PRE-FEASIBILITY REPORT
Modernization cum Expansion of Sugar Unit from 5,000 to
8,000TCD Capacity and Cogeneration Project of 19.5 MW
Installed Capacity
M/s. Karmayogi Shankarraoji Patil Sahakari Sakhar Karkhana Limited
Mahatma Phule Nagar, Bijwadi, Taluka Indapur, District Pune, Maharashtra
Prepared By
VASANTDADA SUGAR INSTITUTE *
Manjari (Bk), Pune, Maharashtra 412 307
Telephone: (020) 26902100, 26902343/7/6, Fax (020) 26902244
Web Site: www.vsisugar.com
*Accredited by QCI/NABET (Provisional) for EIA consultancy services
Recognized R & D Center by Department of Scientific and Industrial Research (DSIR), Ministry of
Science and Technology, Government of India and P.G. and Doctoral Research Center by ‘University
of Pune’
March 2012
Prefeasibility Report Sugar and Cogeneration Project
Karmayogi Shankarraoji Patil SSKL, Indapur
2
PRE-FEASIBILITY REPORT
KARMAYOGI SHANKARRAOJI PATIL SAHAKARI SAKHAR KARKHANA LIMITED
EXPANSION OF SUGAR UNIT FROM 5,000 TO 8,000TCD AND 19.5MW COGENERATION
UNIT
1.0 INTRODUCTION
The Karmayogi Shankarraoji Patil Sahakari Sakhar Karkhana Limited (KSPSSKL), is
located at Mahatma Phule Nagar, village Bijwadi Tal-Indapur, Dist-Pune. It is 1.5km off
Pune-Hyderabad National Highway (NH 9). Initial crushing capacity of the KSPSSKL was
1750 TCD. On account of modernization of the plant from time to time and by effective
utilizing of in-built capacity of the plant the KSPSSKL has achieved a crushing capacity of
+5,000 TCD since 1999-2000. The sugar factory also operates a molasses based
distillery of 30 KLPD capacities.
2.0 HIGHLIGHTS OF THE PROJECT
Project
Proponent
Karmayogi Shankarraoji Patil Sahakari Sakhar Karkhana Limited
(KSPSSKL)
Geographical Location 18008’N;
74057’E
523 MSM
Nearest City/Town Indapur is the nearest town 08 km from the site.
Road The site is located off Pune-Solapur National highway
No. 09. Distance- 1.5 km from factory site
Railway Station Baramati railway station 45 from the site.
Air Port Pune is the nearest airport 135 km from the site.
East Village Rajwadi 2.5
West Kaulthali 3.5 Km
North National Highway 9 – 1.5km
South Village Ramoshiwadi 1.5Km
Prefeasibility Report Sugar and Cogeneration Project
Karmayogi Shankarraoji Patil SSKL, Indapur
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Location of the
project
Mahatma Phule Nagar, village Bijwadi Tal-Indapur, Dist-Pune
Maharashtra
Email : indrasugar@yahoo.com
Ph no: 02111-2886103/123/144/146
Fax : 02111 – 286105
Land 18 acres built up area after expansion,
6 acres provided for green belt development
Project Modernization cum expansion of sugar unit from 5,000 TCD to
8,000 TCD along with cogeneration unit of 19.5 MW installed
capacity
Product i) White Sugar: 920 MT/Day
ii) Bagasse : 2240 MT/Day
iii) Molasses ; 320 MT/Day
iv) Press mud: 320 MT / Day
v) Power: 18.585 MW electricity
Running Days 210 Days
Main Raw
Material
i) Sugar Cane: 8,000 MT/Day
ii) Lime : 9.76 MT/Day (0.15% Cane )
iii) Sulfur: 4.64 MT/Day (0.05% Cane )
iv) Bagasse : 1,690 MT/day
Water
Requirement
2,835 m3/day Ujani dam (Permission available )
Fuel Bagasse –1690 MT/day
3.0 Need of Project and its importance to the country and region:
India is the second largest producer of sugar over the globe. With more than 45
millions of sugar cane growers in the country, the bulk of the rural population in India
depends on this industry. One of the agro-based industries in India, the sugar industry is
the second largest agricultural industry followed after the textile industry. Maharashtra
Sugar Industry is one of the most notable and large-scale sugar manufacturing sectors in
the country.
There are few major reasons for the expansion of the sugar factory and
increasing availability of cane and pressing demand of the local share holder farmers to
crush all the cane they grow is the foremost reason. Since, the Karkhana is located
Prefeasibility Report Sugar and Cogeneration Project
Karmayogi Shankarraoji Patil SSKL, Indapur
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towards east of the Pune district, where an excellent network of canals exist. The
command area of the KSPSSKL comprises 112 villages from Indapur and Daund talukas
of Pune district and Karmala, Malshiras & Madha talukas of Solapur district. Out of total
command area of the KSPSSKL, 70% area is irrigated by Ujani and 30% area is under
well irrigation. Nira right bank canal project also covers some area under irrigation.
Hence the availability of water is ample in the area; and thus the area under cultivation
of sugar cane is going on increasing every year. Increase in the cane production can also
trace though the figures of cane crushed by the KSPSSKL during previous 10 years.
