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Maximising revenues from sugarTRANSCRIPT
04/10/2023 1
EMERGING TECHNOLOGIES FOR MAXIMIZING REVENUE FROM SUGARCANE
Paul Ratnasamy
04/10/2023 2
Indian Sugar Industry at a glance
Sr. Particulars Crushing Season
2010-
2011
2009-
2010
1Number of Sugar Factories in Operation
527 490
2Crushing Capacity (million TCD)
24.171
23.625
3Sugarcane Crushed (million tons)
239.807
185.548
4Sugar Produced (million tons)
24.394
18.912
5 Recovery % Cane10.1
710.19
6Yield of sugarcane (tons per hectare)
68.670.0
04/10/2023 3
Statewise Yield of Sugarcane in India [Season 2010-2011]
Statewise Yield of Sugarcane in India [Season 2010-2011]
04/10/2023 4
Maharashtra – Sugar Statistics (VSI)
Sugar StatisticsMaharashtra State (India)
State at a glance
Sr. Particulars Crushing Season
2010-2011
2009-2010
1 Number of Sugar Factories
(a) Installed 209 199(b) in operation 167 142
2Crushing Capacity (million TCD)
0.533 0.501
3Sugarcane Crushed (million tons)
80.215
61.390
4Sugar Produced (million tons)
9.052 7.066
5 Recovery % Cane 11.31 11.55
6 Pol % Cane 13.26 13.46
Sr. Particulars Crushing Season
2010-2011
2009-2010
1 Number of Sugar Factories
Installed 209 199in operation 167 142
2Crushing Capacity (million TCD)
0.533 0.501
3Sugarcane Crushed (million tons)
80.215
61.390
4Sugar Produced (million tons)
9.052 7.066
5 Recovery % Cane 11.31 11.55
6 Pol % Cane 13.26 13.46
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Source: VSI
04/10/2023 6
Elementwise Average Cost per Ton of Sugarcane Crushed of Co-operative Sugar Factories Crushing at More Than 90% Capacity( VSI)
Sr. Particulars Sugar Zones of Maharashtra State
South Central North-East State
1
Cane Cost
Cane Price 2420.21 2370.92 2172.99 2359.34
2 Harvest and Transport 286.08 314.05 305.83 302.84
3 Purchase Tax 67.65 69.52 73.57 69.52
4 Total Cane Cost [1+2+3] 2773.95 2754.49 2552.40 2731.70
5
CashConversion Cost
Power 9.66 8.98 8.41 9.12
6 Chemical and Consumable 20.85 24.43 20.43 22.56
7 Salary and Wages 194.25 179.56 125.11 176.78
8 Packing 55.25 55.91 61.05 56.43
9 Repairs and Maintenance 79.28 93.02 68.79 84.53
10 Overheads 98.38 76.49 80.20 84.86
11 Total Cash Conversion Cost [5+6+7+8+9+10] 457.67 438.39 364.00 434.29
12 Depreciation 64.93 57.36 56.04 59.94
13
Interest On
Working Capital 55.26 70.61 73.39 65.53
14 Term Loan 26.93 35.28 33.74 32.00
15 Deposit 25.80 18.93 18.68 21.75
16 Total Interest [13+14+15] 107.99 124.82 125.80 119.28
17 Conversion Cost [11+12+16] 630.59 620.57 545.84 613.51
18Total Cost of Productionper ton of cane crushed [4+17]
3404.54 3375.06 3098.24 3345.21
04/10/2023 7Summary of Technical Performance of Co-operative Distilleries in Maharashtra State
Sr. Particulars Financial year(Apr/Mar)
2010-20112009-2010
1Production Capacity (Million litres/ 300days)Considering all distilleries.
745.5 723.0
2Number of distilleries reported performance
53 52
3 Average net working days 179 149
4 Molasses consumed (million tons) 1.344 1.121
5 Alcohol produced (million litres)363.68
302.38
6 Average Fermentation Efficiency (%) 89.70 89.53
7 Average Distillation Efficiency (%) 98.40 98.43
8Recovery of Alcohol (litres/ ton of molasses) 270.51 269.79
9 Capacity utilization (%) 52.25 46.45
04/10/2023 8
Products From a 3000 tcd Sugar Mill• Sugar : 345 tons( ~9%) tpd• Molasses→ 6000 Litres /day• Bagasse: 1000 tpd ( 50% moisture)• 240 MWh electricity per day(exported); Steam~ 175 tons.• Cane trash : ~1000 tpd• Press Mud ~150 tpd• Spent wash, • CO2
04/10/2023 9
Questions
• Can we get higher - Value Products from Bagasse ( Ethanol, Butanols, LPG, Petrol,Diesel etc) rather than Electricity/ Steam alone ?
• Can we increase the efficiency of power generation from Bagasse ?
• What are the Emerging Technologies that will achieve the above objectives?
