Final_report

REPORT ON PROCESS OVERVIEW OF
GOBIND SUGAR MILLS LTD.
BY-
K.VENUGOPAL
ASST. ENGINEER (MECHANICAL)
CO-GENERATION POWER PLANT

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INDEX
1. INTRODUCTION...............................................................................................................................4
1.1 CONTRIBUTION OF SUGAR INDUSTRY TOWARDS INDIAN ECONOMY.......................5
2. CANE CULTIVATION PROCESS ..................................................................................................7
2.1 SOWING OF SUGARCANE SEEDS ..........................................................................................7
2.1.1 PREPARATION OF FIELD.....................................................................................................7
2.1.2 PLANTING...............................................................................................................................8
2.2 HARVEST OF SUGARCANE.....................................................................................................8
2.3 VENDING PROCESS OF SUGARCANE TO THE PLANT.......................................................8
2.4 INSPECTION OF THE SUGARCANE........................................................................................9
2.5 COST AND PURCHASE OF SUGAR CANE ...........................................................................10
2.6 WELFARE OF FARMERS ........................................................................................................10
3. CANE CRUSHING PROCESS .......................................................................................................13
3.1 STAGES OF CRUSHING SUGARCANE .................................................................................13
3.2 AUXILIARY CANE CARRIER DRIVE....................................................................................15
3.3 BELT CONVEYOR DRIVE.......................................................................................................15
3.4 ROLLER MILL ..........................................................................................................................15
4. SUGAR PRODUCTION ..................................................................................................................19
4.1 COMPOSITION OF SUGARCANE ..........................................................................................19
4.1.1 BOTANY OF SUGARCANE ................................................................................................19
4.1.2 COMPOSITION OF JUICE ...................................................................................................19
4.1.3 COMPOSITION OF FIBRE...................................................................................................20
4.2 SUGAR PRODUCTION PROCESS ..........................................................................................20
5. CO-GENERATION POWER PLANT ...........................................................................................26
5.1 WATER TREATMENT PLANT................................................................................................26
5.2 PROCESS OF WATER TREATMENT .....................................................................................26
5.2.1 BORE WELL..........................................................................................................................26
5.2.2 WATER RESERVOIR TANK AND TRANSFER PUMP ....................................................26
5.2.3 HYPODOSING.......................................................................................................................27
5.2.4 MAKE-UP WATER TREATMENT......................................................................................27
5.2.5 INTERNAL CORROSION.....................................................................................................27
5.2.6 BOILER WATER TREATMENT..........................................................................................28
5.2.7 REVERSE OSMOSIS SYSTEM............................................................................................28
5.2.8 STRONG ACID CATION RESIN .........................................................................................29
5.2.9 STRONG BASE ANION RESIN...........................................................................................29
5.2.10 MIXED BED EXCHANGE PROCESS .............................................................................29
5.3 BOILER ......................................................................................................................................31
5.3.1 WATER & STEAM SYSTEM...............................................................................................31

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5.3.2 AIR & FLUE GAS SYSTEM.................................................................................................33
5.3.3 FUEL STORAGE AND FIRING SYSTEM...........................................................................34
5.3.4 ASH HANDLING SYSTEM..................................................................................................37
5.3.5 BOILER STRUCTURES........................................................................................................37
5.3.6 BOILER TECHNICAL DATA...............................................................................................37
5.4 TURBINE ...................................................................................................................................38
5.4.1 DESIGN FLOW PATH ..........................................................................................................38
5.4.2 NOZZLE SEGMENT AND DIAPHRAGMS ........................................................................39
5.4.3 TURBINE ROTOR AND MOVING BLADES .....................................................................39
5.4.4 ROTOR GLANDS..................................................................................................................40
5.5 ELECRICALS AND EQUIPMENT...........................................................................................41
5.6 ELECTRICAL EQUIPMENTS AND ITS SPECIFICATIONS: ................................................42
6. VARIOUS DEPARTMENT.............................................................................................................45
6.1 HUMAN RESOURCE DEPARTMENT ....................................................................................45
6.2 BIRLA INDUSTRIAL PROVIDENT FUND.............................................................................45
6.3 PENSION BENEFITS ................................................................................................................46
6.4 ACCOUNT DEPARTMENT......................................................................................................47
6.4.1 SALARY BREAKUP FOLLOWED BY THE ACCOUNTS DEPARTMENT ....................47
6.4.1.1 BASIC SALARY-...........................................................................................................47
6.4.1.2 LTA- ...............................................................................................................................47
6.4.1.3 MEDICAL-.....................................................................................................................49
6.4.1.4 EX-GRATIA- .................................................................................................................49
6.5 STORES......................................................................................................................................49
6.5.1 MATERIAL RECIEVEING PROCEDURE ..........................................................................49
6.6 MATERIAL ISSUE PROCEDURE ...........................................................................................51
7. REFERENCE....................................................................................................................................52

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1. INTRODUCTION
Gobind Sugar Mills Limited (GSML), established in the year 1952, was a part of Dr.K.K.Birla
group of sugar companies. The company which is now part of the Adventz Group is one of the
oldest sugar mills in the country with almost 60 years of continuous operation. The sugar mill at
Aira Estate in Lakhimpur Kheri District of Uttar Pradesh has a present cane crushing capacity of
7500 TCD. Apart from selling the finished product plantation white sugar, the company also sells
molasses, the basic raw material for ethanol production and the surplus bagasse from the season
operations.
The company is upgrading the crushing capacity of the mill from 7500 TCD to 10,000 TCD and
is also adding a 5000 TPD sugar refinery. The upgraded plant with the sugar refinery will be
operational for the crushing season 2015-2016. As part of their program to utilize the byproducts
of the sugar mill effectively, GSML has added a 30.8 MW bagasse based Cogeneration plant which
is ready for commissioning. After completing the sugar mill expansion and Cogeneration projects,
GSML proposes to add a 60KLPD ethanol distillery, which will predominantly consume the
molasses generated in-house. The company is currently planning to split the sugar production plant
into two parts, Sugar refinery plant producing the refined sugar of consumer standard and
pharmaceutical standard. Another portion is the old sugar mill producing the double sulphited
sugar. The old plant will be reduced to 5000 TCD from 7500 TCD and the refinery will have the
5000 TCD. The cogeneration power plant is using condense cum extraction turbine providing 3Ata
steam for sugar production use and ~22MW (on season) and ~27MW (off season) electricity is
generated with 10MW for plant use and rest to be sold directly to the Uttar Pradesh government.
The ethanol distillery plant will prove a great profiting factor for the company. Alcohol
manufactured from sugar mills, by virtue of its renewable nature is an eco-friendly fuel which will
be a worthy substitute for gasoline to prevent global warming. Many countries have taken up
aggressive usage of absolute alcohol, also commercially called as Ethanol, to reduce the
dependence on petroleum. Presently, ethanol is blended with gasoline in varying proportions to
get the motor spirit. Brazil has done pioneering work in this direction, followed by many countries.

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1.1 CONTRIBUTION OF SUGAR INDUSTRY TOWARDS INDIAN
ECONOMY
a) Sugar industry is the second-largest agro based industry in India. Which is the 2nd
largest
producer in the world after Brazil over 22 percent of sugar.
b) Sugar industry provides 3.25 lakh employment to the laborers, and indirect employment
to 425 lakh farmers who are producing the sugarcane.
c) The environmental benefits due to green fuel and lower CO2 emission from production
would benefit the national economy in the long term.
d) Ethanol blending from distilleries leads to saving for the national economy due to lower
dependence on crude oil imports and reduction in subsidy expense for gasoline.
e) The sugar industry contributes to the exchequer through a number of taxes levied across
the value chain. When the mills purchase sugarcane, a purchase tax is levied by the
respective state governments.
f) The sugar industry generates surplus exportable energy through cogeneration and
contributes in reducing the energy deficit that India is currently facing.
g) The sugar industry is also the primary source of raw material for the alcohol industry in
India. The annual economic contribution of the sugar industry to the exchequer through
principal indirect taxes amounts to more than INR 2800 crores.

