Ethanol Production for better health of the Indian Sugar Industry NARENDRA MOHAN DIRECTOR NATIONAL SUGAR INSTITUTE, KANPUR

Transcription

1 Ethanol Production for better health of the Indian Sugar Industry BY NARENDRA MOHAN DIRECTOR NATIONAL SUGAR INSTITUTE, KANPUR

2 Sugarcane Source of Green Energy JUICE SUGAR BAGASSE Ethanol LEAVES & TOPS CO-GENERATION OF ELECTRICITY 2

3 Indian Sugar Industry India is Second largest producer and top most consumer of sugar in the World Sugar production in India is cyclic in nature while consumption is constantly climbing In India, 50 million farmers cultivate sugarcane on average 5 million ha area The Sugar Industry is mainly under three sectors viz. Cooperative, Private and Govt. Sector There are over 500 operational sugar mills with crushing capacity varying from 1000 to 16,000 tons per day The yield of sugarcane per ha is high in tropical state like Tamil Nadu (Avg. 110 t/ha) and as we move towards North Productivity goes down (Avg. 55 t/ha) while all India s average yield is 65 t/ha Sugar accumulation in sugarcane is highest in North Karnataka and Center South Maharashtra because of favorable agro-climatic conditions Intensity wise Sugarcane Grown Regions in India 3

4 Sugar or Energy Industry...at the cross roads.. Over the years, the Sugar Industry has transformed itself into the Energy Industry where product or by-products arepotentialsourceofenergyinoneoranotherform.inspite of significant improvement in the technical efficiency, the sugar industry is struggling for survival. WHY? & WHAT TO DO? 4

5 * Diminishing productivity of Sugarcane and recovery of Sugar. * Cost of raw material and other inputs vis a vis un-remunerative price of sugar have put the Sugar Industry on the back foot. The life saving therapy has been the use of by-products in a better way. * The imbalances in the demand-supply position in the domestic market and cyclic nature of the Indian Sugar Industry. 5

6 Major Producers of Sugar Others 34% Brazil 22% India 16% United States 5% Thailand 6% China 7% EU-27 10% 6

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9 The Way Forward Policy Reforms Productivity Enhancement Product Diversification

10 IMPORTANCE OF ETHANOL 1.VALUE ADDITION: Considering molasses price as US$ 60 per MT to realization of US$ by Ethanol manufacturing considering price of Ethanol as US$ 0.66 per liter and yield as 235 liter per MT of molasses. 2. EBP SUCCESS: To cope up with the requirement of approx billion liters for E-5 programme. 3. To balance demand-supply position of sugar by diverting intermediate process liquors for ethanol production. 3. ENVIRONMENT PROTECTION: Clean and green form of energy. 4. FOREX ISSUES : To save foreign exchange required on import of crude oil. 10

11 Revenue through sale of primary by-product (Standalone Sugar Units- conventional route) (per ton of sugarcane) Sl. No. By-product Quantity (ton) Rate (per ton) (Rs.) (per ton of sugarcane) Revenue (Rs) 1. Bagasse 7.0%oncane * % on cane 3. Press Mud 3.5% on cane Total *Average bagasse% cane: 30 and considering installation of low to medium pressure boilers of 32 kg/ sq cm g to 45 kg/sq cm g working pressure having bagasse: steam generation ratio as 2.2 to 2.3 only. Power generation through back pressure turbines to meet sugar plant requirements only. Rs (approx.us$ 5.0) per ton of sugarcane i.e. Rs per qtl of sugarcane 11

12 Revenue through value addition (Integrated Sugar Complexesconsidering high pressure co-generation & ethanol production) (per ton of sugarcane) Sl. No. By-product Quantity (ton) Value added product Rate (Rs) Revenue (Rs) Addl. Cost of conversion Net Revenue (Rs.) 1. Bagasse saved 0.09 Power: Rs per Rs. 9.0% on cane * Units * Per Unit unit i.e. Rs Ethanol: Rs per Rs %oncane liters # Per liter liter i.e. Rs Press Mud Press Mud: Rs. 3.5%oncane ton Per qtl Total Rs per ton of sugarcane * Average bagasse% cane: 30 and considering installation of high pressure boilers of 87 kg/ sq cm g to 110 kg/sq cm g working pressure having bagasse: steam generation ratio as 2.5 to 2.6 only. Power generation through Condensing/Condensation-Extraction or in combination with back pressure turbines to meet sugar plant requirements and surplus for exports. # Considering an average yield of 235 liters of ethanol per ton of molasses. Rs (approx.us $ 9.0) per ton of sugarcane i.e. Rs per qtlof cane Note: The co-generation i.e. export of surplus power is being carried out by around 250 sugar factories, whereas, about 160 sugar factories have integrated distillation units for production of alcohol. 12

