PROPOSAL FOR 104 TPH EXERGY® FLUE GAS

DRYER FOR SUGAR MILL BAGASSE

Submitted to
M/s SHRI PRABHULINGESHWAR SUGARS & CHEMICALS LIMITED
Siddapur – 587301
Tq. Jamkhandi, Dist. – Bagalkot,
Karnataka

Submitted by
EXERGY DRYERS PRIVATE LIMITED,
G-104, Site-B, Surajpur Industrial Area, Greater Noida,
Distt.- Gautambudh Nagar (U.P.) – 201 306
Telephone: +91 (0) 120 256 1125, 26
Fax: +91 (0) 120 256 1125
info@swedishexergy.in; sales@swedishexergy.in
www.swedishexergy.com

Through
M/s CHEMICAL SYSTEMS TECHNOLOGIES (I) PVT. LTD.
M – 58, 2nd Floor Market Greater Kailash Part 2,
New Delhi – 110048
Telephone: 011-29216344/ +91- 9999699588
Contact : Mr. S. N. Saraswat
chemsystems@sugarchem.com ; saraswat@sugarchem.com
www.sugarchem.com

© Copy Right
All the information contained in this document and all other documents associated with this document or any previous
communication is sole property of Swedish Exergy AB and cannot be copied in any form without express written permission
from Swedish Exergy AB.
 INDEX

Sr. No. Particulars Page No.

1. Company Profile 3
2. Introduction 5
3. Process Description 6
4. Design Data 8
5. Installation In India 9
6. List of equipment & scope of supply 10
7. Scope of supply, Battery limits 11
8. Standards 12
9. Price, Terms & Conditions 13

Ref.: 8068-001FGD-PSL Rev.-2 Date: 09-02-2018

1.0 COMPANY PROFILES

Exergy Dryers Private Limited (EDPL) is wholly owned subsidiary of Swedish Exergy
AB, Gothenburg, Sweden. Swedish Exergy AB designs and builds Exergy® drying systems
including Exergy Flue Gas Dryers. This unique process enables difficult products to be dried
with negligible environmental impact.

Exergy have over 30 years world-wide experience spread over a wide variety of engineering
projects, in addition to providing a wide range of engineering skills and services leading to
turn-key systems.

Exergy provides complete solutions for waste management through its drying & evaporating
technologies with minimum energy usage. We provide tailor made solutions with our below
technologies:

Products: Services:
•Exergy Steam Dryer •Project Management
•Exergy Air Stream Dryer •Design and Engineering
•Exergy Bed Dryer •Manufacturing
•Exergy Flue Gas Dryer •Installation
•Falling Film evaporators •Testing and Commissioning
•Forced circulation evaporators •Consulting Services
•Rotary valves •Pilot Testing
•Mixers •Feasibility Study
•Heat Exchangers •Turn-Key Supply

Main Applications:
 Wood waste / Bio-mass
 Animal feed
 Spent wash of grain & molasses
 Industrial/ Municipal Sludge
 Tobacco / Tea
 Waste water treatment
 Industrial waste / Hazardous management
 Bagasse/ Straw
 & many more

Exergy facilities are approved by these certificates:

In India, we are committed to our customers to provide the Swedish technology at Indian
Prices.

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 CHEMICAL SYSTEMS is actively involved in the Sugar industry and they also act as
distributors for some specialty chemicals for the personal care, polymer processing, and
powder metallurgy areas.

Chemical Systems Technologies (India) Pvt. Ltd. are the pioneers in India for a host of new
sugar processing technologies and are the market leaders with the most comprehensive
product range primarily aimed at quality upgradation and yield improvement.

 Refined Sugar  Syrup/ Melt Clarifier

 Raw Sugar  Filtrate Clarification System
 Short Retention time clarifier  Liquid Sugar
 Mud Removal System  Membrane separation
 Multibed filter

We have introduced Membrane based systems for:

 Distillery effluent, to recycle process water

 Brine Recovery from ion exchange decolourisation
 Cane Juice Clarification

We offer a complete range of speciality chemicals for the sugar industry.

 Biocides  Flotation agent

 Antiscalants  Viscocity Reducers
 Defoamers  Colour Precipitant
 pH Booster

The Company started in 1986 as a toll formulator for Mazer Chemicals, USA (now part of
BASF. In 1990 our own branded range of Sugar Processing Chemicals was launched and,
today, we service over 160 sugar mills in the country primarily in the Private sector.