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2. CANE CULTIVATION PROCESS
2.1 SOWING OF SUGARCANE SEEDS
The first blossom of sugar industry starts with the sowing of sugarcane seeds. Careful
measurements to be taken under consideration of for better placement of crops at safe inter
displacement of the sugarcane.
Main Field Preparation for Planting Sugarcane
2.1.1 PREPARATION OF FIELD
a) Wetland (Heavy soils):
In wetlands, preparatory cultivation by ploughing the land and bringing the soil to fine tilth could
not be done.
1. After harvest of the paddy crop, form irrigation and drainage channels of 40 cm depth and
30 cm width at intervals of 6 m across the field and along the field borders.
2. Form ridges and furrows with a spacing of 80 cm between rows with spade.
3. Stir the furrows with hand hoes and allow the soil to weather for 4 to 5 days.
b) Problem soils with excessive soil moisture:
In problem soils, with excessive moisture where it is difficult to drain water, form raised beds at
30 cm intervals with Length 5m, Width 80cm, and Height 15cm.
c) Garden lands with medium and light soils:
In medium and light soil irrigated by flow or lift irrigation adopt the following:
1. The initial ploughing with two disc plough followed by eight disc plough and using cultivator
for deep ploughing followed by one time operation of rotovator to pulverize the soil to get a fine
tilth, free of weeds and stubbles.
2. Level the field for proper irrigation.
3. Open ridges and furrows at 80 cm apart with the help of victory plough or tractor drawn ridger.
The depth of furrow must be 20 cm.

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4. Open irrigation channels at 10 m intervals.
2.1.2 PLANTING
Different systems of planting is not found to influence the millable cane population, commercial
cane sugar per cent, cane and sugar yield.
1. Irrigate the furrows to form a slurry in wet land condition (Heavy soil)
2. Place the setts along the center of the furrows, accommodating 12 buds/meter length. Keep
the buds in the lateral position and press gently beneath the soil in the furrow. Avoid
exposure of setts to sunlight.
3. Plant more setts near the channel or double row planting at every 10th row for gap filling,
at later stage. In dry/ garden land dry method of planting may be followed. First arrange
the setts along the furrows, cover the setts with soil and then irrigate.
2.2HARVEST OF SUGARCANE
Harvesting of sugarcane is done through modern harvesting equipment. Highly efficient harvesting
techniques are used to maintain the decay of sucrose level. Harvesting is done in two methods.
1. Manual harvesting: - This type of harvesting is done manually using various types of hand
knives or hand axes. Among the several tools the cutting blade is usually heavier and
facilitates easier and efficient cutting of cane.
2. Mechanical harvesting: - Mechanical harvesting is widely used nowadays. The mechanical
harvesting attachment is snugged to the tractor and reaping of crop takes place. Main
purpose of shifting to this process has primarily two reasons- 1). Less laborious work
towards reaping of crop. 2) Mechanical device results in better reap of sugarcane from the
roots resulting in slow decay of sugar level from the cane.
2.3VENDING PROCESS OF SUGARCANE TO THE PLANT
Transportation of harvested sugarcane takes place in two ways.
1. Farmers bring the harvested crop to plant by their own transport, bullock cart or tractor.
2. Farmers take the sugarcane to their nearest center and sell their crop at the cane centers.

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PROCESS
A. Cane department of Gobind sugar mills start this process by survey of the agriculture area
of all farmers involved in the vending process. Survey lead to categories each farmers on
the basis of their cultivation area.
B. Each farmers is given the schedule and date on which they have to transport the crop to
plant. The schedule will depend on the survey data.
C. Farmers on the scheduled date will be lined up outside the plant or cane centers. There are
over 57 centers dispersed over the radius of more than 80 KM.
D. Tokens will be issued to each vehicle (Bullock cart or tractor). Apart from token a smart
card will be provided which the farmer has to punch during the weightment process.
E. Inspection of sugarcane is done visually by the expert in the cane yard. This is the primary
inspection on the quality of the sugarcane.
F. Each vehicle is brought to the weight pavement and net weight is measured. After
unloading the cane the vehicle is weight measured again to calculate the total weight of
sugarcane brought by the farmers.
G. Unloading of the cane from the vehicle is done at the final stage. Manual unloading is done
or two way overhead conveyer is used to unload. The unloaded cane is sent feeder through
cane carrier for crushing process.
H. Cane payment receipt is given to the farmers, amount is paid within 14 days as per
government norms.
2.4INSPECTION OF THE SUGARCANE
1. Inspection for the quality of the sugar cane takes place in two places:
a. Cane yard
b. Weight platform
2. There are two inspection officer one from company side and another from Uttar Pradesh
government society.
3. Every process is carefully overviewed by the government officer and his signature is needed
to go through further operation of vending process.
4. Inspection officer from company side visually go through every lot for quality checking.
5. Quality of sugarcane is categorized under three parts.

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a. Early stage
b. General stage
c. Rejected stage
6. Usually early stage is the best in terms of sugar recovery rate. Rejected stage cane lot is
received for lesser amount, due to low recovery rate.
2.5COST AND PURCHASE OF SUGAR CANE
1. Costing of the sugarcane is done by the Uttar Pradesh government. These price are fixed
in accordance with the following situation:
a. Economy of India for sugar sales
b. Farmer’s welfare
c. Sugar mill welfare
2. In the seasonal year 2014-2015 the rate fixed by the Uttar Pradesh government for sugar
cane is Rs.280 per quintal.
3. For low recovery stage cane the price is around Rs.275 per quintal
4. Price breakup for government fixed price is
a. Factory---------------------------------------------------------------Rs.240 per quintal
b. Uttar Pradesh Government----------------------------------------Rs.28 per quintal
c. Transport charge----------------------------------------------------Rs.12 per quintal
5. After receiving the indent from the engineering department for the target of crushing per
day, cane department orders the required cane.
6. Purchase orders and purchase receipt are made in the cane centers and in the plant after the
weighing is done.
7. Payment receipt is computer generated, after the calculating the net weight of the cane the
payment receipt is generated by the software used for making the payment receipt.
2.6WELFARE OF FARMERS
Various activities are undertaken for the welfare of the farmers cultivating sugarcane. These
includes:

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1. Provision of fertilizers manufactured by Zuari agro chemicals Ltd. These fertilizers are
custom manufactured for sugarcane to improve the growth and to defend the diseases in
the cane cultivation.
2. High yield crop seeds are provided by the Uttar Pradesh government after the influence of
the sugar mills association.
3. Cane department and soil expert team of Gobind Sugar Mills Ltd. meet the farmers and
educate them about the correct procedure for using the fertilizers and the right amount of
chemicals to be mixed with the fertilizers.
4. Cane department team work on the ways to increase the yield of the sugarcane from the
same piece of cultivation land. Recent success of the team lead to increase in the 450-500
quintal per hectare from 300 quintal per hectares.
5. Loans are provided to farmers for advancement in the process of cultivating the crops.
6. Mechanical harvesting equipment are provided to the farmers at lower prices for improved
reaping of the crops leading to less loss of sucrose level.

