Vasantdada Sugar Institute, Manjari (Bk.), Pune 412 307, India. Author for correspondence: [email protected] [email protected] USE OF ALTERNATE

Vasantdada Sugar Institute, Manjari (Bk.), Pune 412 307,

India.

Author for correspondence: [email protected]

USE OF ALTERNATE SUGAR PROCESSING INTERMEDIATES AND

SUPPLEMENTARY CROPS FOR AUGMENTING ETHANOL SUPPLY

R. V. Godage1, D. A. Patil2 and S. V.

Patil3

mailto:[email protected]

WHY ALTERNATE/SUPPLEMENTARY RAW MATERIALS ?

• International crude price has crossed $100 per barrel.

• The world ethanol production has reached to 62.03 Billion liters in 2007 and expected to increase to about 100 Billion liters by 2012.

• Indian total ethanol demand is projected to reach 5.920 Billion liters in 2010 at 10% and 5% blending rate of fuel ethanol in gasoline & diesel, respectively.

• About 95 % distilleries in the country are based on sugar cane molasses.

• Considering maximum projected sugar cane crushing in the country of 260.0 million MT (Molasses- 11.70 million MT) in 2010, it would be possible to produce maximum 2.574 Billion liters of ethanol.

• This indicates that, cane molasses alone will not be sufficient to meet India’s increasing requirement of ethanol. To overcome this problem, it is possible to produce ethanol from variety of renewable agricultural sources such as various sugar processing intermediates, sugar beet, sweet sorghum, cereal grains etc.

Ethanol: World Scenario

World Total Alcohol Production Year 2003-2007 (In Million Liters)

World Regions

Years

2007 2006 2005 2004 2003

EU & Europe 5,112 4,647 4,229 3,835 3,885

Africa 695 633 608 584 540

N & C America

27,399 20,867 16,875 14,969 12,706

Asia 7,225 6,534 5,920 5,994 6,535

Oceania 202 172 149 149 164

World Total 62,032 51,439 44,331 40,676 39,018

India 2,000 1,650 1,100 1,232 1,770

India-Gasoline & Ethanol demand

Year Gasoline consumption

(m.liters)

Alcohol

consumption for potable &

industrial

(m. liters)

E5

(m. liters)

(Fuel ethanol)

Total Demand of

Alcohol

@ E5

(m. liters)

E10

(m. liters)

(Fuel ethanol)

Total Demand of

Alcohol

@ E10

(m. liters)

1 2 3 4 5= (3+4) 6 7 =(3+6)

2006-07 9.27 1500 580 2080 1160 2660

2007-08 9.91 1575 620 2195 1240 2815

2008-09* 10.61 1620 660 2280 1330 2950

2009-10* 11.35 1700 710 2410 1420 3120

*projected , m = million

Estimated Indian Ethanol demand

Sr. No.

Particulars Requirement of Alcohol

(Million Lit.)1 Industrial +Potable+E10 2815

2 Industrial +Potable+E5+E5(D) 4880

3 Industrial +Potable+E10+E5(D)

5615

4 Industrial +Potable+E10+E10(D)

8285

ALTERNATE SUGAR PROCESSING INTERMEDIATES

Case Study

Crushing capacity = 4000 TCD Distillery capacity = 60 KLPD

Sugar price = Rs. 11.50/kg Ethanol price = Rs. 21.50/Liter Bagasse price = Rs. 250.0/MT

Pol % Cane = 13.23 All data on per day basis

Conventional route(Per day basis)

Particulars General 3m/c boiling

Sugar recovery 11.50 %

Sugar production 4600.0 qtls.

