
BC : Belt conveyor
BS : British Standards
CACW : Closed Air Circuit Water cooled
CBD : Continuous Blow Down
CEMA : Conveyor Equipment Manufacturer’s Association
CT : Current Transformer
CTI : Cooling Tower Institute
CU.M : Cubic Metre
DBT : Dry Bulb Temperature
DC : Direct Current
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 100 of 118
DCS : Distributed Control System
DG : Diesel Generating Set
DM : De-Mineralized
DPR : Detailed Project Report
DSCR : Debt Service Coverage Ratio
EL : Slat Chain Elevator/ Elevation
ENA : Extra Neutral Alcohol
EOT : Electrical Operated Overhead Trolley
ESP : Electrostatic Precipitator
ETH : Ethanol
ETP : Effluent Treatment Plant
FD : Forced Draft
GCV : Gross Calorific Value
GOI : Government of India
GOK : Government of Karnataka
GSC : Gland Steam Condenser
HEI : Heat Exchange Institute
HI : Hydraulic Institute
HP : High Pressure
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 101 of 118
HT : High Tension
HVAC : Heating, Ventilation & Air Conditioning
HYSD : High Strength Deformed Steel
IBD : Intermittent Blow Down
IBR : Indian Boiler Regulations
ID : Induced Draft
IDC : Interest during Construction
IEC : International Electro technical Commission
IEEE : Institute of Electrical and Electronics Engineers
IRR : Interest Rate on Return
ISA : Instrument society of America
KA : Kilo Ampere
KPTCL : Karnataka Power Transmission Corporation Ltd
KV : Kilo Volt
KW : Kilo Watt
LAVT : Lightning Arrestor & Voltage Transformer
LC : Letter of Credit
LP : Low pressure
LS : Lump Sum
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 102 of 118
LT : Low Tension
LV : Low Voltage
MCC : Motor Control Centre
MCR : Maximum Continuous Rating
MNES : Ministry of Non-conventional Energy sources
MSS : Manufacturer’s Standardization Society
MT : Metric Tonnes
NEMA : National Electrical Manufacturer’s Association
NFPA : National Fire Protection Association
NGR : Neutral Grounding Resistor
NPSH : Net Positive Suction Head
PCB : Pollution Control Board
PCC : Power Control Center
PFI : Pipe Fabrication Institute
PLC : Programmable Logic Controller
PLF : Plant Load Factor
PRDS : Pressure Reducing De-superheating Station
PVC : Poly Vinyl Chloride
PT : Potential Transformer
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 103 of 118
RBC : Return Belt Conveyor
RCC : Reinforced Cement Concrete
REC : Rural Electrification Corporation Limited
RM : Running Meter
RPM : Revolutions Per Minute
RO : Reverse Osmosis
RS : Rectified Spirit
RTD : Resistance Temperature Detector
SA : Secondary Air
SBC : Soil Bearing Capacity
SC : Slat Chain Conveyor
SCADA : Supervisory Control and Data Acquisition
SG : Steam Generator
SQ.M : Square Metre
TAC : Tariff Advisory Committee
TCD : Tonnes of Cane per Day
TCH : Tonnes of Cane per Hour
TEMA : Tubular Exchanger Manufacturer’s Association
TG : Turbo Generator
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 104 of 118
TPH : Tonnes Per Hour
TVM : Trivector Meter
WCM : Working Capital Margin
WBT : Wet Bulb Temperature
XLPE : Cross Linked Poly Ethylene
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 105 of 118
