3. The manufacture of sugar generates large quantities
of biomass waste such as rice husk, bamboo
dust, bagasse, coconut coir, jute and sticks.This
waste is ideal for use as fuel to generate power.
Press mud, which is discarded as a solid waste from
sugar mills and used as a manure or as a landfill, is
found to be an useful substrate for biogas production.
The waste water from sugar treatment plants is
normally subjected to extended aeration in ponds and
is ultimately made to undergo intensive biological
oxidation.
4. Sugar cane straw wastes can be recycled as active
additions once calcined in the temperature range
of 800 or 1000 C.
Chromatographic methods are also used in sugar
production processes (e.g.: green syrup and
molasses) to reduce the non sugars and to
increase the quantity of crystallisable sugar.
As the world’s largest sugar producer, Brazil has
the potential to be a market for bagasse-based
power generation worth $24B, yet less than 10% of
this opportunity is currently being fulfilled.
5. Indian Sugar Industry in India characterized by
High cost of production and 80% of the cost
production goes towards raw material alone
Old ,out dated and obsolete technologies,
Small factories i.e. less than 2500TCD
Relatively concentrating on Sugar only
Hence the need of the hour….
Sugar production alone is not profitable.
Electricity generation, production of Alcohol and
Ethanol are important to ensure sustainability and
financial viability and survival in the competitive
environment.
6. According to the International Sugar Organization
(ISO), Sugarcane is a highly efficient converter of solar
energy, and has the highest energy-to-volume ratio
among energy crops. Indeed, it gives the highest annual
yield of biomass of all species.
Roughly, 1 ton of Sugarcane biomass-based on
Bagasse, foliage and ethanol output – has an energy
content equivalent to one barrel of crude oil.
7. Sugarcane produces mainly two types of
biomass, CaneTrash and Bagasse.
CaneTrash is the field residue remaining after
harvesting the Cane stalk
Bagasse is the milling by-product which remains
after extracting sugar from the stalk.
The potential energy value of these residues has
traditionally been ignored by policy-makers and
masses in developing countries. However, with rising
fossil fuel prices and dwindling firewood supplies, this
material is increasingly viewed as a valuable
renewable energy resource.
8. Around the world, a portion of the CaneTrash is
collected for sale to feed mills, while freshly cut
green tops are sometimes collected for farm
animals.
In most cases, however, the residues are burned or
left in the fields to decompose.
CaneTrash, consisting of sugarcane tops and
leaves can potentially be converted into around
1kWh/kg, but is mostly burned in the field due to
its bulkiness and its related high cost for
collection/transportation.
9. Bagasse is the fibrous residue left over after milling
of the Cane, with 45-50% moisture content and
consisting of a mixture of hard fibre, with soft and
smooth parenchymatous (pith) tissue with high
hygroscopic property.
Bagasse contains mainly cellulose, hemi
cellulose, pentosans, lignin, sugars, wax, and
minerals.
The quantity obtained varies from 22 to 36% on
Cane and is mainly due to the fibre portion in Cane
and the cleanliness of Cane supplied, which, in
turn, depends on harvesting practices.
10. 1. Bagasse is usually combusted in furnaces to
produce steam for power generation.
2. Bagasse is also emerging as an attractive
feedstock for bioethanol production.
3. It is also utilized as the raw material for production
of paper and as feedstock for cattle.
11. Bagasse is often used as a primary fuel source for
Sugar mills; when burned in quantity, it produces
sufficient heat and electrical energy to supply all
the needs of a typical Sugar mill, with energy to
spare.
The resulting CO2 emissions are equal to the
amount of CO2 that the Sugarcane plant absorbed
from the atmosphere during its growing phase,
which makes the process of cogeneration
greenhouse gas-neutral.
12. Bagasse is used for our biodegradable takeaway
boxes and containers, our range of
disposable plates and bowls and our ice cream cups.
They are:
Reasonably priced: Comparative to paper and foil
products
Heat resistant up to 100˚C
Water resistant
Oil proof
Microwave safe
Freezer friendly
Breathable –Your food won’t sweat.