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3. CANE CRUSHING PROCESS
3.1STAGES OF CRUSHING SUGARCANE
Crushing of sugarcane is the most critical process in sugar industries. The recovery of sucrose
from the cane depends upon the crushing process. Power cogeneration in sugar industry rely on
the bagasse as the fuel from the sugar mill. The crushing technique undergoes mainly two stages:
a. PREPARATION -
1. This involves slicing of sugarcane into small chunks. Chunks of cane result in better
recovery of sugarcane juice.
2. Use of knife and hammer gear system results in slicing action sustained with hammering
action.
3. The object of cane preparation is to pulverize cane into small pieces for feeding the mills
and also to rupture the cells, without extracting juice.
4. Hammering action is used to beat the chunks of cane to blow up the porous fiber of cane.
5. Sugarcane accumulates sucrose at concentrations up to 62% dry weight (16 to 25% fresh
weight) in the storage parenchyma cells of the mature culm.
6. The preparatory devices commonly employed and installed before the milling tandem are
classified into three types-
i. Knives which cut the cane into pieces,
ii. Shredder which shred cut cane into long fine pieces,
iii. Fibrizer combining the features of (i) and (ii).
7. The percentage of cells opened, which is indicative of the preparation of the cane is-
i. 50-60% in the case of two sets of knives.
ii. 85-90% with a combination of knives and a shredder or a heavy-duty shredder
alone.
iii. 75-80% for a fibrizer.
b. CRUSHING -
1. The milling process essentially involves the removal of juice from sugarcane by squeezing
the cane between pairs of large cylindrical rolls in a series of milling units collectively
called a milling train

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2. The first milling unit in the milling train is generally identified as #1 mill; the second
milling unit is generally identified as #2 mill, and so on. The last milling unit is generally
called the final mill. At Gobind Sugar Mills Ltd. due to addition of a new 2 gear train mill
it is named as zero mill.
3. The chunks are crushed after the preparation stage in the mill section.
4. 3 gear mills powered but steam turbines and new 2 gear mill powered by the VFD motor
are used in the 4 stage crushing of the cane.
5. The comparison of turbine vs. VFD motor is made which resulted in the higher efficiency
of the VFD motor.
6. The steam used to drive the turbine is replaced with VFD to recover the efficiency loss and
steam loss.
7. After passing through a pair of rolls and expressing juice, the remaining sugarcane material
is known as bagasse.
8. Only the first milling unit in the milling train processes prepared cane. The remaining
milling units process bagasse.
After being processed by a mill, bagasse typically consists of 50-55% of fiber, 50-45% of water
and a diminishing quantity of sugar soluble as subsequent milling units process the bagasse.
To aid in the extraction of juice from the much drier bagasse, water or diluted juice is added to
the bagasse before it enters the milling unit in a process called imbibition. The juice expressed
from the final milling unit is used as imbibition juice for the second last milling unit. The juice
from the second last milling unit is then used as imbibition juice for the third last milling unit.
This process continues back to the second milling unit. After first passing through a juice rotary
screener to remove most of the fiber in the juice, the juice from the first and second milling
units, called mixed juice, is taken away for processing into sugar. The fiber removed in the
juice screen is returned to the milling train, usually before the second milling unit. The bagasse
from the final milling unit is taken away for further processing, typically for burning in the
boiler furnace for power generation.
After the canes are unloaded in the unloading area, cane are transported to the milling section.
The conveying process of the cane undergoes two parts as follow.

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3.2AUXILIARY CANE CARRIER DRIVE
Auxiliary cane carrier is used to feed the cane to the feeder and transference it to the belt conveyor.
It consist of a moving grate which is supported by the chain drive and individual grates for carrying
the whole cane. The chain drive is motor driven and the whole driving system is called auxiliary
cane carrier drive.
3.3BELT CONVEYOR DRIVE
After the auxiliary cane carrier feed the cane to the belt conveyor, it further feeds the cane into
milling section. Belt conveyor transfer the cane by the induced chain drive. The belt drive ramps
at an angle and gradually increases the ramp angle closer to reaching the milling section. The ramp
is provided to feed the cane into the crushing roll from an elevation.
3.4ROLLER MILL
Although there are many mill designs used around the world, the six-roller mill is widely used.
The main crushing part of the milling units consists of three rollers. These rollers are named the
top roller, feed roller and the delivery roller and are collectively called the mill rollers. There are
two nips in this part of the milling unit known as the feed nip and the delivery nip. A trash plate
scrapes the bagasse away from the feed roller and helps to feed the bagasse into the delivery nip.
A pressure feeder consists of two rollers known as the top pressure feeder roller and the bottom
pressure feeder roller. The pressure feeder feeds bagasse through the pressure feeder nip along a
pressure feeder chute into the main crushing part of the milling unit.
The underfeed roller forms a nip with the top pressure feeder roller that is known as the underfeed
nip. Bagasse exiting the underfeed nip is fed into the pressure feeder. A vertical or nearly vertical
closed feed chute feeds the bagasse into the underfeed nip. The six rollers are arranged so that the
prepared cane or bagasse passes through four squeezes between the entry and the exit of the milling
unit.

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Drive system used for the mill is steam turbine driven. A 2MW steam turbine is to drive the mill,
transmission line is interconnected to the turbine for speed reduction. Output speed of the turbine
is 6400 RPM which is reduced to 4 RPM by the secondary and primary gear train of the
transmission system. Steam for the turbine is generated by the boiler house through a 70 TPH
boiler. The new two gear mill system is equipped with VFD drive to get down the cost of steam
production and electricity generation.
TOP PRESSURE FEED ROLL

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4. SUGAR PRODUCTION
4.1COMPOSITION OF SUGARCANE
4.1.1 BOTANY OF SUGARCANE
Sugarcane is a grass grown in tropical and subtropical countries. It is a complex hybrid of various
species, derived largely from Saccharum officinarum and other Saccharum species. It is
propagated vegetatively by planting pieces of cane stalk. Table below shows a typical chemical
composition of sugarcane
4.1.2 COMPOSITION OF JUICE
Sugarcane is by definition a combination of juice and fibre. The mixture of brix and water
constitutes the juice of the sugarcane. Brix refers to the water-soluble solids in the cane and
includes the sugar. Technically, brix is the concentration of a solution of pure sucrose in water
having the same density as a sample of juice at the same temperature Brix typically constitutes
about 17% of the cane. The density of the juice is a function of the brix of the juice and is
approximately 1080 kg/m3 for a juice with a typical brix fraction of 0.2. The cane juice is viscous
owing to the presence of colloids. Besides water and sucrose, other constituents of the juice include

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glucose, fructose, minerals, proteins, gum, polysaccharides and organic acids. These compounds
may be conveniently divided into groups described in Table below:
4.1.3 COMPOSITION OF FIBRE
Fiber is the dry, water-insoluble matter in the cane. It typically constitutes about 14% to 19% of
the cane and includes any dirt, soil and other insoluble extraneous matter as well. The density of
the fiber is approximately 1530 kg/m3. The percentage of sugar in the cane varies from 8 to 16%
and depends to a large extent on the variety of the cane, its maturity, soil condition, climate and
agricultural practices followed. The weight of hygroscopic water (brix free cane water) is typically
25% of the weight of fiber.
4.2SUGAR PRODUCTION PROCESS
Sugarcane processing is focused on the production of cane sugar (sucrose) from sugarcane. Other
products of the processing include bagasse, molasses, and filter cake. Bagasse, the residual woody
fiber of the cane, is used for several purposes: fuel for the boilers and lime kilns, production of
numerous paper and paperboard products and reconstituted panel board, agricultural mulch, and
as a raw material for production of chemicals. Bagasse and bagasse residue are primarily used as