FINANCIAL WORKINGS
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 106 of 118
M/S GM SUGAR AND ENERGY LTD SANGUR, HAVERI DISTRICT (KARNATAKA)
FINANCIAL FORECAST OF THE ANNUAL WORKING OF THE SUGAR FACTORY
AFTER COMMENCEMENT OF THE PROJECT
S NO
. PARTICULARS UNIT 2016-
17 2017-
18 2018-
19 2019-
20 2020-
21
1 PHYSICAL PARAMETERS 1.01
Additional Installed Crushing Capacity TCD 2500 2500 2500 2500 2500
1.02 Operational Crushing Capacity TCD 2250 2375 2500 2500 2500
1.03 Capacity Utilisation % 90 95 100 100 100
1.04 Working days during Season Days 90 180 180 180 180
1.05 No. of Shift/Days No. 3 3 3 3 3
Gross Days Days 300 300 300 300 300 1.06
Cane Expected to be Crushed ( on the basis of 100% capacity)
Lakh MT Tonnes 9.45 9.45 9.45 9.45 9.45
1.07
Crushed cane in Lakh MT (on the basis of working capacity)
Lakh MT Tonnes 8.51 8.98 9.45 9.45 9.45
1.08 Average Sugar Recovery % Cane 10 10 10 10 10
1.09 Baggase Production
30 % of Cane
2.55204
2.69382
2.8356
2.8356
2.8356
1.10 Total Sugar Production M.T. 42534 89794 94520 94520 94520
1.11
Molasses Production(In lakh MT)
4.5 % of Cane
0.3828
0.4041
0.4253
0.4253
0.4253
1.12 Filter Cake Production
3 % of Cane
0.2552
0.2694
0.2836
0.2836
0.2836
1.13
Electricity Production(Peak season) in units (24 Hrs) (180
days) 20717
208 43736
328 46038
240 46038
240 46038
240
1.14
Electricity Production(Off season) in units (24 Hrs) (130
days) 44723
016 47207
628 49692
240 49692
240 49692
240 1.15 Electricity Rate (Rs Per unit) Units 5.79 5.79 5.79 5.79 5.79
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 107 of 118
1.16 Rate of Sugar Rs. / M.T. 36000 36000 36000 36000 36000
1.17 Rate of Molasses Sale Rs. / M.T. 6000 6000 6000 6000 6000
1.18 Rate of Bagasse Rs. / M.T. 1500 1500 1500 1500 1500
1.19 Rate of Filter Cake Rs. / M.T. 100 100 100 100 100
2 INCOME (SALES)
2.1 Sale of Sugar Lakh Rs. 15312
.24 32325
.84 34027
.20 34027
.20 34027
.20
2.2 Sale of Molasses Lakh Rs. 1148.
42 2424.
44 2552.
04 2552.
04 2552.
04
2.3 Sale of Surplus Bagasse Lakh Rs. 0.00 0.00 0.00 0.00 0.00
2.4 Sale of Filter Cake Lakh Rs. 12.76 26.94 28.36 28.36 28.36
2.5 Sale of Electricity (during
season) Lakh Rs. 1199.
53 2532.
33 2665.
61 2665.
61 2665.
61
2.6 Sale of Electricity (during off
season) Lakh Rs. 1294.
73 2733.
32 2877.
18 2877.
18 2877.
18
Total Sales revenue (A) Lakh Rs. 18968 40043 42150 42150 42150
3 EXPENDITURE 3.1.2 Raw Material & Consumables Lakh Rs.
11909.52
25142.32
26465.6
26465.6
26465.6
Purchase tax on Sugar Cane Lakh Rs. 357.2856
754.2696
793.968
793.968
793.968
Chemicals Consumed Lakh Rs. 850.6
8 1795.
88 1890.
40 1890.
4 1890.
4 3.1.3 Power And Fuel Lakh Rs.
861.57
1818.88
1914.61
1914.61
1914.61
3.1.4 Salaries & Wages Lakh Rs.
850.68
1795.88
1890.4
1890.4
1890.4
3.1.5 Insurance Lakh Rs. 21.09 37.15 40.15 40.15 40.15
3.1.6 Repaires & Maintenance Lakh Rs.
102.08
242.44
255.20
255.20
255.20
3.1.7 Total Conversion Cost Lakh Rs.
14952.91
31586.82
33250.33
33250.33
33250.33
3.1.8 GROSS PROFIT Lakh Rs.
4014.76
8456.05
8900.06
8900.06
8900.06
3.1.9
Selling &Adimistrative Exp.@ 2 % of sales Lakh Rs.