FM % cane 3.64 %

FM Production 145.60 MT/day

Ethanol 36.996 KLPD

Ethanol revenue Rs. 7.954 Lac

Sugar revenue Rs. 52.900 Lac

Total revenue Rs. 60.854 Lac

Total revenue per MT of cane

Rs. 1521.35/MT

Two massecuite/B-Heavy molasses route

(Per day basis)

Particulars Two m/c boiling



BH % cane 5.56 %

BH production 222.04 MT/day

Ethanol 74.943 KLPD





Rs. 1532.12/MT

Total secondary juice route (Per day basis)

Particulars PJ for Sugar + SJ for EthanolSugar recovery 8.76 %

Sugar production 3504.0 qtls.FM % cane 2.46 %

FM production 98.538 MT/dayEthanol from FM 22.977 KLPD

SJ % cane 40.94SJ Production 1637.60 MT/day

Ethanol from SJ 78.404 KLPDTotal Ethanol 101.381 KLPD

Ethanol revenue Rs. 21.797 LacSugar revenue Rs. 40.296 LacTotal revenue Rs. 62.093 Lac


Rs. 1552.32/MT

Partial secondary juice route (Per day basis)

Particulars PJ for Sugar + Partial SJ for ethanol (as per distillery capacity)



FM % cane 2.72 %

FM production 108.95 MT/day

Ethanol from FM 26.595 KLPD

SJ % cane 31.38

SJ Production 1255 MT/day

Ethanol from SJ 60.085 KLPD

Total Ethanol 86.680 KLPD





Rs. 1548.05/MT

Total mixed juice route (Per day basis)

Particulars Total juice for ethanolSugar recovery -

Sugar production -FM % cane -

FM production -Ethanol from FM -

MJ % cane 98.28MJ Production 3931.20 MT/day

Ethanol from MJ 297.496 KLPDTotal Ethanol 297.496 KLPD

Ethanol revenue Rs. 63.962 LacSugar revenue -Total revenue Rs. 63.962 Lac


Rs. 1599.05/MT

Partial mixed juice route(Per day basis)

Particulars Partial MJ for ethanol (as per distillery capacity)

Sugar recovery 9.24 %Sugar production 3696.0 qtls.

FM % cane 2.86 %FM production 114.28 MT/day

Ethanol from FM 27.433 KLPDMJ % cane 20.75

MJ Production 830.0 MT/dayEthanol from MJ 60.540 KLPD

Total Ethanol 87.973 KLPDEthanol revenue Rs. 18.914 LacSugar revenue Rs. 42.504 LacTotal revenue Rs. 61.418 Lac


Rs. 1535.45/MT

Comparative Sugar and Ethanol Production

Particulars Sugar Production

(Qtls/day)

Ethanol Production

(KLPD)

Conventional 4600 36.996

B-Heavy 3928 74.943

Secondary Juice 3504 101.381

Partial Secondary Juice

3764 86.680

Whole Cane Juice - 297.496

Partial Whole Cane Juice

3696 87.973

Comparative Ethanol Yields Particulars(Litres/MT)

FM or BH SJ or MJ Per MT of Sugar cane

Conventional 254.1 - 9.25

B-Heavy 336.97 - 18.74

Secondary Juice 233.17 47.88 25.34

Partial Secondary Juice

233.17 47.88 21.64

Whole Cane Juice - 75.67 74.37


240.05 75.67 21.99

Comparative Revenue Generation(Rs. Lac)

Particulars Sugar Revenue

Ethanol Revenue

Total Revenue

Conventional 52.900 7.954 60.854

B-Heavy 45.172 16.113 61.285

Secondary Juice

40.296 21.797 62.093

Partial Secondary

Juice

43.286 18.636 61.922

Whole Cane Juice

--- 63.962 63.962


42.504 18.914 61.418

Expenditure, (Rs./MT)

Particulars Harvesting & Transport

Cost

Sugar Conversion

cost

Ethanol conversion

cost

Total cost

Conventional 225.0 550.0 52.49 827.49

B-Heavy 225.0 542.0 65.58 832.58

Secondary Juice

225.0 542.7 88.71 856.41

Partial Secondary

Juice225.0 547.0 75.85 847.85

Whole Cane Juice

225.0 267.0 260.31 752.31


225.0 548.0 76.98 849.98

Expected cane price, (Rs./MT)

Particulars

Total revenue

Conventional 1521.35

B-Heavy 1532.12

Secondary Juice

1552.32

Partial Secondary

Juice

1548.05

Whole Cane Juice

1599.05

Total expenditure

Expected cane price

827.49 694.06

832.58 699.54

856.41 695.91

847.85 700.02

752.31 846.74


1535.45 849.98 685.47

Maximum Production (180 days)

