2. Energy Content of Sugar-cane
Sugarcane is an Energy rich Crop and one Ton of
Cane contains about 4500 MJ energy in which about
1800 MJ is lost in the boiler flue gas and about 750 MJ
heat energy is dissipated to atmosphere through the
cooling tower / spray pond.
Energy of one ton of cane approximately equivalent
to 1 barrel of oil
One ton of bagasse at 50% moisture produces about
2.15 tons of steam, and 5.8 tons of bagasse (50%
moisture) equals 1 ton of oil.
4. Individuals, Society, Organization, States, Nations
and entire world aim for Sustainable
development.
Sustainable development benefits entire
community in all aspects viz. social, economic,
technological, and environmental.
5. Present situation in India
Indian Sugar Industry in India characterized by
High cost of production and 80% of the cost
production goes towards raw material alone
Old ,out dated and obsolete Technologies,
Small factories i.e. less than 2500 TCD
Relatively concentrating on Sugar only
Hence the need of the hour….
Sugar production alone is not profitable.
Electricity generation, production of Alcohol and
Ethanol are important to ensure sustainability
and financial viability and survival in the
competitive environment.
6. Why diversification is needed in sugar
industry?
Integrated production of sugar, ethanol and
energy as electricity offers viable potential.
Demand for Fuel ethanol is rapidly growing in
India.
Import substitution for Petrol/Crude and
conservation of Foreign exchange
7. Cogeneration, the combined generation of steam and
electricity, is an efficient and cost-effective means to save
energy and reduce pollution. Many studies around the world
have identified sugar mill cogeneration as an attractive low-
cost option to place additional generating capacity on the
grid.
Several studies revealed that the sugar industry as a prime
candidate for supplying low-cost, nonconventional power
via cogeneration and the advantages of sugar mill
cogeneration include relatively low capital cost
requirements and the use of a renewable, indigenous waste
as a “non-polluting” fuel.( Smouse et al.)
8. What is cogen?Cogeneration means simultaneous production of heat and power,
with a view to the practical application of both products. Heat is main
product, electricity by-product or alternate, uses heat that is lost
otherwise.
Cogeneration is not new to the cane sugar Industry , but however
Cogeneration based on High pressure boilers and extraction
condensing or straight condensing machines are definitely new to the
industry
All sugar plants are Cogenerating power right from their inception,
Cogeneration for surplus power generation has gained momentum in
1993.
Cogeneration scheme should consider the available bagasse,
variations in the bagasse availability during season and availability of
coal or biomass during off season and process steam requirements in
the factory during crushing season.
.
9. Benefits of cogen
Cost of production of power per unit is very cheap.
Quick return on investments.
Restore ecological imbalance. Reduced use of fossil fuel.
Ability to use Bio-Mass and other locally available organic matters
Availability of power during crushing period- between Nov. to May.
economic and timely solution of Power problems in the country.
Reduction CO2 in the environment
Conservation of Natural Resources
Lower T&D losses
10. Cogen principle
When steam or gas expands through a turbine, nearly 60 to 70% of
the input energy escapes with the exhaust steam or gas.
This energy in the exhaust steam or gas is utilized for meeting the
process heat requirements.
Such an application, where the electrical power and process heat
requirements are met from the fuel, is termed as “Cogeneration”.
Cogeneration is the most efficient way of generating electricity and
heat from a given amount of fuel. It saves between 15-40% of energy
when compared with the separate production of electricity and heat.
A number of different fuels(multiple fuel) and proven, reliable
technologies can be used
It is also known as ‘Combined Heat and Power (CHP)’ and ‘Total
Energy System’. Power and Combined Heat and Power (CHP) plays
an important role in sustainable development.
12. Pre requisites
Feed water quality control and Boiler Water Management,
An effective bunker system for the storage of bagasse, moisture in the
bagasse controlled to a value of around 50%.,
turbine for the Sugar plant Cogeneration-servicing and spares
availability,
Process side steam Economy,
design of the electrical systems for the Cogeneration parallel the
cogeneration plant at 110 kV level.
Distributed Control System(DCS)
skilled Man Power,
13. Some considerations
The initial investment of cogeneration projects may be
high but payback period is low( between 3-5 years).
The payback period and profitability of cogeneration
schemes depends upon realisation of sales price for
electricity.
Environmental concerns, new avenues for non
conventional energy sources and increased demand for
power are likely to improve market conditions for
cogeneration.
14. Where energy savings in sugar mills
Conversion from low Pressure to HP Boilers(Saving of Bagasse by
adopting high technology HP Boilers, Reduction of moisture in
bagasse 50 to 45% by improving Milling Technique).
Mill House/Crushing section-Reducing moisture percentage in
Bagasse, Reduction in consumptions of power per Ton of Cane by
installing Variable frequency drives and high efficient auxiliaries.
Evaporator section(Reduction in Process steam consumptions in
evaporator and Prime movers by installing Planetary Gear systems
Reduction in live steam consumption
15. Save power inside the factory to
export more power to grid
Electrical Energy consumption can be reduced by incorporating
various Energy Efficient Equipment like , VFD, Energy Efficient
Transmission gears, pumps and motors, etc. and thereby power export
can be increased.
Energy efficient gears may be introduced Feeder table, Cane Carrier,
Milk of lime stirrers, Crystallizers drives, Molasses and magma pumps,
Pug-mills and Magma Mixers, etc to save power consumption in the
factory.
Condensers & Cooling System, Energy efficient Pumps and Motors,
Juice and Water Flow Meters
16. 1 ton of cane gives
125 units of Power of which 35 units required for
the mills and 90 units of may be exported to Grid.
In addition
1) Sugar (9.5% recovery) : 95 kg
2) Molasses ( 4.5%) : 45 kg(10.8 Lit of Ethanol)
3)Press mud ( 3%) : 30 kg
(Recovery is considered at 9.50 %)
(As per the amended Sugar cane control order, if Ethanol is produced directly from Juice 60
liter will be obtained)
17. One ton of Molasses gives
Rectified Spirit : 220 Litres
or Ethanol : 210
Litres
or ENA ( Extra Natural Alcohol) : 215 Litres
18. Molasses is one of the important by product of
the sugar industry. Molasses, on distillation
produces rectified spirit, extra neutral alcohol,
denatured spirit, and ethanol.
Alcohol is used in Liquor, pharmaceuticals and
chemicals industries.
Ethanol is also a valuable fuel, which is blend
with Petrol.
19. Demand for Alcohol /Ethanol
Demand for alcohol is increasing every day for IMFL/
Chemical industries
Mandatory for blending with Petrol and frequent
increase of petro products have increased the
demand for ethanol
In addition to sugar mills, corn based alcohol/ethanol
plants are coming up to meet the increased demand.
Potential is unlimited for alcohol and ethanol in
India.
20. Biofertilisers from cane
Press mud a byproduct, is sold as such by some mills
to the cane growers
Some mills process the press mud and sell it as
enriched pressmud, which can be directly applied in
the field.
Some mills process pressmud with cowdung and
earthworm and sell as Vermicompost or fertilisers ata
higher price from Rs 1500 per MT
21. Road ahead
Sugar complexes instead of Sugar mill
Production of sugar, biofertiliser, power, alcohol and
ethanol under one roof.
Increased financial profitability and self reliance
Taking care of environment along with the economic
development of farmers and march towards
sustainable development.