13 VALUE ADDITION THROUGH CO-PRODUCT UTILIZATION 13

14 UTILIZATION OF CO-PRODUCTS There is urgent need for improvising the by-product utilization through optimization of existing resources and also vide innovative techniques to have higher revenue. Working out models for diversion of intermediate products for alternate use in order to earn higher revenue. We can specifically discuss about utilization of bagasse and molasses in a better way. As a convention, bagasse containing 49-50% moisture is used as fuel in boilers for cogeneration of power, whereas, final molasses is used for alcohol/ethanol production. 14

15 Molasses 15

16 World Ethanol production by feedstock NATIONAL SUGAR INSTITUTE, KANPUR Total Ethanol= 105 billion ltrs 16

17 S.No. OVERVIEW OF SUGAR & MOLASSES PRODUCTION Sugar Season NATIONAL SUGAR INSTITUTE, KANPUR No. of Sugar factories in operation Sugarcane produced (Lakh tonnes) Sugarcane Crushed (Lakh tonnes) Sugar Produced (Lakh tonnes) Molasses Produced (Lakh tonnes) # #Provisional 17

18 Considering 5 % diversion of molasses for export, cattle feed, other uses and wastage/deterioration etc. and assuming an average realistic yield of alcohol@ 235 liters/ton of molasses(considering average Total Reducing Sugar Content as approx. 47.5), the total possible production of alcohol: Sugar Season Total Molasses Production (Lakh tonnes) Molasses available for alcohol production (Lakh tonnes) Estimated Alcohol Production Potential (Crore liters) # # Provisional (2.42 Billion Liters) 18

19 SECTOR-WISE REQUIREMENT/AVAILIBILITY OF ALCOHOL S.No Particulars In crore liters (Estimated) 1. Requirement for potable liquor industry Requirement for chemical and other industrial uses 3. Total requirement for potable liquor & Chemical Industry NATIONAL SUGAR INSTITUTE, KANPUR Less Grain alcohol usage for potable liquor Net requirement for potable liquor & Chemical Industry(molasses based alcohol) Net availability of alcohol for EBP Less 5% loss on de-hydration Net availability of Ethanol for EBP (0.56 Billion liters) (0.87 Billion liters) (0.78 Billion liters) (114 Billion liters) 19

20 Installed Capacity Base. 1. Gross Distillation Capacity: Billion Liters per annum. 2. About 74% installed capacity is molasses based and 26% grain based. 3. Ethanol Production Installed base: Approx Billion Liters per annum.(157 Units) in KLPA S.No. EtOH capacity (units attached with Private Sugar Mills) EtOH capacity (units attached with Co-operative Sugar Mills) EtOH capacity (Stand alone units) Total

21 Installed base in India over 6 billion liter mark Total Installed base= 6.25 Billion Ltrs per annum Grain Plants- Major Locations: Maharashtra, Andhra Pradesh,MP, Punjab, Haryana, Rajasthan 21

22 Rising import bills Alternate fuel is needof hour Crude Oil Import Bill in USD Billion NATIONAL SUGAR INSTITUTE, KANPUR (Est) 16 Domesticdemandforcrude oilandimportbill forthesamemovedupby 13timesin last20years Alarmingsituation By2020, India's dependencyonoilimportsis projectedtogo beyond90% from80% atcurrent level Timetoshift foralternatefuels like Ethanoland Biodiesel 22

23 Use of Bio-fuels- Present & Future Production of bio-fuels in the world was 16 billion liters in 2000 which grew steadily to more than 100 billion liters in It is estimated that: 3% of road transport fuel is bio-fuel globally. 23% of the road transport fuel is bio-fuel in Brazil. By 2020, 8% of the road transport fuel will be biofuel globally. 23

24 Indian Bio-fuel Policy. *Strengthen India s energy security by encouraging the use of renewable energy resources to supplement transport fuels. A 20 percent target for blending of biofuel for both biodiesel and bio-ethanol is proposed. *Meet the energy needs of a vast rural population in India to stimulate rural development and create employment opportunities. *Address global concerns about containment of carbon emissions through the use of environment friendly biofuels. *Derive bio-fuel from non-feed stock that would be raised on degraded or wastelands that are not suited to agriculture, thus avoiding a possible conflict of fuel verses 24 food security.