Particulars Sugar Production

(Qtls)

Ethanol Production

(KL)

Conventional 8,28,000 6,659.28

B-Heavy 7,07,040 13,489.74

Secondary Juice 6,30,720 18,248.58

Partial Secondary Juice 6,77,520 15,602.40

Whole Cane Juice - 53,549.28

Partial Whole Cane Juice 6,65,280 15,835.14

SUPPLEMENTARY CROPS

Tropical Sugar Beet

• New varieties suitable for tropical regions.• Sugar content 12-18 %.• 5 to 6 months crop.• Less water requirement.• High salt tolerance.• Constitutes 22.02 % of world sugar production.• Used for production of sugar, ethanol and cattle feed.• Additional supply of raw material to sugar mills after

sugarcane crushing season.

SUGAR BEET CROP YIELD

Varieties Root wt (MT/ha)

HI 0064 110.7

Dorotea 107.64

Posada 106.11

Average Composition of Sugar Beet

Parameters Sugar beet

Water (%) 73 – 76.50

Dissolved solids (%) 23.50 – 27.0

Sucrose (%) 16 – 18

Water insoluble (Marc %) 4 - 5

CHARACTERISTICS OF SUGAR BEET JUICE

Parameter Sugar beet juice

pH 6.0 – 6.5

Reducing Sugars (%) 0.2 - 0.3

Total reducing sugars (%) 15.0 -16.0

Unfermentable sugars (%) 0.2 – 0.3

Fermentable sugars (%) 14.8 – 15.7

Alcohol (as R.S.) Yield-

(Lit./MT of sugar beet)

89.0 – 94.0

Sugar beet roots

Beet washer

Beet slicer

Beet weighment

Beet Diffuser

Juice evaporation & syrup cooling

Diffused Juice

Screening

Syrup weighment

Fermentation

Primary distillation (R.S.)

Dehydration Ethanol

Sp. wash

Bio-methanation or Bio-composting

Pulp press

Diffused pulp

Pulp for cattle feed

Low brix juice to diffuser

CO2

Suspended matter

Wash water to fieldWater

Process flow diagram of Ethanol manufacturing from sugar beet juice –

Water &Yeast

Steam

Exhaust steam

Case Study

Sugar beet Crushing capacity

TBD 500

Sugar beet crushing plant cost – 500 TBD(Wash water pump, beet conveyer, beet washer, beet slicer, cosset conveyer, diffuser, pulp

press Evaporation unit etc.)

Rs. Lac 1150.0

Existing Distillery Capacity KLPD 45

Ethanol price Rs./Lit. 21.50

Fusel oil price Rs./Lit. 28.00

Beet Pulp price Rs./MT 500.00

Compost price Rs./MT 250.00

Case Study 500 TBD to connect with existing 45 KLPD Distillery Unit

Particulars Unit Value

Sugar beet processing per day TBD 500

Net working days Days 60

Total beet processing MT 30,000

Alcohol yield Lit/MT 90

Total alcohol production (94.68 % v/v) Lits. 27,00,000

Total Ethanol production (100% v/v) Lits. 25,47,170

Fusel oil Lits. 8,197.2

Beet Pulp (20% on beet) MT 6,000

Spent wash production M3 27,000

Spent wash recycle (30%) M3 8,100

Spent wash outlet M3 18,900


Press mud requirement MT 7,560

Compost production MT 5,117

Realization (Rs. Lac)

Ethanol Rs./Lit. 21.50 547.64

Beet Pulp Rs./MT 500 30.00

Fusel oil Rs./Lit. 28.00 2.30

Compost Rs./MT 250 12.79

Total (A) 592.73


Processing cost (Rs. Lac)

Beet to syrup conversion cost Rs./MT 80.00 24.00

Syrup to Ethanol cost

Steam ( 2.6 kg/lit. of ethanol) Rs./MT 500 33.11

Power (6850 units/day) Rs./Unit 1.65 6.78

Water (4 lac lits./day) Rs./10M3 9.00 0.22

Chemicals Rs./Lit. 0.20 0.05

Insurance 0.025 2.88

Repair & Maintenance % 1.50 17.25

Interest on working capital 0.41


ETP (Rs. Lac)