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a fuel source for the boilers in the generation of process steam. Thus, bagasse is a renewable
resource. Dried filter cake is used as an animal feed supplement, fertilizer, and source of sugarcane
wax. Molasses is produced in two forms: inedible for humans (blackstrap) or as an edible syrup.
Blackstrap molasses is used primarily as an animal feed additive but also is used to produce
ethanol, compressed yeast, citric acid, and rum. Edible molasses syrups are often blends with
maple syrup, invert sugars, or corn syrup.
The juice from the mills is strained to remove large particles and then clarified. In raw sugar
production, clarification is done almost exclusively with heat and lime (as milk of lime or lime
saccharate); small quantities of soluble phosphate also may be added. The lime is added to
neutralize the organic acids, and the temperature of the juice raised to about 95EC (200EF). A
heavy precipitate forms which is separated from the juice in the clarifier. The insoluble particulate
mass, called “mud”, is separated from the limed juice by gravity or centrifuge. Clarified juice goes
to the evaporators without additional treatment. The mud is filtered and the filter cake is washed
with water.
Evaporation is performed in two stages: initially in an evaporator station to concentrate the juice
and then in vacuum pans to crystallize the sugar. The clarified juice is passed through heat
exchangers to preheat the juice and then to the evaporator stations. Evaporator stations consist of
a series of evaporators, termed multiple-effect evaporators; typically a series of five evaporators.
Steam from large boilers is used to heat the first evaporator, and the steam from the water
evaporated in the first evaporator is used to heat the second evaporator. This heat transfer process
continues through the five evaporators and as the temperature decreases (due to heat loss) from
evaporator to evaporator, the pressure inside each evaporator also decreases which allows the juice
to boil at the lower temperatures in the subsequent evaporator. Some steam is released from the
first three evaporators, and this steam is used in various process heaters in the plant. The evaporator
station in cane sugar manufacture typically produces a syrup with about 65 percent solids and 35
percent water. Following evaporation, the syrup is clarified by adding lime, phosphoric acid, and
a polymer flocculent, aerated, and filtered in the clarifier. From the clarifier, the syrup goes to the
vacuum pans for crystallization.

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Crystallization of the sugar starts in the vacuum pans, whose function is to produce sugar crystals
from the syrup. In the pan boiling process, the syrup is evaporated until it reaches the super
saturation stage.
At this point, the crystallization process is initiated by “seeding” or “shocking” the solution. When
the volume of the mixture of liquor and crystals, known as massecuite, reaches the capacity of the
pan, the evaporation is allowed to proceed until the final massecuite is formed. At this point, the
contents of the vacuum pans (called “strike”) are discharged to the crystallizer, whose function is
to maximize the sugar crystal removal from the massecuite. Some mills seed the vacuum pans with
isopropyl alcohol and ground sugar (or other similar seeding agent) rather than with crystals from
the process. From the crystallizer, the massecuite (A massecuite) is transferred to high-speed
centrifugal machines, in which the mother liquor (termed “molasses”) is centrifuged to the outer
shell and the crystals remain in the inner centrifugal basket. The crystals are washed with water
and the wash water centrifuged from the crystals.
The liquor (A molasses) from the first centrifugal is returned to a vacuum pan and reboiled to yield
a second massecuite (B massecuite), that in turn yields a second batch of crystals. The B massecuite
is transferred to the crystallizer and then to the centrifugal, and the raw sugar is separated from the
molasses.
This raw sugar is combined with the first crop of crystals. The molasses from the second boiling
(B molasses) is of much lower purity than the first molasses. It is reboiled to form a low grade
massecuite (C massecuite), which goes to a crystallizer and then to a centrifugal. This low-grade
cane sugar is mingled with syrup and is sometimes used in the vacuum pans as a “seeding”
solution. The final molasses from the third stage is a heavy, viscous material used primarily as a
supplement in cattle feed. The cane sugar from the combined A and B massecuites is dried in
fluidized bed or spouted bed driers and cooled.
After cooling, the cane sugar is transferred to packing bins and then sent to bulk sugar godown.
Cane sugar is then generally bulk loaded to trucks.

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5. CO-GENERATION POWER PLANT
5.1WATER TREATMENT PLANT
Feed water to be used in boiler for steam generation has to be free from minerals and dissolved
gases which might cause scale and sludge formation. Scale formation in pipe cause various
problem in heat insulation and damage to the pipe. Water purification is the process of removing
undesirable chemicals, materials and biological contaminants from raw water. The goal is to
produce water fit for a specific purpose. Water is purified for human consumption but its
purification may also be designed for a variety of other purposes, including meeting the
requirements of medical, pharmaceutical, chemical and industrial applications. Demineralization
water treatment plant is used in Gobind Sugar Mills Ltd. Dimeralised water is soft water but soft
water is not demineralised water Deionization process removes all the anions and cations present
in the hard water. TDS is as low as 10 ppm and the water can be used even in high pressure boilers
Demineralisation of water is done in an ion exchanger. Ion Exchange resins are insoluble cross
linked long chain macro polymer with micro porous structure and the functional groups attached
to the chains are responsible for the ion exchanging properties.
5.2PROCESS OF WATER TREATMENT
Demineralization water treatment plant under goes various stages of treatment which includes:
5.2.1 BORE WELL
Water required for the plant use is taken from underground water sources. Gobind Sugar Mills
Ltd. is located between two rivers namely Sarda River and Ghagra River, contributing rich
resources of water.
5.2.2 WATER RESERVOIR TANK AND TRANSFER PUMP
Water reservoir tank stores the water pumped from the bore well. Water reservoir tank act as the
parent storage tank for all the operation in the water treatment plant. Piping from reservoir tank
goes for fire safety system as the raw water input. Raw water reservoir transfer pump is used to
transfer the raw water from tank for plant operations.

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5.2.3 HYPODOSING
Chlorination is a process used to disinfect the water from bacteria contamination. When chlorine
is added to water, several chemical reactions take place. Some involve the water molecules and
some involve organic and inorganic substances in the water. Hypochlorite compound is used to
treat water to achieve same results as chlorine gas in that they each produce HOCl in water as a
disinfectant. Hypochlorite may be applied in the form of sodium hypochlorite (NaOCl). The
chemical reactions of hypochlorite in water is given below:
NaOCl + H2O HOCl + NaOH
Sodium Hypochlorite Water Hypochlorus Acid Sodium Hydroxide
5.2.4 MAKE-UP WATER TREATMENT
Trouble-free and continuous operations of high pressure boilers call for very stringent feed water
quality. Total dissolved solids and silica, other than corrosion products, being the main
constituents, are responsible for carryover and deposition. Make-up water required is to be
controlled and maintained at low levels. Silica in particular is carried over in the form of vapour
at high pressures, needs to be controlled at low levels. Feed water is used for de-superheating spray
and any contamination of feed water, either from steam condensate or from makeup water, directly
enters the super-heated steam.
5.2.5 INTERNAL CORROSION
Corrosion is a common phenomenon in high pressure boilers. Corrosion in boiler circuits as well
as in pre-boiler circuits can cause tube failures followed by forced shut down of boilers. The causes
of corrosion are
a. pH (acidity or high alkalinity)
b. Oxygen
c. Excessive ammonia (on copper base alloys)