04/10/2023 10
PRODUCTION OF ALCOHOL FUELS
04/10/2023 11
Bagasse To Ethanol- Potential in Maharashtra Sugar Produced ~ 8.5-9.0 M. tons(ET, march 26,2012)Cane Crushed(2011-12) ~ 90-100 Million tonsDry Bagasse ~ 15 M. tonsElectricity / Steam For sugar mill = 8 M. tons of Bagasse.“Available” Dry Bagasse = 7 M. tons;Emerging Technology 1 ton Dry bagasse → 400 Litre Anh.Ethanol(Hybrid Tech)7 M.ton bagasse → 2800 M.Litres Ethanol. = Rs. 7000 Crores(at Rs.25/Litre)-For a Single Sugar Mill of 5000 tpd crush capacity:5000 tpd cane →800 tpd Dry bagasse →320K L/day→ Rs.80 lacs/day = 80X200= 160 Crores/season additional Revenue. -Scope For Using other wastes( MSW, cane trash, grain stalks,husks.. as RM)
- CO2 (molasses Fermentor, cement plant etc)can be used as Raw Material for CO in Gasifier; CO2 + C= 2CO
04/10/2023 12
Technology Paths From Bagasse To Ethanol
1. The Thermochemical path; Biomass feedstock is gasified to produce syngas (carbon monoxide, hydrogen and carbon dioxide) which is then converted into ethanol by a chemical reaction utilizing chemical catalysis.
2. The Hybrid path; Bagasse is gasified to Syngas; Syngas is fermented to Ethanol.
3. The Biochemical path ; Sacharification + Fermentation; Uses enzymes to convert pretreated Bagasse to Sugars which is, then,fermented to Ethanol.
04/10/2023 13
The “Hybrid” path – progress to commercialization
• Three companies ‐ Ineos BIO, Coskata, Lanzatech Moving from demonstration to Commercial project;
• INEOS Bio and NPE Florida to produce about 30,000 Kilo liters/year of ethanol;
• Coskata commercial project ‐ Location SE US; 55 million GPY capacity; Woody biomass feedstock;
04/10/2023 14
Advantages of new Ethanol Production ProcessesEthanol Synthesis Technology
Biochemical(pretreat+enzyme+fermentation)
Thermochemical(gasification+ Catalysis)
Hybrid(gasification+Fermentation)
Catalysts Enzymes + microorganisms
Metal catalysts microorganism
Feedstock flexibility
No Yes Yes
Significant feed pretreat required
Yes No No
Low pressure Yes No Yes
Selective Ethanol production
Yes No Yes
Ethanol Yield(gal/ton BM)
70-90 74-86 >100
Coskata
04/10/2023 15
Technologies For Conversion of Bagasse To “drop-in” Hydrocarbon Fuels( LPG, Petrol, Kerosene, Diesel)
•Syngas – based Fischer – Tropsch Process
•Pyrolysis- based Processes•Sacharification-Cum- Catalytic Reforming Processes
•Synthetic Biological Processes
The Pyrolysis Route• Slow Pyrolysis→ Char(~20- %) + Gas (~80%) [CO+
CO2, H2O, H2]
• Fast Flash Pyrolysis (wt%): Gas ~ 15 Bio Oil ~ 35 Aqueous Condensate ~ 35 Char ~15
• 5 - 6 tons of dry Bagasse needed per ton of Hydrocarbons.
• Char & Gas used for generating process heat.
OGJ Eur Mag. 32(2007)
Pyrolysis Bio Oil -1• Water Miscible, dark brown Liquid, Not miscible with
hydrocarbons• Combustible; Heating Value ~ 17 MJ / Kg.• Density = 1.2 Kg/l• pH ~ 2.5; Corrosive ;Pungent Odor• Storage Instability: Viscosity increases; volatility
decreases; Phase Separation; Deposits; Gums Formation;
• Needs some stabilisation at point of origin.
17
Pyrolysis Bio Oil -2• Chemical Composition : CH1.4O0.5
Water : 20-30 %;
Lignin fragments: 15-30% ;
Aldehydes:10-20%;
Carboxylic Acids: 10-15%;
Carbohydrates:5-10%;
Phenols: 2-5%;
Furfurals; 2-5%; Ketones : 1-5%;
18
Stabilizing & Upgrading of Bio Oils
• Physical Methods
- Filtration For Char Removal
- Emulsification with hydrocarbons
- Solvent Addition• Chemical Methods
- Catalytic Esterification
- Catalytic Deoxygenation :
Hydrotreating;
Zeolite Vapor Cracking;
19
04/10/2023 20
Sacharification-Cum- Catalytic Reforming Technologies
04/10/2023 21
Bagasse To Fuels- Emerging Liq Phase Technologies
• Stage 1: Pretreatment; Removal Of Lignin. • Stage 2:
A. Sacharification and Fermentation Of Cellulose and
Hemicellulose To Alcohol Fuels(Ethanol, n-Butanol
(Cobalt, China Industrial Biotech), Isobutanol (Gevo,
Butamax).
B. Sacharification Followed By Catalytic Reforming To
Gasoline(Virent).
C. Sacharification Followed By Fermentation Of Sugars To
Farnesene(Amyris);Farnesene To Diesel.
D.Sacharification Followed By Fermentation Of Sugars To
Fatty Acids(LS9); Fatty Acids To Diesel.