379.35
800.86
843.01
843.01
843.01
3.1.10 Depreciation Lakh Rs.
694.17
694.17
694.17
694.17
694.17
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 108 of 118
3.1.11 Preliminary Expenses W/off Lakh Rs. 40.00 40.00 40.00 40.00 40.00
3.2 INTEREST 3.2.1 Interest on Working Capital loan Lakh Rs. 35 70 70 70 70
3.2.2 Interest On Term Loan Lakh Rs.
283.80
387.04
290.28
193.52 96.76
3.2.3 Total Interest Lakh Rs. 318.8
457.04
360.28
263.52
166.76
4 Total Cost (B) Lakh Rs. 16385
.23 33578
.89 35187
.79 35091
.03 34994
.27
5 Profit Before Tax (A-B) Lakh Rs. 2582.
44 6463.
98 6962.
60 7059.
36 7156.
12
6 Provision For Tax * Lakh Rs. 852.2
1 2133.
11 2297.
66 2329.
59 2361.
52
Net Profit Lakh Rs. 1730.
24 4330.
87 4664.
95 4729.
77 4794.
60
Add: Depreciation Lakh Rs. 627.5
0 627.5
0 627.5
0 627.5
0 627.5
0
Add: Preliminary exp w/off 40.00 40.00 40.00 40.00 40.00
Cash accruals Lakh Rs. 2397.
74 4998.
37 5332.
45 5397.
27 5462.
10
Cumulative Cash accruals Lakh Rs. 2397.
74 7396.
11 12728
.55 18125
.83 23587
.93
* Assuming tax rate in india 33%
Working for Reserve and \Surplus
Opening 0.00 1730.
24 6061.
11 10726
.05 15455
.83
Current Year Profit 1730.
24 4330.
87 4664.
95 4729.
77 4794.
60
Closing 1730.
24 6061.
11 10726
.05 15455
.83 20250
.43
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 109 of 118
M/S GM SUGAR AND ENERGY LTD SANGUR, HAVERI DISTRICT (KARNATAKA)
PROJECT COST FINANCING PATTERN
PARTICULARS % AMOUNT(in
lakhs)
OWN Finance 10 923
Equity 30 2769
Cash Credit from Bank 8 700 TERM LOAN from Bank 52 4838
Total 100 9230
REPAYMENT OF TERM LOAN
PARTICULARS 2016-17 2017-18
2018-19
2019-20
2020-21
Opening Balance Of Principal 4838.
00 3870.40 2902.
80 1935.
20 967.6
0
Total Installment 967.6
0 967.60 967.6
0 967.6
0 967.6
0
Balance 3870.
40 2902.80 1935.
20 967.6
0 0.00
Interest 283.8
0 387.04 290.2
8 193.5
2 96.76 Note:- Interest for Rs 200 lacs during constructions period is capitalised .
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 110 of 118
M/S GM SUGAR AND ENERGY LTD SANGUR, HAVERI DISTRICT (KARNATAKA)
CALCULATION OF DEBTORS & CREDITORS & INTEREST ON WORKING CAPITAL.
PARICULARS UNIT 2016-
17 2017-
18 2018-
19 2019-
20 2020-
21
Sugar Production MT 42534 89794 94520 94520 94520
Rate 30000 Rs
MT
Total Lakhs 15312.
24 32325.
84 34027.
20 34027.
20 34027.