28
d. Concentration of alkalizing agents due to localized overheating.
e. Poor quality of passivating layer or breaking layer due to thermal shocks
f. Decomposition of organics into corrosive products.
5.2.6 BOILER WATER TREATMENT
It is recommended to use coordinated phosphate – pH treatment (sodium to phosphate ratio=3)
method for high pressure treatment excludes free caustic from the boiler water. Caustic present in
boiler results in a ductile-gouging type corrosion. Even if bulk water does not contain large amount
of free caustic, there is great potential for caustic to concentrate and cause corrosion. Internal metal
oxide deposits provide sites for concentration. As steam is produced, dissolve solids concentrate
in the thin filling between tube wall and bulk fluid. Low sloped tubes permit concentration. It has
been well established that phosphate even concentrated under hide- out conditions is not aggressive
to the tube metal. Congruent phosphate program (sodium to phosphate ratio 2.6) takes care of both
caustic and acid corrosion but control of sodium phosphate ratio is difficult, calling for continuous
feed and blow down.
5.2.7 REVERSE OSMOSIS SYSTEM
Reverse osmosis technology has developed substantially. Systems have become more reliable, and
membrane performance has improved to a level where RO systems can routinely remove 99% or
greater of the influent dissolved solids. Reverse osmosis has become particularly popular as a
retrofit ahead of an existing demineralizer, or as part of a combined system, i.e., RO plus mixed
bed, for new installations. The economics are particularly favorable when reverse osmosis is used
to pretreat high TDS waters. The RO greatly reduces ion loading on the demineralizer, which
lowers conventional filtration. The associated regeneration frequency and chemical costs.
Although reverse osmosis is considered to be a filtration technology, the process is more complex
than conventional filtration. In an ordinary depth or weave filter, water flows perpendicularly to
the filter. Particles are removed throughout the depth of the filter. When the differential pressure
between the inlet and outlet becomes too large, the filter is replaced. In an RO system, water flows
parallel to the membrane surface. Applied pressure at the influent forces a portion of the water
through the membrane as it passes from one end to the other. Solids are swept along with the water
that does not pass through the membrane. This water, which becomes increasingly concentrated,
flows to the end of the pressure vessel and is discharged. This is known as cross flow filtration.

29
5.2.8 STRONG ACID CATION RESIN
Strong acid cation (SAC) resins have an affinity for cations over hydrogen, and will exchange
hydrogen for them as water flows through the vessel. Because the resin behaves as a strong acid,
it will split salts and separate cations from their corresponding anions. A water containing the ions
calcium, magnesium, sodium, chloride, sulfate, bicarbonate, and silica will exit the vessel as a
dilute solution of hydrochloric, sulfuric, carbonic, and silicic acids. The order of affinity the resin
has for ions is Ca+2
> Mg+2
>Na+
.
5.2.9 STRONG BASE ANION RESIN
Strong base anion (SBA) resins are the counterpart to SAC resins and will remove virtually all
anions. The resin exchanges hydroxide ions for the anions in the preferential order SO4
+
> CI-
>
HCO3
-
> HSiO3
-
. The final product is water. Two kinds of SBA resins are most common, Type I
and Type II. Type I resins contain quaternary amine exchange sites. Type II contains the quaternary
ammonium functional group. Type I resins are more stable at higher temperatures. Type II resins
are slightly less basic and can be regenerated a bit more efficiently.
5.2.10 MIXED BED EXCHANGE PROCESS
Water from a cation/anion system, although of high quality, still contains too many contaminants
for use in high-pressure boilers. A mixed-bed exchanger contains intimately intermixed SAC and
SBA resins. The exchanger performs as if it consisted of millions of miniature cation/anion units.
A mixed bed exchanger usually serves as a polisher of effluent from a cation/anion system, reverse
osmosis unit, or other purification arrangement. The mixed-bed will reduce contaminants from
ppm levels to ppb levels.

31
5.3BOILER
This Boiler has a steam generating capacity of 1 x 150 TPH operating with a Super heater outlet
pressure of 110 Ata and a super heater steam temperature of 540°C at Main Steam Stop Valve
(MSSV). This Boiler is a single drum, balance draft, Traveling grate, natural circulation,
membrane wall, three (3) stage super heater with two (2) stage spray type attemperators and top
supported Boiler, suitable for outdoor installation. The main fuels for the Boiler are Bagasse with
50% Moisture and Indian coal. The Boiler has a vertical furnace where fuel is burnt and heat is
absorbed by radiation. The furnace operates at slightly negative pressure during the entire
operation from start up to full load. The hot flue gases leaving the furnace at the temperature less
than the Initial Deformation Temperature (IDT) of the ash, enters the RSH, FSH, screen tubes and
then to the second pass Low Temperature super heaters and economiser. The gas leaving the
economiser enters the Air heater block. The flue gas after all heat transfer systems, reaches to ID
fan after passing through dust collection equipment. The dust collection equipment considered for
this boiler is the Electrostatic Precipitator (ESP). The ID fan evacuates the clean gas from ESP to
atmosphere through RCC chimney at suitable elevation. The Boiler structures are designed as per
the latest codes with the wind velocity and the seismic zone as given in the site data. Platforms and
staircases are provided to access various zones of the Boiler for regular operation and maintenance.
The elevation of Boiler is comfortably arranged such that adequate sized hoppers are provided at
ash collection points for convenient disposal of ash.
5.3.1 WATER & STEAM SYSTEM
De-aerator is considered in the feed water circuit, to remove the corrosive gases present in the feed
water such as dissolved oxygen and free carbon-dioxide from the Boiler feed water by heating the
feed water to the operating temperature by steam and vigorously scrubbing the water with steam,
so that traces of non-condensate gases are removed from feed water. This ensures protection of the
feed water lines, Economiser coils, Steam lines, boiler tubes and other pressure parts of the boiler
against corrosion and pitting, this saves costly boiler re-tubing and expensive plant shut downs.
Further, the temperature of the feed water is raised to de-aerator temperature and then fed to the
boiler, which boosts up the overall plant efficiency. Boiler feed water from De-aerator flows to
Economiser through Boiler Feed Pump (BFP), HP heaters and feed control station in a regulated
manner depending on boiler load. As the feed water travels to the steam drum through the

32
economiser it gets heated adding sensible heat to it. Economiser of the boiler is non steaming
design and expected feed water temperature leaving Economiser at MCR is specified in the design
data The water near saturated conditions from steam drum enters to first & second pass water walls
& Evaporators through down comers and absorbs heat from the fuel which is fired in the grate and
WATER CIRCULATION FLOW DIAGRAM

