DETAILED PROJECT REPORT
OF

2500 TCD SUGAR WITH 14 MW COGENERATION PLANT

For
OM SUGARS PVT LTD.,
BC – 132 LODGE ROAD, BOGARVES CAMP, BELGAUM

By
Ugar Consultancy Ltd., Ugar Khurd, Tq Athani Dist Belgaum
MAY 2011

Contents
EXECUTIVE SUMMARY HIGHLIGHTS OF THE PROJECT 1. 2. 3. 4. 5. 6. 7. INTRODUCTION NEED FOR THE PROJECT SUGAR CANE AVAILABILITY PRODUCT SALE POLICY TECHNO COMMERCIAL ASPECTS LOCATION AND SITE ASSOCIATED DETAILS TECHNICAL FEATURES (SPECIFICATIONS) OF MAJOR EQUIPMENTS 8. 9. 10. 11. 12. DESCRIPTION OF MAJOR PROCESS RISK ANALYSIS AND MANAGEMENT PROJECT COST ESTIMATION PROJECT IMPLEMENTATION SCHEDULE MANPOWER REQUIREMENT LIST OF ANNEXURES 13. ANNEXURE – I KERC / KPTCL POLICY LIST OF APPENDICES 14. 15. APPENDIX – I BAGASSE ANALYSIS APPENDIX – II CANE TRASH ANALYSIS 124 125 118 – 123 85 – 97 98 – 104 105 – 109 110 – 114 115 – 117 1–8 9 – 11 12 – 16 17 – 19 20 – 36 37 – 39 40 – 47 48 – 59 60 – 84

16. 17.

APPENDIX – III RICE HUSK ANALYSIS APPENDIX – IV COAL ANALYSIS LIST OF DRAWINGS

126 127

18.

DRAWING – I BAGASSE BALANCE – SEASON OPERATION

128

19. 20. 21.

DRAWING – II STEAM BALANCE – SEASON OPERATION DRAWING – III POWER BALANCE – SEASON OPERATION DRAWING – IV STEAM BALANCE – NON CRUSHING OPERATION

129 130 131

22.

DRAWING – V POWER BALANCE – NON CRUSHING OPERATION

132

23.

DRAWING – VI HEAT & MASS BALANCE - SEASON OPERATION

133

24.

DRAWING – VII HEAT & MASS BALANCE – NON CRUSHING SEASON

134

25. 26. 27. 28. 29. 30.

DRAWING – VIII LAYOUT DRAWING (TENTATIVE) FINANCIAL PROJECTIONS ASSUMPTIONS FOR PROJECTIONS HIGHLIGHTS OF PROJECTIONS SCHEDULES A – H ANNEXURES 1 TO 17

135 137 137 – 139 140 – 142 143 – 152 153 - 172

Executive Summary Preamble (Process Description)
1.1 Sugarcane grown in the field will be harvested after maturity and harvested cane (de-trashed) will be brought to the