Chemical Systems has more products and more customers in the Indian sugar industry
than any other competitor.

Sunil Singhal, the President, graduated as a Chemical Engineer from I.I.T/Kanpur in 1971
and has been associated with the sugar industry for over twenty years. He has been in
the speciality chemicals marketing area for the last forty years.

The total staff strength is 81 comprising of:

 Sugar Technologists
 Chemical Engineers
 Instrument Engineers
 Plant Operators
 Mechanical Design Engineers

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2.0 INTRODUCTION

Sugar and Ethanol are the main product which are extracted from sugarcane, the byproduct
is in the form of bagasse. Bagasse is used as fuel in boiler to produce process steam and
electricity through cogeneration systems. The electricity generated is used for self-
consumption and the surplus, if any, is supplied to grid.

Typically, the mill wet bagasse contains around 48 to 50 % moisture with a gross calorific
value (GCV) of around 2270 Kcal/kg. Normally the bagasse is directly fed to the boiler to
generate steam and surplus bagasse is stored in the bagasse yard. The boilers installed in
the plants are designed to burn bagasse with this moisture content.

It is known fact that GCV of bagasse is largely dependent upon its moisture content. High
moisture content in bagasse reduces its GCV and also results in high energy loss because
fuel moisture carries that latent heat of vaporization up the stack.

Therefore, by reducing the moisture content in the bagasse, the efficiency of the boiler can
be improved and extra bagasse will be saved. The stack losses are related to the flue gas
temperature and the extent of loss is directly proportional to the final flue gas temperature
– higher the exit temperature, higher are the losses.

The most common devices for an industrial energy recovery configuration are simple air
heater. Economizers are being included lately and bagasse dryers have not been frequently
used in sugar – ethanol plants. The Exergy flue gas dryer is an open system where the
material to be dried is exposed to flue gases. In the dryer the flue gases serves as a transport
gas for the material in the dryer. The heat for drying is transferred directly from the flue
gases to the suspended material. Dried material and flue gases are separated in a cyclone.

Typical residence time for the material is 10-20 seconds in the flue gas dryer. Transport
velocities within the dryer are fixed at optimal values to minimize fan operating costs. If
required, flue gases after cyclone can be cleaned in a scrubber and discharged to
atmosphere through a chimney.

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3.0 PROCESS DESCRIPTION

The Exergy Flue Gas Dryer is installed between the boiler ID fan and the chimney. The wet
bagasse from mill is drawn from the bagasse elevator and is transported to the dryer by belt
conveyor. After drying process, the dried bagasse is transported back to the main bagasse
carrier for boiler by another belt conveyor.

The dryer fan moves the flue gases and bagasse mix throughout the dryer duct where the
temperature of the flue gases and the moisture of bagasse is reduced. Dried bagasse and
Flue gases are separated in cyclone.

The dried bagasse is discharged on the belt conveyor at the bottom of the cyclone through
Rotary valve and the flue gases are discharged to atmosphere through chimney.

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3.1 ADVANTAGES

 Increase in steam fuel ratio thereby tremendous saving of bagasse.

 Boiler efficiency is increased.
 As water is evaporated from the bagasse in the dryer, excess air requirement is
reduced to a certain extent: thereby flue gas volume will be reduced. Therefore,
power consumption by the ID Fan is reduced considerably.
 There will be a complete burning of bagasse due to which stack emissions are
reduced (Complete burning of any fuel can be achieved by lower moisture content,
low excess air and high furnace temperature).
 The dryer can work as a filter for suspended solids in the flue gases, and its SPM
levels are reduced drastically.
 When the bagasse is dried, it gains a certain temperature and spontaneously burns
in suspension, hence boiler pressure and temperature fluctuations are always in
control.
 Boiler steam production capacity is also increased due to more intake of dried
bagasse for fixed volume of furnace: so boiler capacity is increased.
 Negligible maintenance cost.

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Wet Scrubber for Boiler 2:

Flue gases after dryer for boiler no. 2 will be fed to wet scrubber where these will be
cleaned with water.