33
from the hot flue gases generated from the fuel. The near saturated water absorbs heat and the
water is converted to wet steam. This wet steam (Steam and water mixture) from the furnace water
wall, flows back to steam drum through riser pipes, by natural circulation. Efficient drum internals
consisting of primary and secondary separators separates steam from steam water mixture in steam
drum. The dry steam from the steam drum enters the Low temperature super heater (LTSH)
assembly. Super heaters are provided in the boiler to raise the steam temperature above the
saturation temperature by absorbing heat from flue gas. By increasing the temperature of the steam,
the useful energy that can be recovered increases there by increasing the efficiency of the thermal
cycle also. Super-heated steam eliminates the formations of condensate in steam piping which is
harmful to the turbine blades and pipe lines. In this Boiler Three stage super heater (LTSH ,
Radiant & Final super heaters) with two stage inter stage de-superheating is provided, to maintain
the super heater outlet temperature with in the design range of 540ºC +5 ºC /-0ºC from 60 to 100%
(Bagasse) of the boiler load.
5.3.2 AIR & FLUE GAS SYSTEM
Air is required for combustion of fuel and the required quantity of air has to be regulated to
maintain the combustion efficiency. This Boiler is having the following air systems,
- FD air system, which is for combustion of the fuels in the grate
- SA air system which is used for spreading the fuel and to supply secondary air into the furnace
to complete the combustion of volatiles/fines, which escapes from the grate, thereby improving
combustion efficiency.
The FD & SA fan takes air from atmosphere discharge to Air heater through Steam coil Air Pre
heater (SCAPH). SCAPH is provided to preheat the air, for avoiding the air heater block cold end
corrosion. This combustion air flows inside the tubes and absorbs heat from flue gas passing
outside the tubes. This recuperator type Air heater helps to recover the heat from flue gas leaving
the Boiler which in turn helps to increase the efficiency. The flue gas temperature leaving the Air
heater shall be maintained near to the Design value. Hot air leaving the air heater helps to improve
the combustion of fuel. The Manual dampers provided at the hot air ducting shall be set during
commissioning to give proper distribution of the combustion air, to reduce unburnt and enhance
the suspended burning of fuel at lower zone. Part of secondary air is supplied to pneumatic spreader

34
to spread the fuel across the furnace depth. Manual dampers provided in the pneumatic spreader
duct shall be set during commissioning period to obtain the proper distribution of fuel. ID fan is
provided to evacuate the flue gas from furnace and discharge in to the chimney. ID fan helps to
maintain the negative draft in furnace. Pressure on the furnace shall be maintained to -5mmWC by
modulating FD & ID fan inlet guide vane/damper. Furnace draft control system automatically
maintains the draft. It is necessary to regularly monitor the draft across the boiler as per the
predicted value, any abnormality observed during the operation shall be analyzed. Increase in draft
indicates choking/fouling of pressure parts, air pre heater tubes which may lead to major damage
to pressure parts/Air heater tubes. Flue gas temperature at various locations along the gas path
shall also be monitored. By considering many variables involved in the Boiler operation it is not
possible to predict exactly the flue gas temperature and steam temperature. But gas and steam
temperature will definitely fall around the predicted value specified. It is also necessary to observe
the furnace exit gas temperature which will be around 854ºC while firing bagasse and 782 ºC while
firing Indian coal. Higher furnace exit temperature may lead to fouling of super heater coils.
5.3.3 FUEL STORAGE AND FIRING SYSTEM
The Boiler is designed to fire the fuel as per the analysis indicated in the boiler technical data. It
is necessary to monitor periodically the fuel analysis (Proximate analysis, Ultimate analysis and
Ash elemental analysis) and maintain the record of the same. Review of ash analysis will give a
clear indication of fouling / slagging tendency of fuel. Depending on the fuel and ash analysis, the
slagging / fouling behavior of ash have to be studied and corrective actions have to be taken before
firing the fuel in the boiler. It also helps to plan the shutdown of Boiler for cleaning. Soot blowers
(LRSB & RSB) are to be operated once or twice in a shift as determined by actual observation to
avoid accumulation of ash on heating surface. The bagasse storage and feeding scheme considered
for this project is given below.

35
The silo is fuel storing equipment, which is
connected between carrier and Extractor. The storage
capacity of silo was selected to have minimum
storage of at least 10 minutes to feed continuously
fuel to furnace at rated load of the boiler. Drum
extractor, which is located below the storage silo, is
intended to feed controlled and varied quantity of
bagasse in to the boiler. The drum extractor extracts
the fuel from the storage silo and the quantity
extracted shall be proportional to the speed of
rotation of the drum. The extracted fuel is fed to the
pneumatic distributor through a screw conveyor. The
pneumatic distributor has an adjustable feed plate for
adjusting the trajectory of fuel distribution and
ensures a uniform fuel distribution over the grate.
The Boiler is provided with the traveling grate. The
traveling grate is a continuous ash discharge type
with hydraulic drive. The fuel is burnt in suspension
as well as in the surface of the traveling grate.

37
5.3.4 ASH HANDLING SYSTEM
The quantity of ash generated in the boiler depends on the percentage ash content in the fuel. Part
of the ash is collected in the grate and the remaining ash is carried away with the flue gas. The ash
carried away with the flue gas is collected in various hoppers present in the boiler. Majority of the
ash is collected in the ESP. The ash collected in the hopper is further conveyed in to the ash silo
through properly designed ash conveying system.
5.3.5 BOILER STRUCTURES
The Boiler supporting structure is well braced structure with both vertical and horizontal bracings
for the transfer of loads effectively. The vertical bracing has been arranged from top to bottom and
is continuous so as to transfer the horizontal loads to the base columns. The horizontal bracings
are arranged at discrete levels to transfer the horizontal loads due to wind, seismic and thermal
loads from Boiler, transmitted to the columns. The structural columns and beams have been sized
adequately. The columns are provided with shear lugs on the bottom side on the base plate such
that horizontal shear loads get transferred to the foundation. Access openings are provided
wherever required and sizing of the stairs and spacing of the walk ways have been done liberally.
Galvanized gratings and hand rails have been provided.
5.3.6 BOILER TECHNICAL DATA
TYPE DESCRIPTION
BOILER TYPE Single drum, Natural circulation, Top supported,
Balanced draft,
Water Tube, outdoor boiler.
FUEL Bagasse & Indian coal
FIRING SYSTEM Traveling grate with spreader stoker
BAGASSE FEEDING
EQUIPMENT
Silo, Drum feeder, Screw conveyor & Pneumatic
distributor
COAL FEEDING EQUIPMENT Bunker, Drag Chain Feeder & Coal spreader
SUPER HEATER LTSH , Radiant and Final super heater
NO OF STAGES IN SH 3 stages
DE-SUPERHEATER TYPE Direct spray type

38
ECONOMIZER Plain tube, Inline arrangement
AIR HEATER Tubular
DUST COLLECTOR Electro Static Precipitator
NO OF ID/FD/SA FANS 2 X 60%/ 2 X 50%/ 2 X 50%
NO OF BFP 4 X 42%
NO OF AH BLOCKS Four
5.4TURBINE
The steam turbine is a single cylinder, multistage, impulse-reaction type condensing turbine. The
turbine is equipped with two uncontrolled steam extractions. The direction of rotation is
counterclockwise looking from turbine inlet end. The turbine is mounted on a base frame.
The turbine is designed to drive electric generator using the double helical speed reducing gear
box. Inlet steam is lead into the turbine via the Emergency Stop Valve and three control valves.
The turbine is designed to comply with the following requirements for:
Required output
High reliability
Operational flexibility
High efficiency
High availability
Easy maintenance
Low costs for planned maintenance
Faultless operation
5.4.1 DESIGN FLOW PATH
Steam enters the turbine through the hydraulically operated Emergency Stop Valve. Steam line is
connected from bottom to the ESV inlet flange. The ESV outlet flange is bolted to the inlet flange
of the throttle valve chest. Throttle valve chest is mounted on the top of the steam end casing and

