Warana Cogeneration Project 44 MW

44 MW capacity bagasse based cogeneration power plant at Shree Tatyasaheb Kore Warana Sahakari Sakhar Karkhana Ltd. Warananagar (Warana Sugar Co-Operative Sugar Industries), Taluka: PanhaIa, Dist. Kolhapur has been prepared for implementation on Build, Own, Operate & Transfer (BOOT) principles and will be transferred back to warana sugar co-operative after 7 to 8 years till then the sugar industries will get benifit nearly of Rs. 200/ T, through the Special Purpose Vehicle (SPV) sponsored by Urjankur Nidhi (the Fund), a scheme under Urjankur Trust of Government of Maharashtra. The proposed Project has envisaged parameters for steam at a pressure of 110 kg cm2 and 540"C temperature, which shall give optimum efficiency and power generation, with a matching turbo generator set. The boiler will be capable of firing bagasse, imported coal or biomass such as sugarcane trash, cotton stalk, rice husk. julie flora, sawdust etc.

The design philosophy for the boiler is to satisfy the process steam requirement of the sugar plant (at peak crushing rate) and ancillary- plant's. The turbo-generator will be sized to take 82% MCR rating of boiler during off-season. Correspondingly, the capacity of the boiler works out to be 2x 115 TPH and that of the turbo-generator 44 MW.

All the equipment shall be designed to 'achieve best possible efficiencies under the specified operating conditions. State of the art Distributed Control System (DCS) shall be employed for monitoring and controlling the plant performance. The layout adhering to the best engineering practices shall be designed for ease of maintenance, material handling, operational requirements and minimal capital cost.

The power from the Project shall be evacuated at 110 kV (compatible to 132 kV) Extra High Voltage (EHV) Wathar substation of the Maharashtra State Electricity Transmission Company Limited (MSETCL), which is at a distance of approximately 10 km from the proposed cogeneration power plant.

The availability of bagasse from the HSF has been worked out based on an average crushing rate of 8000 TCD of the sugar plant. The bagasse generation shall be 28% on cane. After accounting 0.5% for bagacillo and handling losses, bagasse equivalent to 27.5% on cane will be available for usage in the boiler. Project shall operate for 150 net crushing season days (excluding stoppages) on bagasse. During off-season or non-crushing season the plant, shall operate for 1 day on saved bagasse and 159 days on imported coal or purchased bagasse/biomass. The imported coal will be made available to the plant from the Ratnagiri or Goa (Margaon Nasco) ports. It is envisaged that the Cogen Plant will operate for 310 days per annum.