Operation of wet scrubber Hybrid Dryer System

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4.0 DESIGN DATA

4.1 Design Data for Boiler – 1 , 50 TPH Boiler Capacity

Input Data

 Feed Rate of Bagasse : 23 TPH

 Mill Wet Bagasse Moisture : 50.0 %
 Temperature of Flue gas : 130 °C

Output Data

 Dried Bagasse from Dryer : 19.16 TPH

 Evaporated Water : 3.84 TPH
 Desired Bagasse Moisture : 40 %
 Temperature of flue gas : 75 – 80 °C

Utility consumption

Electrical Power Power Consumption

Rotary Valves (Inlet) ~ 16 KW
Booster Fan (ID Fan) ~ 200 KW

Note:

1. Above mentioned parameters are for proposal stage & may vary slightly during detailed
engineering.
2. Total flue gas shall be passes through the dryer.
3. Dryer Chimney will be connected at the bottom to Existing ID Fan duct.

Ref.: 8068-001FGD-PSL Rev.-2 Date: 09-02-2018

4.2 Design Data for Boiler – 2 , 50 TPH Boiler Capacity

Input Data

 Feed Rate of Bagasse : 27 TPH

 Mill Wet Bagasse Moisture : 50.0 %
 Temperature of Flue gas : 143 °C

Output Data

 Dried Bagasse from Dryer : 22.55 TPH

 Evaporated Water : 4.45 TPH
 Desired Bagasse Moisture : 40 %
 Temperature of flue gas : 75 – 80 °C

Utility consumption

Electrical Power Power Consumption

Rotary Valves (Inlet) ~ 18 KW
Booster Fan (ID Fan) ~ 180 KW
Water Recirculation Pump ~ 12 KW

Note:

1. Above mentioned parameters are for proposal stage & may vary slightly during detailed
engineering.
2. Total flue gas of boiler 2 shall pass through the dryer.

Ref.: 8068-001FGD-PSL Rev.-2 Date: 09-02-2018

4.3 Design Data for Boiler 3, 120 TPH Boiler Capacity

Input Data

 Feed Rate of Bagasse : 54 TPH

 Mill Wet Bagasse Moisture : 50.0 %
 Temperature of Flue gas : 155 °C

Output Data

 Dried Bagasse from Dryer : 45 TPH

 Evaporated Water : 9.00 TPH
 Desired Bagasse Moisture : 40 %
 Temperature of flue gas : 75 – 80 °C

Utility consumption

Electrical Power Power Consumption

Rotary Valves (Inlet) ~ 20 KW
Booster Fan (ID Fan) ~ 340 KW

1. Above mentioned parameters are for proposal stage & may vary slightly during detailed
engineering.
2. Total flue gas shall be passes through the dryer.
3. Dryer Chimney will be connected at the bottom to Existing ID Fan duct.

Ref.: 8068-001FGD-PSL Rev.-2 Date: 09-02-2018

 5. INSTALLATION IN INDIA

OPERATION OF BAGASSE DRYER

View of Bagasse Dryer in operation during night View of Bagasse Dryer in operation from 5 km away.

Wet Bagasse Dry Bagasse to Boiler

Wet Bagasse v/s Dry Bagasse Dry Bagasse to Boiler

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 6.0 LIST OF EQUIPMENTS & SCOPE OF SUPPLY
S. No. Description QTY. MOC SCOPE
Motorized Bagasse Diverter
1. 04 No. MS EDPL
Valve with suitable Motor at MBC
2. Chute for Bagasse Distribution 01 lot MS EDPL
3. Feed Conveyer Belt As required Length – As per Layout EDPL
4. Feed chute before Rotary Valve 03 No. MS EDPL
Feed Rotary Valve with suitable
Motor
MS with 2 mm SS lined
5. 01 No. for Boiler – 1, 03 No. EDPL
rotor buckets
01 No. for Boiler – 2,
01 No. for Boiler – 3
Drying conduit and specially
designed connections
6. 01 No. for Boiler – 1, 03 Nos. SS-409, 5 mm thickness EDPL
01 No. for Boiler – 2,
01 No. for Boiler – 3,
Cyclone with vent and hopper
01 No. for Boiler – 1, SS-409, 5 mm thickness
7. 01 No. for Boiler – 2, 04 No. EPDL
02 No. for Boiler – 3,
Booster ID Fan
01 No. for Boiler – 1,
8. 01 No. for Boiler – 2, 03 No. Suitable EPDL
01 No. for Boiler – 3,

