S C.

Natu
Sr. Vice President (Power Division)
MITCON Consultancy & Engineering Services Ltd.
 All India potential, 7000 MW (650 sugar mills)
 Achievements as of September 30, 2012, 2250 MW
(200 projects)
 Under construction, 750 MW (50 projects)
 Total, 3000 MW (250 projects), 43% penetration
 Private sector leading in States like UP, Tamil
Nadu, Karnataka & Andhra Pradesh
 Co-operatives leading in Maharashtra & Tamil
Nadu
 Own investment & BOOT models established
 Conducive CERC / SERC orders, CDM, REC &
power trade, the key drivers
 Results of promotional measures, mainly by
MNRE
 Conventional rankine cycle technology
 Own / saved bagasse, biomass & coal used as

primary fuels, during season & off season of the

sugar mills
 Travel grate type boilers designed for multi-fuel

operations
 High pressure / temperature steam generated

and expanded through back pressure or double

extraction cum condensing TG set
 Medium pressure steam at 8 kg/cm2 pressure
used for HP heater & process requirements
 Back pressure steam at 1.5 kg/cm2 pressure

used for process requirements & de-aerator

 Balance steam condensed through the
condenser
 Power generated during season used for cogen

plant auxiliaries, sugar / by-product process &

balance exported to the grid
 Power generated during off season used for cogen
plant auxiliaries, by-products, colony & balance
exported to grid
 Steam to fuel ratios range from 2.4 kg/kg to 2.65

kg/kg
 Steam to power ratios range from 5.2 – 5.6 kg/kw

during season & 3.6 – 4.0 kg/kw during off season

 PLF, 55 – 60% during season & 90% during off

season
 Boiler efficiencies, 68-72% on bagasse & 80%
on coal
 TG efficiency of 90%
 Station heat rates, 3600 – 3800 kcal/kwh
 Capex, Rs. 5.25 crore / MW for cogen power

plant & Rs. 1.0 – 1.5 crore / MW for concurrent

sugar factory modernization
 O&M, 3-5%
Main packages
 Boiler & auxiliaries
 Turbine, generator & auxiliaries
 Cooling tower or ACC
 Fuel & ash handling
 Electrical distribution / evacuation
 Water treatment plant
 Civil works
Main packages (contd.)
 Plant DCS
 EOT crane
 AC & ventilation system
 Air compressor
 DG set
 Interface HP / MP / LP steam, cooling water, DM

water & compressed air piping

 Fire fighting
 110 828 105 826.3
97 540 96.51 535
BOILER TO GSC & SJAE
0.49 TPH 20 MW 18.65 MW
36.60 TPH 100 TPH
BAGASSE 110 Kg/Cm 2 STEAM
540°C 25 748 TURBINE GEN.
11.64 359 B B
BLOW
DOWN
150 226 1 TPH 0.1 580
0.19 TPH 1.26 TPH
98 220 704.5 2.5 659 7.45
8 8 704.5 J 40
I
9.7 249 8 700.5 15.51 249 61.92 150
6 180
M.P. STEAM TO
ETHANOL PLANT
HP
HEATER 2.5 659 - 40
FLASH RECOVERY 0.5 TPH
NO 2 600 40
58.33 150
152 169 L.P. STEAM TO CW OUTLET
98 2.5 659 SUGAR FACTORY
166 - 228
SURFACE
11.64 222 4.85 150 - 32
HP CONDENSER
HEATER 600 32
NO 1 CW INLET
4 124.5
9.7 124.5
HOT
A WELL 0.49 TPH
7.94 TPH FROM SJAE & GSC
154 116
CONDENSATE RETURN FROM DEAERATOR
98 115
SUGAR FACTORY 55.4 TPH, 95°C SJAE
G.S.C. COND.
FEED WATER
DM WATER
MAKE UP