Table 1: Production of Sugar cane and cane crushing for last 10 Years
Sr. No. Year Total Cane crushed
(MT)
Total Cane production in area
(MT)
1 2000-01 5,91,560 87,000
2 2001-02 8,08,516 3,53,000
3 2002-03 7,49,863 8,00,000
4 2003-04 4,16,597 5,00,000
5 2004-05 3,98,077 5,00,000
6 2005-06 8,76,907 10,46,000
7 2006-07 12,34,935 13,50,000
8 2007-08 12,11,128 13,25,000
9 2008-09 9,89,976 11,00,000
10 2009-10 12,83,800 14,00,000
In season 2010-11 the expected crushing will 13, 59,500 where as the production or
availability is about 16, 00,000 MT. The above table infers that there is ample sugarcane
available in the command area of the KSPSSKL. However, the crushing capacity is a
limiting factor to fulfill the demand of the local farmers. The sugar cane cultivation is
anticipated to grow at least for next few seasons. Thus, the KSPSSKL has to develop its
infrastructure to crush all available cane in the command area. Hence, the management
has decided to modernize the existing 5,000 TCD sugar factory and install a 3,000 TCD
unit so as to increase the cane crushing capacity of the KSPSSKL to 8,000 TCD.
The present peak demand of power is more than 16,000 MW and only 13,000 MW is met
thorugh various sources. Considering the immediate requirements of energy and till the
end of the present period, about 5,737 MW shall be installed during the next four years,
hence the government of Maharashtra permitted such an sugar factory to utilize the
Prefeasibility Report Sugar and Cogeneration Project
Karmayogi Shankarraoji Patil SSKL, Indapur
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resource-able energy fuel and to make a power which will helps to decrease the energy
deficit.
While doing this, optimum utilization of the available resource is strived by the
management, by using a renewable energy source of bagasse. Bagasse is a by-product of
sugar factory, used as a fuel for boilers that produces process steam. Bagasse-based
cogeneration project is an effort for efficient use of available bagasse and steam to
generate the power for to fulfill the captive need and export the surplus to the state grid.
Hence, the KSPSSKL is installing a new 15MW capacity steam turbine, in addition to
existing 1.5 and 3MW. Thus, it will have an installed capacity of 19.5MW and it will
produce an electricity of 18.585MW.
4.0 Demand- Supply Gap
The present peak demand of power is 15,988 MW and only 11,800 MW is met during the
period 2009. Including the present deficit and projected growth rate, about 18,759 MW
shall be added till the end of 12th plan period. Considering the immediate requirements
of energy, another 5,600MW shall be added during 11th plan period ending 2012; hence
the Government of Maharashtra permitted such an sugar factory to utilize the resourceable
energy fuel and to made a power which will helps to decrease the energy deficit.
Table 2: Data on Monthly Demand~ Supply gap in MW in the state for Year 2009
2009
Month Demand Availability Short fall*
Jan-09 14,926 10,151 4,775
Feb-09 15,272 11,010 4,262
Mar-09 15,332 11,536 3,796
Apr-09 15,195 11,325 3,870
May-09 15,304 11,179 4,125
Jun-09 14,387 11,175 3,212
Jul-09 13,044 10,317 2,727
Aug-09 15,171 11,384 3,787
Sep-09 14,800 11,598 3,202
Oct-09 15,572 11,714 3,858
Nov-09 15,988 11,883 4,105
Dec-09 15,386 11,713 3,673
*Peak shortfall on a particular day of the month
V. Import vs. Indigenous production
Prefeasibility Report Sugar and Cogeneration Project
Karmayogi Shankarraoji Patil SSKL, Indapur
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The process is straight line and the technology even for the pollution control/disposal is
available indigenously
VI. Export Possibility
The finished products viz. Sugar, have export possibility and the surplus power
generated form cogeneration will be export to the local grid.
VII. Domestic / export markets
Local as well as international market is available for sugar and molasses. Electricity will
be exported to the local grid of MSEDCL.
VIII. Employment Generation:
The KSPSSKL requires educated and skilled staff at expanded sugar factory as well as
cogeneration unit. This requirement is furnished table 3. The indirect employment is
anticipated to be plenty, since the project is going to produce surplus power. This power
may be used to run various businesses and agricultural activities
Table 3: Employment Potential of Sugar & Cogeneration Project
Engineer Department Manufacturing
department
Additional Manpower
Designation Number Designation Number Designation Number
Assistance Engineer 04 Manufacturing
Chemist
04 Instrument engineer 01
Electrical engineer 01 Juice
Supervisor
04 Mechanical Engineer 01
Electrical supervisor 04 Pan In charge 04 Electrical Engineer 01
Mill & Boiling House
Fitter (A grade)
08 Pan man 04 Instruments
Technician
04
Mill & Boiling house
Fitter (B grade)
04 Quadruple
met
04 Electrical
Supervisor
01
Turbine attendant 04 Centrifugal
Met
04 Mechanical
Supervisor
01
Electrician 04 Sugar house
Clerk
04 Switch board
attendant
03
Wireman 07 ——– —— —— —–
Total Staff 40 Total 28 Total 12