Wet Scrubber assembly

9. including venturi, demister pad 01 No. SS 409, 5 mm thickness EDPL
for boiler 2
Water pump for wet scrubber
10. along with Piping 02 Nos. CI/CS EPDL
(01 working+01 standby)
11. Flue Gas Dampers 8 Nos. MS EDPL
12. Discharge Conveyer Belt As required Length – As per layout EPDL
Dry Bagasse Chute above Slat
13. 1 lot MS EPDL
conveyer
Electrical – MCC Panels, Power & EPDL
14. As required Suitable
control Cables and cable Trays etc.
15. Thermal Insulations As required Suitable EPDL
16. Steel Support Structure As required Suitable EPDL
At inlet & outlet of bagasse EPDL
17. Load Cell 2 Nos.
feed

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 PLC Based automation for bagasse
18. 1 No. - EDPL
dryers
Installation & Erection of plant
19. - - EPDL
at site
20. All Civil and Foundation works As required - CLIENT

Notes:

1. All drawings and documents will be supplied in Acrobat PDF format in 2 hard copies. All
CLIENT scope of supply will be as per SUPPLIER specifications, where applicable.
2. The Exergy Flue gas Dryer can be designed to suite your requirements. Feeding and
discharge can be placed at heights as required by other equipment/site layout.
3. Items specified in customer scope should be approved by supplier.
4. All electrical & mechanical drawings will be provided by EDPL.

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7.0 SCOPE OF SUPPLY
Scope of supplies of EDPL has been given below:

 EQUIPMENTS (See List of Equipment under section 6.0)

 TECHNICAL SERVICES
i. Design, Engineering and Drawings
ii. Process flow sheet and P & I Diagrams
iii. Supervision of Erection & Commissioning
iv. Performance Trial
v. Training of factory personnel

7.1 Terminal Points

 Wet Bagasse in - at inlet of rotary valve.

 Flue Gas in - at the Inlet of booster fan.
 Dry bagasse out - at bottom of cyclone.
 Flue gas out – at the inlet duct of Chimney
 Electricity – One point connection in MCC Panel

7.2 Customer Scope

 Equipment & Accessories mentioned in equipment list.

 Fabrication of Structure, Platform & Staircase etc.
 Utilities – Electric Power.
 All civil work
 Manpower - Necessary manpower to operate the complete system.
 Lodging & Boarding – The client will provide suitable Lodging & Boarding to our
personnel working at site.
 Workshop Facilities – Workshop Facilities, if required during erection.
 Crane or JCB is to be provided by the client during the erection of the plant.
 Loading/Unloading, Shifting of equipment.
 Any other item, not mentioned in EPDL scope of supply

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8.0 STANDARDS

8.1 General

The plant is designed and manufactured in accordance with the current Exergy standards and
standard specifications. If required, we can meet any specific local standard applicable.

8.2 Units
S.I. units shall be used.

8.3 Quality Assurance

General Statement

Our parent company, Swedish Exergy AB is an ISO 9001:2008 and ISO 14001:2004 certified
company.

Quality Assurance aspects for this project will meet the requirements of the Exergy Quality
Management System which is in accordance with SS EN ISO 9001:2008 and ISO14001:2004.

Management Overview

Exergy provides engineering and design, project management, procurement, construction

management, testing and commissioning services for food/dairy, chemical, pharmaceutical,
environmental installations on a world-wide basis.

The objectives of the management of Exergy are:

- To provide these services in a manner which conforms to contractual and regulatory

requirements, using qualified, trained and experienced personnel
- To provide confidence to its clients on such compliance
- To comply with and implement the quality policy of the Exergy
- To execute a continuous improvement plan

Quality

In order to achieve its objectives, it is the policy of Exergy to establish and maintain an
effective, efficient and certified quality system, planned, and developed in conjunction with
other management functions. The quality system shall comply with international standards.
The assessment of conformity of work to contractual and regulatory requirements is made on
the basis of objective evidence of quality.

Safety

Safety is a key item in the Exergy business environment. Exergy management is committed to
implement and persistently maintain high standards of safety. Specific management tools at

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company/project level and specific communication with clients will be deployed to achieve the
objective.