39
chest houses four control valves that feed the inlet nozzles housed in nozzle banks integrated into
the inner casing.
Uncontrolled extractions as per Section B taken from the bottom part of turbine casing through
flanges. Exhaust from LP part of the turbine is lead through a spool piece and expansion bellow to
main steam condenser.
5.4.2 NOZZLE SEGMENT AND DIAPHRAGMS
The admission arcs of governing stage (control stage) are built up from nozzles machined out of
solid steel. The above nozzles have integral top shroud. The shrouds are provided with peripheral
tenons that are radially straight. The peripheral tenons of the nozzle segments are fitted into circular
grooves turned in the nozzle box portion of the inner casing. The nozzle segments butt one to
another and fit circumferentially into the nozzle end pieces which close the grooving. The external
joints between the nozzle segments and the nozzle box are welded. There are 4 groups of nozzles.
At the horizontal joint the diaphragm assemblies are provided with radial keys to locate the two
halves and prevent leakage across the joint.
The diaphragms are located axially in internal circumferential grooves machined in the turbine
casing and centralized by three radial keys in each half-two side keys and one bottom or top key.
Thereby free radial expansion of the diaphragm assembly is permitted whilst concentricity with
the rotor is maintained. The bores of the diaphragms are grooved to accommodate spring backed
segmental caulked packing’s for sealing purpose.
5.4.3 TURBINE ROTOR AND MOVING BLADES
The turbine rotor is designed to be run at speeds above the first transverse critical speed and is
machined from a single solid alloy steel forging. All stages are machined out of the forging.
Moving blades of HP Stages are of cylindrical type. High efficiency twisted and tapered blades
are used in stages i/p & LP the moving blades are machined from solid bar or forging. Mounting
provisions are machined in rotor, minimizing the out-of-balance effects. The blade profiles are
milled and roots are cut, using special tools. Due consideration is given both in design and
manufacturing to the avoidance of stress raisers. Consideration is also given in the design of all

40
rows of blades to ensure that the natural frequencies of the blades are tuned well away from any
running frequencies. Provision for weight addition during balancing is provided on sufficient no.
of discs and other locations on the rotor. The interstage gland seals have common stepped
diameters on the rotor and match the high-low caulked fins on the spring-loaded gland packing’s.
The rotor thrust bearing collar, which is integral with the rotor shaft, is precision ground. The rotor
shaft is designed with a flange as part of the forging at the drive end to mount the high-speed
coupling. The turbine rotor is fitted at the steam end with extension piece with geared disc for
speed measurement and axial displacement sensors.
5.4.4 ROTOR GLANDS
In order to restrict the leakage in areas where the turbine rotor shaft passes through the casing or
interstage diaphragm, non-contact glands are provided. Various designs of glands are used in
different sections of the turbine. On the stationary side, these glands consist of rings cut into four
radial segments with serrations turned inside the rings or series of fins caulked in. Stationary seals
have axial segments with finite number of restrictions. The assembly presents a tortuous, labyrinth
path against steam (or air) leakage. The many restrictions and corresponding spaces rapidly drop
the pressure of the steam thereby increasing its volume and limiting the quantity that can pass the
final restrictions. Glands at the high pressure end of the casing are formed with alternate caulked
fins on casing and rotor. The gland segments on the casing are spring backed. The wheelcase (first
stage) pressure increases progressively with the load on the turbine and at full load this pressure is
considerably in excess of atmospheric pressure. To break this pressure down and to reduce Steam
leakage outwards from the wheelcase, it is necessary to use five separate groups of fins providing
four pockets at the steam end labyrinth. The exhaust end labyrinth is formed from segments of
stepped labyrinths machined from metal rings on the stationary side and matching pips machined
on the rotor. It is divided along its length into three separate groups of fins providing two separate
pockets. Caulked type spring backed seals with matching pips on the rotor are provided at the inner
diameter of each diaphragm in order to limit the interstage leakage in all the above cases, the
labyrinth segments in diaphragms are supported in ‘T’ slots in the gland and are held concentric
with the turbine shaft by radial leaf springs. lf rubbing occurs the segments are pushed outwards
against the springs to a larger diameter until the disturbance is over LP diaphragms have caulked
type glands, integral to diaphragm with plane surface on the rotor, forming see-through glands.

41
The top half gland housings are trapped in the top half casing by button screw similar to the
diaphragm arrangement. At assembly the turbine parts are carefully aligned so that the labyrinth
packing clearances and consequent leakage will be small. Provided that the turbine is warmed
through, drained correctly and run up to speed slowly. The clearance will remain small and little
or no labyrinth wear will occur. Sufficient clearance between stationery and moving parts is
provided to allow for abnormal operating conditions.
5.5ELECRICALS AND EQUIPMENT
The 30.8MW cogeneration plant is operated by heating the bagasse in a boiler and thereby running
the turbine and from there to generator and finally to the grid. From the grid, we can supply to
nearest substations such as Dhaurahra (132KV/33KV), Nighasan (220KV/132KV). In addition to
that, the company has also installed 69 towers of 132KV feeders in order to export the generated
30.8MW to the grid of U.P government. The single line diagram of the cogeneration power plant
is shown:
The cogeneration power plant can be sectioned into two major control centers: Power Control
Centre (PCC) and Motor Control Centre (MCC). Each has two sections according to the control
function required.
The substation switch yard of the company connects to the grid of the UPPCL, Dhaurahra through
40MVA, 132/11KV OLT transformer followed by Sulphur Hexafluoride (SF6) circuit breaker. In
addition to that there is outdoor Vacuum Circuit Breaker of 11KV capacity. From this it is then
connected to the 11KV bus bar. From 11KV bus, we have two 4MVA 3 phase transformer, sugar
tie-line along with two spare ties. From the first 4MVA transformer it goes to 3MW 415V bus bar
of the PCC section 1 and from there to section 2 respectively.
From the second 4MVA transformer of the same 11KV bus, it goes to MCC section 1 and from
there to MCC section 2 via, bus coupler as shown. Presently we are getting power supply from
UPPCL and after getting the government approval we can connect to the grid and export our green
power.

42
5.6ELECTRICAL EQUIPMENTS AND ITS SPECIFICATIONS:
Name of the equipment’s specifications
Sulphur Hexafluoride breaker ( near UPPCL
line)
132KV
Step down transformer 40MVA, 132/11KV
Outdoor circuit breaker 11KV
11 KV Bus Bar
Turbine-Generator 30.8 MW
Step down transformer- 2 NOS 4MVA, 11KV/415V
Spare tie- 2 NOS
Sugar tie
PCC section 1 : 3MW 415V bus bar
Capacitor Panel 1 1000 Amps TPN
Feeder to RO plant and MCC 1
Spare 1 &2
Main Line Distribution board
Feeder to T.G MCC 1
Auxiliary MCC
Material Handling system
D.G incomer 1 & 2
PCC section 2 : 3MW 415V bus bar
Tie feeder to VFD panel board 2
Feeder to Panel Board 2
ESP MCC
Capacitor Panel 2 1000 amps TPN
RO MCC 2
Tie for existing PHR
MCC section 1&2 : 415V bus bar
Stand by Drive 1
Boiler feed pump – 2 Nos 535KW, 2980 rpm S/D

43
Induced Draft Fan & Forced draft fan- 1 0.25KW
SA fan 1 0.33KW
Air Compressor 250A
Flag gate 3.7KW RDOL
Rotary Vane feeder 1.5KW DOL
Vapour Extraction 1.5KW
Condensate Extraction Pump A,B &C 37 KW
Aux. Condensate oil pump 18.5 KW DOL
Belt Conveyor- 8 Nos 11KW/15KW/18.5KW
Slat Chain Conveyor- 2 Nos 37KW
Ash Conditioner- 2 Nos 11/15KW DOL
Main oil pump 2 Nos 37KW DOL
Electromagnetic Vibrator- 4+1 Nos 0.5KW
Purge Air heater -5Nos 12KW
Plenum Hopper- 4 Nos 0.75KW
HP dosing 1 &2 0.75KW DOL
Electric Heater for air heater hopper – 3 Nos 15KW
Oil tank heater 40KW
Rack and Pinion gate 2.2 KW RDOL
Mechanical Spreader 3.7KW DOL
The relays are made by ALSTOM Company. 11KV panels and bus couplers are done by ABB ltd.
Lightning Arrestors are made by Crompton greaves. Power Transformers are made by DELTA
Company. Currently the company is waiting for the government approval. Then this plant will be
running throughout the year.

