SUGARCANE PLANTATION AND SUGAR MILL WITH BY PRODUCT AND ETHANOL FOR ELECTRICITY [CODE NO 3725]
In general sugarcane grows well in well drained, medium loam soil which is neither too acidic nor too alkaline, though cane is grown in the pH range 4.5 to 8.5. In sandy loam soil, incorporation of organic matter is necessary as also additional irrigation. If the soil is clayey, more care is necessary in cultivation. The soil should preferably be deep. Sugarcane can grow in low lands, provided water logging does not persist for a long period and the variety grown is tolerant to the situation.
It is best to grow sugarcane on a 3-year rotation - plant crop, first ratoon, second ratoon and cereal, leguminous/green manure crop. It is important that the organic matter and the nitrogen content of the soil is maintained properly. The practice of green manuring, as followed in Australia, is important. If possible the green manure crop should be grown separately and ploughed in at the appropriate time. If this is not feasible, the green manure crop should be taken as an inter crop by sowing along with the planting of sugarcane or a little earlier.
COST ESTIMATION
Plant Capacity SUGARCANE PLANTATION & SUGAR MILL WITH BY PRODUCT AND ETHANOL FOR
ELECTRICITY
Land & Building (130000 Hactare) US$. 66.53 Cr
Plant & Machinery US$. 12.94 Cr
Working Capital for 2 Months US$. 39.51 Lacs
Total Capital Investment US$. 80.90 Cr
Rate of Return 19%
Break Even Point 56%
INTRODUCTION
CHARACTERISTICS OF SUGAR CANE:
AREA AND PRODUCTION OF SUGAR CANE:
CLIMATE & SEASON:
ETHANOL
ETHYL ALCOHOL
GASOHOL
AZEOTROPIC DISTILLATION
PROPERTIES OF SUGAR
RAW SUGAR:-
CUBE SUGAR:-
ICING SUGAR:-
LIQUID SUGAR:-
UTILISATION OF BY-PRODUCTS:-
ALCOHOL AND ITS USES:-
BAGASSE AS RAW MATERIAL FOR PAPER AND BOARDS:
USES & APPLICATION
MANUFACTURING STEPS
RAW MATERIALS & OTHER SPECIFICATIONS
THE RAW MATERIALS ARE DESCRIBED HERE:-
SUGARCANE:-
LIME STONE:-
COKE:-
SULPHUR:-
SUPERPHOSPHATE:-
SODIUM HYDROSULPHITE:-
FLOCUULENTS:-
FILTER CLOTH:-
GUNNY BAGS:-
QUALITY CONTROL AND SPECIFICATIONS
INDIAN STANDARD REQUIREMENTS FOR DIFFERENT KINDS OF SUGAR
GLOBAL MARKET POSITION OF SUGAR
GLOBAL SUGAR PRODUCTION UP SLIGHTLY IN 2019/20:
GAINS IN BRAZIL AND EUROPEAN UNION OFFSET DECLINES IN INDIA
SELECTED MY 2018/19 REVISIONS FROM NOVEMBER 2018 FORECAST:
WORLD CENTRIFUGAL SUGAR: PRODUCTION AND CONSUMPTION
1,000 METRIC TONS, RAW VALUE
WORLD CENTRIFUGAL SUGAR: IMPORTS AND EXPORTS 1,000 METRIC
TONS, RAW VALUE
WORLD CENTRIFUGAL SUGAR: ENDING STOCKS 1,000 METRIC TONS,
RAW VALUE
GLOBAL MARKET SITUATIONS AND FUTURE OF SUGAR
PROJECTION HIGHLIGHTS
MARKET TRENDS AND PROSPECTS
PRICES
FIGURE. EVOLUTION OF WORLD SUGAR PRICES
PRODUCTION
FIGURE. WORLD SUGAR CROPS
FIGURE. SUGAR PRODUCTION CLASSIFIED BY CROP
CONSUMPTION
FIGURE. PER CAPITA SUGAR DEMAND IN MAJOR COUNTRIES & REGIONS
TRADE
FIGURE. SUGAR EXPORTS FOR MAJOR COUNTRIES AND REGIONS
FIGURE. SUGAR IMPORTS FOR MAJOR COUNTRIES AND REGIONS
MAIN ISSUES AND UNCERTAINTIES
SUGAR CANE PLANTATION
PREPARATORY CULTIVATION:
SEED RATE, TIME OF PLANTING AND SPACING:
HOEING AND WEED CONTROL:
IRRIGATION:
PROCESS FLOW SHEET
MANUFACTURING PROCESS FOLLOWED IN SUGAR INDUSTRY
MACHINERY SUPPLIERS FOR SUGAR INDUSTRY IN INDIA
SEQUENCES IN SUGAR MANUFACTURE
MILLING:
CLARIFICATION:
EVAPORATION:
CRYSTALLIZATION:
SEPARATION:
REFINEMENT:
DRYING:
PACKING:
PROCESS OF MANUFACTURE
JUICE EXTRACTION
CLARIFICATION:-
EVAPORATION:-
CRYSTALLIZATION:-
CENTRIFUGATION:-
DRYING:-
DRYING OF SUGAR :-
DRYING OF SUGARS AND THEIR IMPORTANCE ON KEEPING QUALITY :-
DETAILED PROCESS DESCRIPTION IS SUGAR MANUFACTURE
PROCESS DESCRIPTION
CANE SUGAR PRODUCTION -
FIGURE SIMPLIFIED PROCESS FLOW DIAGRAM FOR CANE SUGAR PRODUCTION.
REFINED SUGAR PRODUCTION -
FIGURE SIMPLIFIED PROCESS FLOW DIAGRAM FOR REFINED SUGAR
PRODUCTION.
CHANCES OF LOSSES IN DIFFERENT SECTION
BY-PRODUCTS OF SUGAR INDUSTRY
BAGASSE:-
MOLASSES:-
FILTER CAKE:-
SUGARCANE WAX:-
BYE PRODUCTS OF THE SUGAR INDUSTRY
BAGASSE :-
CHEMICALS :-
MOLASSES :-
ALCOHOL BY PRODUCTS AND DERIVATIVES :
FILTER MUD :
MANUFACTURING PROCESS OF ETHANOL FROM MOLASSES
CHEMICAL REACTIONS:
FIGURE. MANUFACTURE OF ETHANOL FROM MOLASSES
FUNCTIONAL ROLE OF VARIOUS UNITS
(A) MOLASSES STORAGE TANK:
(B) STERLIZATION TANK:
(C) YEAST CULTIVATION TANK:
(D) YEAST STORAGE TANK:
(E) FERMENTATION TANK:
(F) DILUTER:
(G) SCRUBBER:
(H) BEER STILL:
(I) ALDEHYDE STILL:
(J) DECANTER:
(K) RECTIFYING COLUMN:
(L) STORAGE TANK:
(M) MIX TANK:
(N) TERNARY AZEOTROPIC DISTILLATION:
SUGAR CANE ETHANOL PRODUCTION
FIGURE: SCHEMATIC OF PROCESS OF SUGARCANE TO PRODUCE
ETHANOL AND SUGAR.
PROCESS IN DETAILS FOR ETHANOL PRODUCTION
BY PRODUCT OF SUGAR CANE (PER TON OF SUGARCANE)
SUPPLIERS OF PLANT AND MACHINERY (GLOBAL)
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF RAW MATERIALS
QUICK LIME
SODA ASH
CASTOR OIL
HYDROCHLORIC ACID
SULPHURIC ACID
SODIUM HYDROSULPHITE
SUPER PHOSPHATE
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