Environment

Exergy supports the concept of an environmentally conscious business community, caring

about the environment in an active way. This shall be reflected both in the management of its
facilities as well as in the environmental quality of its design.

The Exergy Quality Management System

A fully integrated Quality Management System has been in operation for a number of years
and has been developed to meet the stringent requirements of the Chemical Industry and in
particular the very demanding quality criteria laid-down by major international companies
working in this field.

Exergy have developed a fully documented set of detailed procedures and work instructions to
meet the demands of this business and in particular to cover the activities of large multi-
discipline design and procurement projects.

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9. PRICES, GENERAL TERMS & CONDITIONS
9.1 Price
Description Unit Price (INR)
Price for manufacturing & supply of Exergy Flue Gas
6,41,10,000
Bagasse Dryer as per scope of supply

Price for supply of bagasse belt conveyor system

2,57,06,000
including load cells, chutes, diverters & accessories

Price for Supervision of erection & commissioning 62,40,000

Total Price 9,60,56,000

Price in words: INR Nine Crore Sixty Lacs Fifty Six Thousand Only

Quotation is valid for 30 days from date of offer submission. Validity can be extended on
written confirmation of Exergy.

9.2 Packing & forwarding

Packing and forwarding shall be extra @ 3% of Main Equipment value.

9.3 Payment Terms

30% advance along with techno-commercially clear order.
65% against Performa Invoice on pro rata basis.
5% within 1 week after successful commissioning of Plant but not later than 90 days of
completion of erection.

9.4 Delivery Terms

Ex-works, Nalagarh, Himachal Pradesh.

9.5 Delivery Period

 Design and Engineering Documents and Drawings delivery

- 4-6 working weeks from the date of first payment

 Main Equipment delivery after drawing finalization

- 12-14 working weeks from the date of first payment

9.6 Taxes and Duties

All applicable taxes and duties, such as GST, etc. shall be extra at prevailing rate at the time of
delivery of material / service.

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9.7 Transit Insurance
To be borne by CLIENT.

9.8 Transportation and unloading of material at site

Shall be in scope of CLIENT.

9.9 Commissioning

After completion and connection of the utilities the CLIENT shall notify EDPL and the plant will
be commissioned.

EDPL commissioning engineer shall make the necessary adjustments to ensure the plant can
process the specified product.

During plant commissioning “Instruction of Use and Operation” will take place with CLIENT’S
qualified operators.

Immediately after plant run test acceptance CLIENT and EDPL shall jointly sign a “Project
Acceptance Certificate”. This certificate implies CLIENT’s full acceptance that all deliverables
provided by SUPPLIER are fit for CLIENT’s purpose and as per agreed terms and conditions. A
template certificate shall be provided by EDPL.

9.10 Plant commissioning

To & fro travel expenses of one commissioning engineer is included in the total price. CLIENT
needs to provide suitable boarding and lodging to our commissioning engineer at site. During
plant commissioning, any stand-by time, additional time or delay beyond EDPL control or
where EDPL is not directly responsible will be invoiced to CLIENT at full daily rate of Rs.
25,000/- per day plus any additional travel expenses, airfares, airfare re-booking beyond those
already included. EDPL expects to have a smooth coordination of activities with CLIENT to avoid
any extra charge.

9.11 Plant acceptance

Immediately following plant commissioning the acceptance test will take place. The following
parameters shall be demonstrated during the test run / trials:

 Product throughput capacity as agreed.

 Product moisture content based on given feed moisture content as agreed.

Measurement method for the acceptance test shall be agreed between CLIENT and EDPL
before commissioning.

CLIENT shall supply and bear the cost for all relevant personnel, equipment and laboratories for
acceptance test.

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9.12 Process Guarantees and Mechanical Warranty

12 months mechanical warranty from commissioning or 18 months from the date of delivery,
whichever is earlier.

9.13 Excess Material

Any excess material reached at site for commissioning or erection purpose will be assets of
Exergy. This material will be taken back by Exergy.

Date: 09-02-2018

For Exergy Dryers Pvt. Ltd.,

(Priyank Singh)
Mobile: +91- 8527599756

Ref.: 8068-001FGD-PSL Rev.-2 Date: 09-02-2018