25 MOLASSES.PRECIOUS FEED STOCK OF FUTURE AS AUTOMOBILE FUEL 25

26 Factors to be taken care to improve productivity *Quality of molasses, in terms of total sugars, available to distilleries is deteriorating due to extraction of more sugar by sugar factories by using better equipment and process technique. *The Volatile Fatty Acid content and Sludge Content of molasses also increasing. * Increasing cases of molasses deterioration upon storage. * Molasses contain un-fermentable sugars to the extent of 5-7%. If they can be converted to fermentable sugars, yield of alcohol may increase by 8-10%. 26

27 Other process liquors for alcohol production Cyclic nature of the Indian Sugar Industry and various other including state policies effect the availability of molasses. Thus, there is need to look for other feed stocks and sugarcane juice may one such alternative. However, with the present policies in the matter, price of sugarcane and ethanol, the option is out of consideration. Other options may be: 1. Ligno-cellulosic Ethanol from bagasse. 2. Diversion of B-heavy molasses. 3. Diversion of Secondary juice. 4. Diversion of Filtrate(filtered juice). 27

28 First Generation Ethanol, Sugar and Electricity Production From Sugarcane 28

29 Ethanol from Molasses and Juice SUGARCANE Sugars = Suc + Glu + Fru JUICE FOR SUGAR MILLING JUICE FOR ETHANOL FACTORY MOLASSES MASH DISTILLERY FERMENTATION DISTILLATION SUGAR ETHANOL FROM MOLASSES ETHANOL ETHANOL FROM SUGARS 29

30 Integrated 1stand 2ndGeneration Bio-ethanol Production from Sugarcane 30

31 DIVERSION OF INTERMEDIATE PROCESS LIQUORS FOR ETHANOL PRODUCTION ---Diversion shall help in keeping the production of sugar as per requirement & in coping up with the increased requirement of Ethanol to make EBP a success. (assumption: EtOH yield 235/320 liter/ton, EtOH rate Rs. 42 per liter, Sugar Rs. 24 per kg) 31

32 Chemical Composition of B- Heavy and Final Molasses S.No PARAMETERS B-HEAVY MOLASSES FINAL MOLASSES 1 Reducing sugars (g %) 4-16(10) 7-16(13) 2 Total Reducing sugars (g %) 49-59(53) 35-51(45) 3 UFS (g %) (2.5) (5.0) 4 Volatile fatty acids (ppm) ph

33 Fermentative Production of Alcohol from Intermediate Molasses S.No PARAMETERS B-HEAVY MOLASSES FINAL MOLASSES 1 Weight of molasses 1000g 1000g 2 Initial TRS content g/100 ml 14.86% 13.75% 3 UFS (g/100 ml) 0.60% 1.12% 4 FS (g/100 ml) 14.26% 12.63% 5 Theoretical ethanol yield (% v/v ) 9.183% 8.13% 6 Practical ethanol yield 7.42% 6.73% (% v/v ) 7 Ethanol yield (litre/ ton )

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35 Particulars Units Three Massecuite Boiling Two Massecuite Boiling Cane Ton 1 1 Recovery % Cane Sugar Price Rs. / Ton Gross Revenue from Sugar Rs. / Ton Cane Conversion cost Rs. / Ton Net Revenue from Sugar Rs. / Ton Cane Molasses % Cane Ethanol Production Rate Litres per Ton of Molasses Ethanol Production Litres Ethanol Price Rs. / Litre Gross Revenue from Ethanol Rs. / Ton Cane Conversion cost Rs. / Litre 8 8 Net Revenue from Ethanol Rs. / Ton Cane Total Net Revenue Rs. / Ton Cane Difference Rs. / Ton Cane Net Additional Revenue for a 5000 TCD Plant working for 160 Days US$ i.e. Rs. 2,56,72,000