20
Average Stock Period @ 20 Days Lakhs
1276.02
1771.28
1864.50
1864.50
1864.50
Average Debtor Period @ 20
Days Lakhs 1276.0
2 1771.2
8 1864.5
0 1864.5
0 1864.5
0
Sugar Cane MT 425340 897940 945200 945200 945200
Average Creditor Period @ 20 Days Lakhs
1701.36
1795.88 1890.4 1890.4 1890.4
Interest 10% 35.00 70.00 70.00 70.00 70.00
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 111 of 118
M/S GM SUGAR AND ENERGY LTD SANGUR, HAVERI DISTRICT (KARNATAKA) CALCULATION OF BREAK EVEN POINT
PARICULARS UNIT I II III IV V
Net Sales Lakhs
18,967.68 40043 42150 42150 42150
Variable Cost
Raw Material Lakhs
11,909.52
25142.32 26465.6 26465.6 26465.6
Purchase tax on Sugar Cane Lakhs
357.29 754.27 793.97 793.97 793.97
Chemicals Consumed Lakhs
850.68 1795.88 1890.4 1890.4 1890.4
Power And Fuel Lakhs
861.57 1818.88 1914.61 1914.61 1914.61
Salaries & Wages Lakhs
850.68 1795.88 1890.4 1890.4 1890.4
Repairs & Maintainance Lakhs
102.08 242.44 255.20 255.20 255.20
Selling &Administration Expences
Lakhs
379.35 800.86 843.01 843.01 843.01
Total
15,311.18 32350.5
2995 34053.1
8942 34053.1
8942 34053.1
8942
Fixed Cost
Insurance Lakhs
21.09 37.15 40.15 40.15 40.15
Depreciation Lakhs
694.17 694.17 694.17 694.17 694.17
Preliminary Expenses W/off Lakhs
40.00 40.00 40.00 40.00 40.00
Interest On Term Loan
283.80 387.04 290.28 193.52 96.76 Interest on Working Capital
loan
35.00 70.00 70.00 70.00 70.00
Total
1,074.06 1228.36 1134.60 1037.84 941.08
Contribution Lakhs
3,656.50
7,692.34
8,097.20
8,097.20
8,097.20
Contribution Per KG Lakhs
8.60
8.57
8.57
8.57
8.57
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 112 of 118
Break Even Point(In MT Of Sugar)
M.T
12,493.89
14,338.8
1
13,244.3
4
12,114.8
4
10,985.3
5
Break Even Sales(in lacs)
5,571.54
6,394.27
5,906.20
5,402.51
4,898.82 Break Even sales in terms
of % 29.37
15.97
14.01
12.82
11.62
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 113 of 118
M/S GM SUGAR AND ENERGY LTD SANGUR, HAVERI DISTRICT (KARNATAKA)
STATEMENT SHOWING DEBT SERVICE COVERAGE RATIO SNO. PARTICULARS UNIT
2016-17
2017-18
2018-19
2019-20
2020-21
1 Net Profit / Loss Lakh Rs.
2582.44
6463.98
6962.60
7059.36
7156.12
2 Add Back: Depreciation 627.5
0 627.5
0 627.5
0 627.5
0 627.5
0
Add Back: Preliminary Expencesw
w/off 40.00 40.00 40.00 40.00 40.00
3 Interest on Term Loan 283.8
0 387.0
4 290.2
8 193.5
2 96.76
Interest on Cash Credit 35.00 70.00 70.00 70.00 70.00
4 Cash Available for DSCR 3568.
74 7588.
52 7990.
38 7990.
38 7990.
38
5 Debt to be Serviced
Term Loan From bank 967.6
0 967.6
0 967.6
0 967.6
0 967.6
0
Interest on Term Loan 283.8
0 387.0
4 290.2
8 193.5
2 96.76
Interest on Cash Credit 35.00 70.00 70.00 70.00 70.00
Total 1286.
40 1424.
64 1327.
88 1231.
12 1134.
36
6 Debt Service Coverage ratio 2.77 5.33 6.02 6.49 7.04 7 Average DSCR 5.53
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 114 of 118
M/S GM SUGAR AND ENERGY LTD SANGUR, HAVERI DISTRICT (KARNATAKA)
STATEMENT OF SOURCES AND APPLICATIONS OF FUNDS DURING
CONSTRUCTION AND THE YEAR THEREAFTER
SNO PARTICULARS UNIT
2016-17
2017-18
2018-19
2019-20
2020-21
SOURCES OF FUNDS A INTERNAL:
1 Profit after Depreciation but before
intt/tax 2582.
44 6463.
98 6962.
60 7059.
36 7156.
12
2 Depreciation 627.5
0 627.5
0 627.5
0 627.5
0 627.5
0 40.00 40.00 40.00 40.00 40.00 B EXTERNAL
1 Share Capital Lakh Rs. 923
Equity 2769
2 Term loan AND CASH CREDIT From
Bank 5538
TOTAL 12479
.94 7131.
48 7630.
10 7726.
86 7823.
