Maximising revenues from sugar

1. 11/15/2012 1
EMERGING TECHNOLOGIES FOR
MAXIMIZING REVENUE FROM
SUGARCANE
Paul Ratnasamy

2. 11/15/2012 2
Indian Sugar Industry at a glance
Sr. Particulars Crushing
Season
200
2010
9-
-
201
2011
0
Number of Sugar
1 Factories in 527 490
Operation
Crushing Capacity 24.1 23.
2
(million TCD) 71 625
Sugarcane 185
239.
3 Crushed (million .54
807
tons) 8
Sugar Produced 24.3 18.
4
(million tons) 94 912
10.1 10.
5 Recovery % Cane
7 19
Yield of sugarcane 70.
6 68.6
(tons per hectare) 0

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Statewise Yield of Sugarcane in
India [Season 2010-2011]
Statewise Yield of Sugarcane in
India [Season 2010-2011]

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Maharashtra – Sugar Statistics (VSI)
Sugar Statistics
Maharashtra State (India)
State at a glance
Sr. Particulars Crushing Season
2010-
2009-2010
2011
1 Number of Sugar Factories
Number of Sugar Factories
(a) Installed
Installed 209 199
(b) in operation
in operation 167 142
Crushing Capacity
Crushing Capacity
2 0.533 0.501
(million TCD)
(million TCD)
Sugarcane Crushed
Sugarcane Crushed 80.21
3 61.390
(million tons)
(million tons) 5
Sugar
Sugar Produced
Produced
4 9.052 7.066
(million tons)
(million tons)
5 Recovery % Cane
Recovery % Cane 11.31 11.55
6 Pol % Cane
Pol % Cane 13.26 13.46

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Source: VSI

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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 Price 2420.21 2370.92 2172.99 2359.34
2 Cane Cost 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 Power 9.66 8.98 8.41 9.12
6 Chemical and Consumable 20.85 24.43 20.43 22.56
7 Cash Salary and Wages 194.25 179.56 125.11 176.78
Conversion
8 Packing 55.25 55.91 61.05 56.43
Cost
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 Working Capital 55.26 70.61 73.39 65.53
14 Interest On 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
Total Cost of Production
18 3404.54 3375.06 3098.24 3345.21
per ton of cane crushed [4+17]

7. 11/15/2012 7
Summary of Technical Performance of Co-operative Distilleries in
Maharashtra State
Sr. Particulars Financial year
(Apr/Mar)
2009-
2010-2011
2010
Production Capacity (Million litres/
1 300days) 745.5 723.0
Considering all distilleries.
Number of distilleries reported
2 53 52
performance
3 Average net working days 179 149
4 Molasses consumed (million tons) 1.344 1.121
363.68
5 Alcohol produced (million litres) 302.38
6 Average Fermentation Efficiency (%) 89.70 89.53
7 Average Distillation Efficiency (%) 98.40 98.43
Recovery of Alcohol (litres/ ton of
8
molasses)
270.51 269.79
9 Capacity utilization (%) 52.25 46.45

8. 11/15/2012 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

9. 11/15/2012 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?

10. 11/15/2012 10
PRODUCTION OF ALCOHOL FUELS

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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 tons
Dry Bagasse ~ 15 M. tons
Electricity / 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

12. 11/15/2012 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.

13. 11/15/2012 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;

14. 11/15/2012 14
Advantages of new Ethanol Production Processes
Ethanol Synthesis Biochemical Thermochemical Hybrid
Technology (pretreat+enzyme+ (gasification+ (gasification+
fermentation) Catalysis) Fermentation)
Catalysts Enzymes + Metal catalysts microorganism
microorganisms
Feedstock No Yes Yes
flexibility
Significant feed Yes No No
pretreat required
Low pressure Yes No Yes
Selective Yes No Yes
Ethanol
production
Ethanol 70-90 74-86 >100
Yield(gal/ton BM)
Coskata

15. 11/15/2012 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

16. 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)

17. 17
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.

18. 18
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%;

19. 19
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;

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Sacharification-Cum- Catalytic
Reforming Technologies

21. 11/15/2012 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).

22. 11/15/2012 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).

23. 11/15/2012 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).

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Virent-Shell’s Bioforming Technology

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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

26. 11/15/2012 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.

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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.

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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.

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Schematic of a Gas Engine

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G.E. LM 5000 Gas Engine( 55 MW)

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Schematic of a Combined Cycle gas
Turbine (CCGT) Plant

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Flow Diagram of Bagasse IGCC

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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);

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THANKS !!!
(paul_ratnasamy@yahoo.com)