Press-mud requirement Rs./MT 50.00 3.78

Cost of culture Rs./Kg 30.00 2.27

Cost of Diesel (100 Lit./day) Rs./Lit. 40.00 2.40

Total (B) 93.15

Fixed Cost

Depreciation 140.00

Interest on Term loan 52.44

Interest -Own contribution 7.94

Total fixed cost Total C 200.38

Total processing cost Total D= (B+C)

293.52


(Rs. Lac)

Gross profit Total E =(A-D) 299.21

Add :Depreciation F 140.00

Total cash Accrual G = (E+F) 439.21

Less: Term loan H 207.00

Cash Available for beet cost

I = G-H 232.21

Sugar beet cost- Rs./MT 774.03

Sweet Sorghum (Sorghum Bicolor (L.) Moench)

• Short duration crop (120 – 140 days).

• Cheaper to grow.

• Less water requirement than any other crop.

• Has a good tolerance to wide range of climatic & soil

conditions.

• This crop can be taken twice in a year.

• The quality of Rectified Spirit obtained is superior.

• The effluent volume can be reduced to 3 lit/lit.

• Sweet Sorghum is grown in – Africa, South & Central

America, China, India, Pakistan and United States.

SOWING AND HARVESTING

• 7 Varieties in Kharip Season & 7 Varieties in Rabi season.

• RSSV-9 From MPKV, Rahuri.

• SSV-84, ICSV-93046, ICSV-700, NTJ-2, SPV-472 & S-35 From

ICRISAT, Hyderabad.

• Sown at V.S.I. Farm by dibbling method.

• 6 Irrigations at an intervals of 20 days.

• NPK Fertilizer doses of 120, 60 & 60 kg/ha were given.

• The crop was harvested at an intervals of 10 days i.e. 100 days, 110

days, 120 days, & 130 days from sowing.

Sr.No. Particulars 1 ha. Cost Rs.

1. Preparatory Tillage

Ploughing, Harrowing, Cleaning Collection, layout preparation etc.,

3245.40

2. Cultivation & Plant Protection

•Seed cost, dibbling labour,

•Fertilizers & Its application

•Weed Control

•Irrigation Charges

•Plant Protection

3350.50

1455.00

825.40

1112.40

1603.40

3. Supervision Charges 10 % on above 1159.21

4. Total cost of cultivation 12751.31

COST OF CULTIVATION FOR S. SORGHUM

SWEET SORGHUM PLOT AT VSI

Sr.No. Particulars Raw Juice Clarified juice

1. 0 Brix 16.97 - 19.65 16.32 - 19.36

2. pH 4.84 – 5.10 7.04 – 8.66

3. Reducing Sugar (%) 1.0 – 1.88 0.98 – 2.29

4. Total Reducing Sugar (%) 12.97 – 15.73 13.12 – 15.99

5. Calcium Oxide (CaO) PPM 1185 – 1960 1120 – 1875

6. Magnesium (MgO), PPM 58 – 70 40 – 65

7. Phosphate (P2O5), PPM 850 – 1150 70 – 100

8. Starch, PPM 772 – 5521 775 – 4317

9. Polyphenols, PPM 475 – 1125 512 – 981

10. - Amino Nitrogen, PPM 27 – 121 17 – 83

11. Aconotic Acid, % v/v 1.04-1.36 0.93-1.32

ANALYSIS OF RAW AND CLARIFIED JUICE

S. SORGHUM – STALK AND JUICE ANALYSIS

Sr.No Particulars Analysis Report

1. Pol % in stalk 8.78 – 11.39

2. Fiber % in stalk 12.30 –18.58

3. Juice Purity (%) 64.21 – 69. 47

4. Mud volume in juice (%) 48.7 – 65.80

ALCOHOL YIELD

1. Fermentable Sugar in stalk (subtract 2.5% sugar loss in baggase), Kg/ha.

2720.60 –5270.90

2. Alcohol Yield (Expected) – Lit./Ha

(F.E. –90%, D.E.-98.5%, Alcohol %- 94.68)

1640.80 – 3178.27

3. Alcohol Recovery (B.L. /MT of stalk) 49.69 –63.07

Economics of Ethanol Production From Sweet Sorghum

Sr.