E.Conversion Of Alcohols To gasoline / diesel (Mobil,PNNL).
04/10/2023 22
The Pretreatment Processes-1• Objective: Overcoming BM recalcitrance to produce sugars is the
crucial First step for downstream production of alcohol / hydrocarbon fuels.
• Required to Increase enzyme accessible surface area of the biomass; Feedstock Specific.
• Physical,Chem, Biological,Solvent fractionation (ILs).• Strategies• Remove Lignin and Hemicellulose• Reduce Cellulose Crystallinity• Increase Enzyme Accessible Surface Area• Increase number of Cellulose reducing ends• Modify cellulose crystal polymorphism(Iβ→IIII)
• Break interlayer H-bonds in Cellulose.
Challenge: ACHIEVE ALL THESE WITH MINIMAL SUGAR LOSS AND FORMATION OF ENZYME INHIBITORS( Furans and Phenolics).
04/10/2023 23
Sugars To Fuels & Chemicals:Some Low Temperature Technologies
1. Microbial Conversion To Ethanol & Butanols.
2. Co-fermentation of C5 and C6 sugars To
Ethanol.
3. Microbial Conversion of Sugars To alkanes,
Fatty Acids / Alcohols (Amyris, LS9)
4. Catalytic Conversion of bagasse to (1)sugars and , then,(2)to Gasoline, diesel and BTX (Virent).
04/10/2023 24
Virent-Shell’s Bioforming Technology
04/10/2023 25
Bagasse To LPG, Kerosene & Gasoline Product Yields And Economics.( Virent Data)(2008/0300435A1)
Feed: ( Cellulosic+ Hemicellulosic) Sugars.
PRODUCT YIELDS(wt% of feed carbon)- LPG = 22%; Gasoline/kerosene = 48%.- Total Hydrocarbons = (22+48)=70% of carbon in Sugar (C6H12O6).
- Wt% Carbon in carbohydrates~ 40-45 %; - Hence, 1 t sugar →~ 280 kg(400L) of HC(90LPG+190 (Gasoline)).- 1 ton dry bagasse ~70% ( Cellulose + Hemicellulose)- Case 1. 100% recovery of Cellulose+Hemicellulose from sugars- 1 t dry bagasse→~200kg (=280X0.7) of HC fuels (70kgLPG
+130kg gasoline) - = 70 X 25 Rs/kg+190L X 50Rs/L = Rs.11,250 / t dry bagasse.
- Case 2. At 90% Recovery of Sugars~ Rs10,000 /ton dry bagasse; Vs; Rs.1000-4000 when used for electricity
04/10/2023 26
Power generation From Bagasse
• 100 tons of sugarcane gives ~ 30-33 tons of Bagasse with ~ 50% Moisture; ~ 16 tons of Bone-dry bagasse (0% H2O)
• Theoretical maximum thermal to electric efficiency of steam turbines ~ 30%; By current Technology using Burner-Boiler- Steam Turbine, one ton of DRY bagasse can generate ~ 1 MW Electricity; i.e. ~ 20 % thermal to electric efficiency is the common norm.
04/10/2023 27
ADVANTAGES OF IGCC Technology
- Higher efficiencies(40-45 % vs 10 - 20 % in steam
Turbines).
- Additional raw material like Cane trash, Press Mud,
Spent wash etc can be used in gasifier and increase
electricity Generation by ~25%.
- Lower Pollution: Less particulate matter, Char, CO,
tar in Power plant effluent.
04/10/2023 28
Gas Turbines are more efficient• Gas turbines mix a fuel (naphtha, diesel, natural gas,
LPG, Syngas etc) and air and combust the mixture. The
hot mixture(1200 C),first, passes through a steam generator raising high pressure steam, then passes through gas turbines to generate electricity at 40% efficiency and, finally, again through a steam generator. The combined steam from the two steam generators is used for generating electricity at 20% efficiency. • The overall efficiency of the (gas + steam) turbine
combination is ,hence, ~45 % , much higher than that of the steam turbine alone.
04/10/2023 29
Schematic of a Gas Engine
04/10/2023 30
G.E. LM 5000 Gas Engine( 55 MW)
04/10/2023 31
Schematic of a Combined Cycle gas Turbine (CCGT) Plant
04/10/2023 32
Flow Diagram of Bagasse IGCC
04/10/2023 33
Commercialisation Of Technologies For Biofuels – Current Status• Already Commercial: Biogas ; Ethanol from Sugar &
Starch; FAME diesel; ”Green” diesel & Biojet Fuel From Lipids(Neste); Sugar To Diesel( Amyris);
• Demo Plants : Cellulosic Ethanol(many), Butanol (Cobalt), Isobutanol(Gevo); Gasification To SG & FT (UOP & Range Fuels); SG To Ethanol(Inobios,Coskata, LanzaTech); Pyrolysis- based Fuels(UOP, KIOR); Sugar-based Gasoline and Para Xylene (Virent-Shell);
• Gasification-Based Power Plants(Hafei, Battelle, Concord..)
• R & D / PP Level: Algae to BD(Solazyme); Sugar To Fatty Acids(LS9);