TANK CEP

64.82 TPH LEGENDS :-

4 33 G.S.C. - GLAND STEAM COOLER LEGEND :-
9.42 33 TRANSFER SJAE - STEAM JET AIR EJECTOR
PUMP PRESSURE ENTHALPY
CEP - CONDENSATE EXTRACTION PUMP
BFP - BOILER FEED PUMP Kg/Cm 2 Kcal/Kg
MP - MEDIUM PRESSURE FLOW TEMP.
LP - LOW PRESSURE TPH °C
BFP CW - COOLING WATER
TPH - TONNES PER HOUR
4 116 10 116
1.26 115 0.19 115 - PRESSURE CONTROL VALVE
J I
 110 828 105 826.3
82 540 81.59 535
BOILER TO GSC & SJAE
0.41 TPH 20 MW
30.94 TPH 100 TPH 20 MW
BAGASSE 110 Kg/Cm2 STEAM
25 748 TURBINE GEN.
540°C
9.84 359 B B
BLOW
DOWN
150 226
0.8 TPH 0.14 580
0.11 TPH
82.8 220 2.5 659
8 704.5 8 704.5 52.21 54
J
8 700.5 0.28 TPH 5.63 150
8.2 249 13.92 249
I
6 180
M.P. STEAM TO
ETHANOL PLANT
HP
HEATER - 40
FLASH RECOVERY 0.4 TPH
NO 2 4300 40
152 169 CW OUTLET

82.8 166 - 228 2.5 659

SURFACE
9.84 222 5.74 150 - 32
HP CONDENSER
HEATER 4300 32
NO 1 CW INLET
4 124.5
8.2 124.5
HOT
A WELL 0.41 TPH
52.62 TPH
FROM SJAE & GSC
154 116
CONDENSATE RETURN FROM DEAERATOR
82.8 115
SUGAR FACTORY 0 TPH, 95°C SJAE
G.S.C. COND.
FEED WATER
DM WATER

TANK
MAKE UP

CEP

6.4 TPH
4 33 LEGENDS :- LEGEND :-
6.4 33 TRANSFER G.S.C. - GLAND STEAM COOLER
PUMP PRESSURE ENTHALPY
SJAE - STEAM JET AIR EJECTOR
Kg/Cm 2 Kcal/Kg
CEP - CONDENSATE EXTRACTION PUMP
BFP - BOILER FEED PUMP FLOW TEMP.
MP - MEDIUM PRESSURE TPH °C
BFP LP - LOW PRESSURE
CW - COOLING WATER
4 116 4 116
TPH - TONNES PER HOUR
0.11 115 0.28 115
J I - PRESSURE CONTROL VALVE
 Extra high pressure boiler (87 kg/cm2 pressure
& 110 kg/cm2 pressure), commercialized
 Matching back pressure, single / double
extraction cum condensing type TG sets,
commercialized
 Air cooled condensers and RO type water

treatment plants for overcoming water quality

and availability issues, commercialized
 Plant DCS, VFDs, ACVFD drives, grid
synchronization, etc. technologies,
commercialized
 Extended off season by utilization of cane trash

& other biomass materials, getting progressively

commercialized
 Equipment, technology & services available

indigenously
 All India potential, 18000 MW from agro waste materials
(excluding sugar mills)
 Potential will explode with energy plantation on waste
lands for power generation
 Achievements as of September 30, 2012, 1250 MW (160
projects) & under construction, 250 MW (20 projects),
only 8% penetration
 Conducive CERC / SERC orders, CDM, REC & power
trade, the key drivers
 Results of promotional measures, mainly by MNRE
 Conventional rankine cycle technology, similar to
bagasse cogen
 Extra high pressure boiler (67 kg/cm2 pressure & 87
kg/cm2 pressure), commercialized
 Variety of biomass materials established, although fuel
linkage difficult
 Equipment, technology & services available indigenously
 Independent biomass power plant models established,
yet captive power plants in industries through biomass in
experimental stages
 Continuation of MNRE / MoF fiscal & financial support
 Rationalization of tariffs, other provisions of ERC orders
& adequate hikes due to rise in capital & operating costs
 Consideration capex for essential sugar mill
modernization for tariff determination
 Demonstration & commercialization of fuel linkage
mechanisms & energy plantation models
 Capacity building & information Dissemination
 Technology development / demonstration, difficult
biomass materials like paddy straw, mustard husk
 Level playing field for CDM, REC & power trade
 Engineering / consultancy services
 Technology transfer & equipment / EPC supply
 O&M contracts
 Financing, equity & debt
 Capacity building
 Information dissemination
 Consultancy / engineering company, established in 1982
 Central / State Government stakeholders, 59.5% of shares &
Private shareholders, 40.5% shares
 Profit making & IS/ISO 9001:2008 certified company
 Sugar & Power, infrastructure, energy & carbon, environment,
agri business, finance & market research, biotechnology, main
consultancy / engineering divisions
 Latest infrastructure & experienced manpower (totaling to 225,
engineering about 100)
 Offices in Pune, Mumbai, New Delhi, Ahmedabad, Chennai &
Nagpur