62 APPLICATION OF FUNDS 1 Capital Expenditure On Project 8330
2 paymant of Term Loan 967.6
0 967.6
0 967.6
0 967.6
0 967.6
0
3 Working Capital Margin 566.4
1
4 preliminary expences 200.0
0
TOTAL 10064
.01 967.6 967.6 967.6 967.6
Opening Balance 0 2415.
93 8579.
82 15242
.32 22001
.59
Additions 2415.
93 6163.
88 6662.
50 6759.
26 6856.
02
Closing Balance to be utilised into further expansions
2415.93
8579.82
15242.32
22001.59
28857.61
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 115 of 118
M/S GM SUGAR AND ENERGY LTD SANGUR, HAVERI DISTRICT (KARNATAKA)
STATEMENT OF AFFAIRS
SNO PARTICULARS
2016-17 2017-18 2018-19 2019-20 2020-21
I. Equity and liabilities 1 Shareholder's funds (i) Share capital 3692 3692 3692 3692 3692
(ii) Reserves and surplus
1730.
24 6061.11 10726.0
5 15455.8
3 20250.4
3
5422.
24 9753.11 14418.0
5 19147.8
3 23942.4
3 2 Non-current liabilities (i) Long-term borrowings
Bank Loan
3870.
40 2902.80 1935.20 967.60 0.00 (ii) Other long term liabilities Long-term provisions
3870.
40 2902.80 1935.20 967.60 0.00 3 Current liabilities (i) Short-term borrowings
(ii) Trade payables
1701.
36 1795.88 1890.4 1890.4 1890.4 (iii) Other current liabilities Working Capital Margin 700 700 700 700 700
Provision for Tax
852.2
1 2133.11 2297.66 2329.59 2361.52
3253.
57 4628.99 4888.06 4919.99 4951.92
Total
12546
.20 17284.9
0 21241.3
1 25035.4
2 28894.3
5
II. Assets
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 116 of 118
1 Non-current assets
(i) Fixed assets
7635.
83 6941.66 6247.49 5553.32 4859.15 Capital work-in-progress
CAPITAL EXPANSION
PROGRAMME 200 800 1600 2500 (ii) Non-current investments
(iii) Long-term loans and advances
(iv) Other non-current assets 160 120 80 40 0
7795.
83 7261.66 7127.49 7193.32 7359.15 2 Current assets Current investments
(i) Inventories
1276.
02 1771.27
8904 1864.50
411 1864.50
411 1864.50
411
(ii) Trade receivables
1276.
02 1771.27
8904 1864.50
411 1864.50
411 1864.50
411
(iii) Cash and bank balances
122.6
7 115.55 235.34 239.91 209.3
(iv) Short-term loans and advances
2674.
71 3658.10
7808 3964.34
8219 3968.91
8219 3938.30
8219
10470
.54 10919.7
7 11091.8
4 11162.2
4 11297.4
6
-2075.
66 -6365.13
-10149.4
7
-13873.1
8
-17596.8
9
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 117 of 118
M/S GM SUGAR AND ENERGY LTD SANGUR, HAVERI DISTRICT (KARNATAKA)
DEPRECIATION CHART
ASSET UNIT BUILDING AND CIVIL
WORKS PLANT AND MACHINERY
MISC. FIXED ASSETS
TOTAL
Capital Cost Lakh Rs. 620 7210 500
8330
Life Of Asset years 12 12 12 12
Dep for the year 51.67 600.83 41.67 694.17
Expansion cum Modernization Project (2500 TCD to 4800 TCD), for M/s GM Sugar
and Energy Ltd Prepared by National Sugar Institute, Kanpur.
Page 118 of 118
M/S GM SUGAR AND ENERGY LTD SANGUR, HAVERI DISTRICT (KARNATAKA)
CALCULATION OF INTERNAL RATE OF RETURN
S NO. PARTICULARS UNIT CONST.
2016-17
2017-18
2018-19
2019-20
2020-21
1 Total Inflow Lakh Rs.
3568.74
7588.52
7990.38
7990.38
7990.38
2 Capital Expenditure Lakh Rs. 8330
3 Net Cash InFlow 35128.42
4 IRR 8.63%