45
6. VARIOUS DEPARTMENT
6.1HUMAN RESOURCE DEPARTMENT
Human resources department at Gobind Sugar Mills Ltd. works conscientiously to establish a
better managerial quality and relationship with employees and management. It is responsible for
following roles.
 Hiring
 Promotions
 Reassignments
 Position classification and grading
 Salary determination
 Performance appraisal review and processing
 Personnel data entry and records maintenance
 Consultation and advisory to employees
 Conduct problems
 Performance problems
 Policy development
 Technical policy interpretation
 Benefits
 Health care insurance
 Life insurance
 Retirement
 Leave Transfer Program
 Training opportunities
 Workers' compensation
6.2BIRLA INDUSTRIAL PROVIDENT FUND
Gobind Sugar Mills, one of the Adventz group of companies follows provident schemes for the
employee’s benefit as per government P.F norms: Some of them are as follows:

46
FORM NO EXPLANATION
FORM NO: 2 (REVISED) Nomination/Declaration form
FORM NO:2A Change of P.F nomination ( Ex: Change to
wife’s name from mother/father’s name)
FORM NO: 2B Application for change in P.F
contribution.(Employees can voluntarily ask
for P.F)
FORM NO:2C P.F application for rectification of name ( In
case of any mistakes in names)
FORM NO: 13 (REVISED) P.F / Pension transfer
FORM NO:13A Form for internal transfer of account. It
usually occurs when the person goes to other
company or other branch in some other region.
FORM NO:14 Application for final settlement of P.F account
FORM NO:29 Form for inoperative account. This will be
provided to the employees after 3 years with
interest.
FORM NO:31 Non-repayable withdrawn. This scheme is
meant for the employees to withdraw their P.F
amount as advance in case of any urgent need.
After 7 years, continuously P.F will be cut for
the employee.
6.3PENSION BENEFITS
Apart from the above provident fund scheme, the company is also providing pension to the
employees those who are in service or had service for a period of 58 years and above. The salary
which the employees are receiving is divided into two parts: Provident fund and Pension benefit.
From the salary for each employee 12.75% P.F is deducted. That 12% is further divided into 8.33%
of provident fund scheme and the remaining portion goes to pension scheme. In addition to this,

47
the organization is also giving 12.75% of provident fund to each employee, which altogether that
particular employee will be receiving after service period from the organization as per the scheme
as shown above. After 58 years of age, pension counts for every employee.
6.4ACCOUNT DEPARTMENT
Account department takes care for financial decision, making payment for purchases, making road
permit for goods order.
6.4.1 SALARY BREAKUP FOLLOWED BY THE ACCOUNTS DEPARTMENT
Accounts department is following the salary breakup procedure made during the days when the
company was a part of Dr.K.K. Birla industries. Salary primarily split into the below given
category according to which the take home salary is calculate:
a. Basic salary
b. LTA
c. Medical
d. Ex-Gratia
6.4.1.1 BASIC SALARY-
Basic salary is the amount paid to an employee before any extras are added or taken off, such as
reductions because of salary sacrifice schemes or an increase due to overtime or a bonus.
6.4.1.2 LTA-
Leave Travel Allowance (LTA) can be claimed when an employeegoes on a vacation and submits
the actual bills to the employer. This amount is also sometimes referred to as Leave Travel
Concession (LTC). Different employers give different amounts as Leave Travel Allowance (LTA)
depending on the position at which the employee is working. At the time of filing the income tax
return, the amount received as Leave Travel Allowance is exempted to a specified level for the
purpose of computing Income The amount so computed after claiming this exemption would be
chargeable to tax as per the Income Tax

48
Tax Exemption of Leave Travel Allowance
Income Tax exemption for Leave Travel Allowance is available from an amount received by an
employee from his employer for himself or his family. This exemption is only allowed if the
amount received is in relation to:
1. Leave to any place within India
2. Any place in India after retirement from service or after the termination of his service
How many times can LTA exemption be claimed?
The taxpayer can claim exemption in respect of any 2 journeys in a block of 4 years. The Income
Tax Department has created block of 4 years each and in each block, the exemption can be claimed
twice.
The block of years during which exemption can be claimed twice are:Block
No. LTA Block Years
1st Block 1986-89
2nd Block 1990-93
3rd Block 1994-97
4th Block 1998-01
5th Block 2002-05
6th Block 2006-09
7th Block 2010-13
8th Block 2014-17
In case a taxpayer has not been able to claim both the exemption or has claimed only 1 exemption
in a particular block, he can carry forward the exemption of 1 journey to the next year.

49
6.4.1.3 MEDICAL-
Medical insurance is provided by the company for the employee and to his/her family. By family
it includes wife and children for married person and parents for unmarried person. No Income Tax
on Medical Reimbursement is levied up to Rs. 25000 provided all bills for the same are furnished
by the employee to the employer. Such exemption of Rs. 25000 from the levy of Income Tax on
Medical Reimbursement is the cumulative exemption allowed in a financial year for the amount
actually incurred by the employee for obtaining the medical treatment of self or any of his family
members. The bills of Rs. 25000 should necessarily be furnished by the employee to the employer.
However, these bills should not necessarily be of Govt hospitals or any specified hospital. Bills
for any expense incurred on Medical Treatment of self or family members in any Private
Hospital/Clinic etc. can also be furnished for Medical Reimbursement to be treated as a taxfree
perquisite.
Any amount in excess of Rs. 25000 being reimbursed to the employee by the employer would be
added to the income under head salary and at the time of filing of income tax return, tax would be
liable to be paid on the same as per the income tax slabs of the individual.
6.4.1.4 EX-GRATIA-
Ex-Gratia is the amount added to the salary for working overtime after office hours. Ex-Gratia of
one month salary is given to the employee at the end of financial year.
6.5STORES
6.5.1 MATERIAL RECIEVEING PROCEDURE
Every material added to the stocks of store has a lenghty process to go with. Each process has to
be completed to accomplish the recieveing of the material. The detailed flow chart of the procedure
is given in the picture below.

51
6.6MATERIAL ISSUE PROCEDURE
Any material which is to be issued from the stores is prepared through the challans. Challans is
designed for each and every purposes.
a. White challan - It is used for issuing repairing material.
b. Pink challan - It is used for issuing capital material.
c. Green challan - It is used for issuing old material (Material already in use)
Procedure for issue of material is given below in the form of flow chart

52
7. REFERENCE
Thaval, O. P., & Kent, G. A. (2012). Modelling the flow of juice through a mill. International
Sugar Journal, 1363(114), 36-40.
Walford, S. M. (1996). Composition of cane juice. Proceedings of South African
Sugar Technologists' Association: 70, pp. (265-266).
Wienese, A. (1995). The effect of imbibition and cane quality on the front end mass balance.
Proceedings of South African Sugar Technologists' Association: 69, pp. (181-185).
Wienese, A., & Reid, M. J. (1997). Soil in cane: Its measurement, its effect on milling, and method
of removal. Proceedings of South African Sugar Technologists' Association: 71, pp. (130-134).
Rein, P. (2007). Cane sugar engineering. Berlin: Bartens.

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