MITCON Consultancy & Engineering Services Ltd.

Vision
To become a ‘One Stop’ service provider
for decentralized Power Projects on any
fuel, from concept to successful
commissioning & establish at the National
& International Levels

MITCON Consultancy & Engineering Services Ltd.

Services (Sugar, Power & Ethanol Projects)
 Pre-investment

(Feasibility study, fuel / biomass / cane survey, bankable DPR,

loan syndication, lender engineering, approval services, MNRE
capital grant & excise duty exemption certificates, project
developer interface services, etc. )
 Pre-contract Engineering
(Basic / detailed design engineering, plant layouts,
specifications and drawings, EPC / packaged bid documents,
bidding / bid evaluation / recommendations, pre-contract
discussions, assistance in signing EPC / package contracts &
manpower planning )

MITCON Consultancy & Engineering Services Ltd.

 Post-contract Engineering / Project Management
(Kick start meetings with vendors / EPC contractors,
PERT / CPM networks, inspection / expediting, vendor
drawling services and approvals, site supervision,
monitoring of erection / commissioning, plant
stabilization & plant MIS development)
 Post-commissioning
(Witnessing PG tests, trouble shooting, plant MIS,
contract to compliance reports, etc. )

MITCON Consultancy & Engineering Services Ltd.

 Macro Assignments & Training

◦ Macro and Policy Studies for biomass, bagasse, natural

gas, fossil fuel based industrial captive / cogen power for
sugar, distillery & ethanol sectors

◦ Organized number of regional / national / international

business meets, interaction meets, workshops, seminars,
training and skill up-gradation programs

MITCON Consultancy & Engineering Services Ltd.

Experience

 National & International experience of two decades,

private, public sector & co-operative sector clients
 Micro level services to over 200 sugar factories, several
biomass & fossil fuel based industrial cogen / captive
power projects & distilleries / ethanol plants
 A dedicated team of qualified and experienced in-house
staff and associate experts at various offices
 State-of-the-art engineering design / drawing equipment

MITCON Consultancy & Engineering Services Ltd.

Experience (contd.)
 Program partner & lead program partner of MNRE, Govt.
of India
 Macro level assignments and promotional work with
IREDA, Winrock International India, USAID, UNDP,
financial institutions & banks
 International exposure & events participation
 Founder member of World Alliance for Decentralized
Energy (WADE) and patron member of Cogeneration
Association of India (Cogen India)

MITCON Consultancy & Engineering Services Ltd.

 International
 Pure Diet Mocambique Limitada, Mozambique
 Sugar Corporation of Uganda Ltd., Uganda
 Alliance Tire Co. Ltd., Israel
 Delta Energy Inc, UK
 Sindicatum Carbon Capital, Singapore
 Charter Oak Energy, Renova Engineering PC & Nitash Inc, USA
 NUCON Energy Corporation, USA
 Ratnala, Behl & Co., USA
 Entech Energy Consultants Ltd., UK
 UNDP-GEF
 USAID
 Winrock International India
 Swiss Development Corporation

MITCON Consultancy & Engineering Services Ltd.