36 Integrated Production of sugar and Ethanol Variation on the ratio of sugar and ethanol produced according to the market will result in sugar price stabilization and coping up with the requirement of EtOH for EBP. Sugarofbetterquality noneedtorecyclemolassesof low purity and thus price premium over the produce Higher purity in the mash (high purity molasses) for high fermentation yield Energetic optimization Energy saving in sugar plant Reduced packing cost and expenditure on manpower At the assumed prices of EtOH and Sugar, apparently the economics is in favor of B Heavy diversion, and has the promise under the existing situation of surplus sugar production and sugar prices. 36

37 Alternate Feed Stocks for Alcohol/Ethanol Production Alcohol in India is mainly produced from cane molasses, the by product of cane sugar industry. However, due to cyclic nature of sugar cane, the sugar and molasses production has been quite variable as a result of which capacity utilization of distilleries remains much lower. Other feed stock which can substitute molasses for the fermentative production of ethanol include Sugar Beet, Sweet Sorghum and Cassava etc. 37

38 Feedstock for Ethanol Production 38

39 SUGAR BEET Considering the advantage of sugar beet cultivation and problems in subtropics, the thermo insensitive varieties have been developed and the trials carried out in winters revealed that the yield ranges from t/ha. The expressed juice of Sugar Beet can be utilized for the fermentative production of alcohol with a possible yield of 100 liters/ton of beet. 39

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41 Fermentative production of alcohol from Sugar Beet Juice S.No PARAMETERS RESULT 1 Qty of sugar beet 3k g 2 Final volume of juice 5 L 3 TRS content 11.4% 4 Theoretical ethanol yield %v/v 7.34% 5 Practical ethanol yield % v/v 6.10% 6 Fermentation efficiency 83.1% 7 Ethanol yield litre/ ton

42 SWEET SORGHUM Sweet sorghum has been noted for its potential as an energy crop. Sweet sorghum can be cultivated in nearly all temperature and tropical climatic areas. The stalks contain fermentable sugars which can be fermented to produce alcohol. The fermentation studies conducted have shown that sweet sorghum can give a yield of 45 liters/ton ofalcohol. 42

43 CASSAVA 43

44 CASSAVA The most productive Cassava farms in the world were observed to be in India, with a nationwide average yield of 33 tonnes per hectare. Cassava is a potential crop for ethanol production because it produces high yield and boats tremendous starch content, therefore producing high ethanol production per ton. Compared to wheat, corn or sugar cane, cassava ethanol yields amount up to about 150 liters/ton. At present, Starch is the most important value added product produced from Cassava. It is also intercropped with short duration crops like black gram, groundnut, coconut, rubber and vegetables in the states of Tamil Nadu and Karnataka. This provides additional income to small and marginal farmers. 44

45 Cassava Plantation/ Production / Productivity Planting area Yield Yield per area (million ha) (million tons) (tons/ha) World Nigeria Brazil Thailand India Source: Office of Agriculture Economics, Thailand (2009) Note: ** India has the highest yield, but has the smallest area NATIONAL SUGAR INSTITUTE, KANPUR Root productivity improvement ( ) Nigeria Brazil Thailand India World 45

46 Fermentative production of alcohol from Cassava Powder - 1 Qty of cassava flour 100 g 2 Starch content 74.6% 3 Starch Content (Dry wt basis) 65.6% 4 Final Volume 650 ml 5 Fermentable Sugars 56% 6 Fermentable Sugars conversion 85.4% 7 Total sugar(g/100ml) 8.61% 8 Ethanol yield theoretical 5.54 % v/v 9 Ethanol yield practical 4.9 % v/v 10 Fermentation efficiency 88.4 % 11 Ethanol yield 354 litre/ton

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48 SO, ETHANOL MATTER US IN INDIA.AND WE HAVE TO WORK ONE # PRODUCTIVITY IMPROVEMENT BY IMPROVEMENT IN PLANT EFFICIENCY # DEVELOPING FLEXI SUGAR FACTORIES AND BIO-REFINERIES. # ADOPTING ALTERNATE MEANS OF ETHANOL PRODUCTION VIZ. DIVERSION OF INTERMEDIATE PROCESS LIQUORS& USE OF OTHER FEED STOCKS. # BALANCING SUGAR & ETOH PRODUCTION AS PER DEMAND AND ECONOMICS. 48

49 Jai Hind 49