No

Particulars Considering 40 T/ha

Per Day Month

A. Ethanol Production & Land Requirement

1. Distillery Capacity, lit. 30,000 9 Lac lit

2. S. S. Stalk Required, Tons 600 18000

3. Sweet Sorghum Stalk Yield,MT/Ha 40 40

4. Ethanol Yield, liters/MT S.S.Stalk 50 50

5. Land Requirement for Sowing 15 ha 450 ha

6. Seed Required for Sowing

(Considering 10 kg/ha)

150

(37.5 Acre)

4500

(1125Acre)

B. Production

1. Ethanol Production, lac lit 0.30 9.0

2. Bagasse Production, Tons ( 28% 0n S. Sorghum Stalk Crushed)

168 5040

3. Tops & leaves for fodder, MT 255 7650

Sr.No Particulars Months (30 Days )

C. Expenses Per Month ( Rs. Lac )

1. Harvesting & Transporting (@ Rs.250/Ton) 45.00

2. Processing to Syrup @ Rs.8.25/lit of Ethanol 74.25

3. Syrup to Ethanol@ Rs. 3.75/ of R. S. 33.75

Total Expenses 153.00

D. Receipts Per Month( Rs. Lac )

1. Ethanol 9.0 lac lit @ Rs. 21.50/lit 193.50

2. Bagasse 5,040Tons @ Rs.500/Ton 25.20

3. Tops& leaves for fodder @Rs.500/T. 38.25

Total Receipts 256.95

E. Gross Profit ( Rs. Lakh) 103.95

Economics of Alcohol Production From Sweet Sorghum

Sr.No Particulars Months (30 Days )

1. Price that can be paid to the farmers after deducting 10% Manufacturer’s Margin

Rs.519.75/MT

2. Price that can be paid to the farmers after deducting 10% Manufacturer’s Margin Rs.20,790/ha/crop

3. Additional Benefit from sale of grains

@ Rs.6000/MT X 1. 5 MT/ha Rs. 9,000/ha/crop

4. Assumed cost of cultivation. Rs. 12,750/ha

5. Total Benefit to the Farmer

( Sr.No. 2 + Sr. No. 3 – Sr.No. 4)Rs. 17,040/ha/crop

Economics of Alcohol Production From Sweet Sorghum

Conclusion1. Conventional molasses route is most economical. However, it

can not fulfill the increasing ethanol demand of the country. It would also result in increasing the sugar stocks.

2. Route that can be used will be determined by the prevailing prices of sugar and ethanol at that time.

3. Excess sugar can be diverted to ethanol production. However, at the same time there is a need to create additional demand for ethanol by initiating minimum 10 % blending with petrol.

4. Though whole cane juice route is showing maximum returns under prevailing prices of sugar and fuel ethanol, it can not be a practicable approach due to the constraints of average distillery capacities in our country.

5. B-Heavy molasses route can be the next choice after conventional route as switch over is fast with better sugar quality and no capital investment.

6. Though partial secondary juice route is also showing higher returns, it would require additional investment.

7. Higher the price of ethanol and comparatively lower the price of sugar, other routes will become viable.

8. B-Heavy molasses can be stored where as secondary juice or mixed juice can not be stored.

9. Indian sugar mills need to develop flexible approach to shift from sugar to ethanol or vice-versa as per the market demand.

10. Ethanol & Cogeneration with their rapidly increasing demand present an opportunity to reduce sugar stocks, provide diversification & supply a steady income stream to protect the bottom line.

11. Sugar beet and sweet sorghum are potential crops for ethanol production. More R & D is needed to establish suitable varieties under Indian conditions.

Documents

Vasantdada Sugar Institute, Manjari (Bk.), Pune 412 307, India. Author for correspondence: [email protected] [email protected] USE OF ALTERNATE