Coverage
Sectoral Geographic

 Power  Maharashtra
 Biomass  Tamil Nadu
 Sugar  Bihar
 Chemical  UP / Uttarakhand
 Steel  Karnataka
 Ethanol  Andhra Pradesh
 Paper  Goa
 Rice Mills  Gujarat
 Infrastructure  Madhya Pradesh
 Waste Heat Recovery  Punjab
 Rajasthan

MITCON Consultancy & Engineering Services Ltd.

Coverage
Services Fuel Types
(End of Pipe, Concept to Commissioning)
 Pre-investment  Biomass
 Engineering  Bagasse
 Project Management  Coal
 Macro Assignments  Natural gas
 Events / Training  Waste heat recovery

Size Range

1 MW to 600 MW

MITCON Consultancy & Engineering Services Ltd.

Micro Level

 Establishment in private, public, co-operative & other

sectors, across India at the national level
 Fuel assessment / DPRs / TEV studies / appraisals /
loan syndication / lender engineering for public, private
& co-operative sector clients & banks / FIs
 Owner Engineering / Consultancy Services for biomass
power, bagasse cogen along with concurrent sugar
factory modernization / expansion & coal fired power
plants

MITCON Consultancy & Engineering Services Ltd.

Micro Level (contd.)
 EPC consultancy services for TANGEDCO / Govt. of TN,
12 cogen power plants along with concurrent sugar
factory modernization projects (installed capacity 183
MW), in advance stages of construction & expected to
commission in Sept – Dec, 2012)
 EPC consultancy services for HPCL Bio Fuels Ltd.,
integrated sugar expansion / modernization (3500 TCD),
cogen power plants (20 MW) & ethanol plants (60 KLPD)
at Lauriya & Sugauli in Bihar

MITCON Consultancy & Engineering Services Ltd.

Micro Level (contd.)
 Consultant to Urjankur Trust for Shri Datta SSKL & Shri
Tatyasaheb Kore Warana SSKL, DPR preparation &
EPC consultancy for concurrent sugar factory
modernization projects
 Appointment as LIE by PNB, 2X600 MW imported coal
based power plant of ITPCL at Cuddalore, Tamil Nadu
 Project developer interface, consultancy & engineering
services for BOOT projects for IREL, BPCL & DCM
 Pre-investment & engineering services for existing / new
sugar plants & ethanol plants

MITCON Consultancy & Engineering Services Ltd.

Micro Level (contd.)
 Engineering services for first 67 Kg/cm2 pressure

bagasse cogen power plant (Mula SSKL, 2006), first 87

Kg/cm2 pressure (YM Krishna SSKL, 2010) & first 110
Kg/cm2 pressure (Shankar SSKL, 2011) in Maharashtra
 Engineering services for biomass, bagasse, coal

based power plants, 412 MW commissioned

capacity (31 projects) & 470 MW under erection (18
projects)
 Approved TEV consultants & lender engineers for large

no. of banks & financial institutions

MITCON Consultancy & Engineering Services Ltd.

Macro Level
 All India Bagasse Cogen Study for IREDA, New Delhi
 Program Partner & Lead Program Partner of MNRE
 Member Secretary, Cogen India & Vice Chairman,
WADE
 Cane Cogen Handbook of USAID / WII (Partner)
 Assessment, Strategy & Action Plan for Non Sugar
Cogen Market Development Initiative for USAID / Nexant
 Guidelines for Captive Cogen – A handbook for Govt. of
Maharashtra, Department of Energy
 UNDP-GEF-MNRE project, Removal of Barriers to
Biomass Power Generation in India
 Renewable Energy Certificates

MITCON Consultancy & Engineering Services Ltd.

S. C. Natu
Sr. Vice President (Power Division)
MITCON Consultancy & Engineering Services Ltd.
1st Floor, Kubera Chambers
Shivajinagar, Pune - 411 005
Tel : (020) 25534322 / 3309, 66289136 (D),
09822684102
Fax : (020) 25533206
E-mail : sunil.natu@mitconindia.com

MITCON Consultancy & Engineering Services Ltd.