13. Bagasse paper
Bagasse makes a great alternative to wood pulp for
paper. Eco friendly toilet paper, serviettes and bowl
lids are made from a minimum of 60 % bagasse and
40% wood pulp from a certified sustainable
source. They are:
Recycled raw material – sugarcane waste fibres
Elemental Chlorine free – Bleached using an elemental
chlorine-free (ECF) process
Locally manufactured
FSC Certified
Recyclable
14. Cogeneration of Bagasse is one of the most
attractive and successful energy projects that have
already been demonstrated in many Sugarcane
producing countries such as Mauritius, Reunion
Island, India and Brazil.
Cogeneration or combined heat and power (CHP)
is the use of a heat engine or power station to
simultaneously generate electricity and useful
heat.
15. Renewable energy option that promotes
sustainable development
Takes advantage of domestic resources
Increase profitability and competitiveness in the
industry,
It cost-effectively address climate mitigation and
other environmental goals.
17. The power produced substitutes the conventional thermal alternative and reduces
greenhouse gas emissions.
In India, interest in high-efficiency bagasse based cogeneration started in the 1980s when
electricity supply started falling short of demand.
High-efficiency bagasse cogeneration was perceived as an attractive technology both in
terms of its potential to produce carbon neutral electricity as well as its economic benefits
to the sugar sector.
In the present scenario, where fossil fuel prices are shooting up and there is a shortage and
non-availability of coal, co-generation appears to be a promising development.The thrust
on distributed generation and increasing awareness for cutting greenhouse gas emissions
increases the need for cogeneration. Also it helps in controlling pollution from fossil fuels.
18. According to a Government policy regulating
cooperative sugar factories, the State Government
provides 5% of the capital expenditure on the
cogeneration project while the factory concerned
puts in an equal amount.
The Sugar Development Fund of the Union
Government provides 30% funding of capital
investment and the remaining is secured through
institutional funding. An investment of around Rs 4.50
crore per MW is needed to start a cogeneration plant
in a cooperative factory.
19.
20.
21. Stage of process in waste water treatment plant of
PT. Gunung Madu Plantations was designed as
follows:
1. oil-solid separation
2. equalization
3. anaerobic digestion
4. facultative decomposition with added degrading
bacteria
5. aerobic decomposition
6. stabilization
22. Before discharge the waste water to river
(Way Putak), the treated waste water should
be through monitor pond with has fish as a
bio-indicator. If the treated wastewater has
concentration lower than effluent standard
and has no problems with fish in monitor
pond, the treated wastewater can discharge
to the river.
23. Distillery Division
The Distillery Division at Bhavani, Erode
District,Tamilnadu produces over 60,000
litres of IndustrialAlcohol and Extra Neutral
Spirit per day from sugarcane molasses.
Alcohol produced in this distillery in the year
2012-13 is 139.04 Lakh Litres.
The distillery has set up a bio-gas plant with
the help of technical know-how from
France, to provide an alternate source of
energy.
24. Bio-Compost Fertilizer Unit
Bio compost is prepared in Sugar Unit I and II of Bannari Amman Sugars
Limited, by mixing the nutrient rich Pressmud from sugar mills with
Nitrogen, Phosphorous and Potassium rich Spent wash obtained from
Distilleries.
Co-Generation Unit
The Co-Generation Plant for generating 20 MW power at the Sugar Unit-I
exports the surplus power to theTamilnadu State Electricity Board.The
Plant has generated 772.27 Lakh Units of power in the year 2012-
13.The Two Co-Generation Plants at the Sugar Unit II withTurbo
Alternators of capacities 16 and 20 MW, export the surplus power to the
Karnataka State Electricity Board's Grid.These two plants have
generated 1839.68 Lakh Units of power in the year 2012-13.
The Co-Generation Plant of 28.8MW capacity at our Sugar Unit-IV has
generated 1588.82 Lakh Units in the year 2012-13.
TheTotal Power Generation capacity of the four plants is now84.8MW.
The Four Co-Generation Plants have generated 4200.77 Lakh Units of
power and exported 2863.39 Lakh Units in the year 2012-13.
25. Wind Mill
The Alternate non-conventional renewable source of energy is the
ultimate answer for the future. Seven nos. of 1250 KWWTG from Suzlon
have been installed in Karunkulam, Radhapuram, Irukkandurai villages .
The power generated from the wind energy generators is fed to the
Tamilnadu State Electricity Board'sGrid and adjusted in the power
consumption of various industries, established by the group.These Wind
Turbines have generated 167.57 Lakh Units in the year 2012-13.
BIO-DIESEL
The Company's Bio Diesel Plant at Sathyamangalam,has commenced
production of 3000 litres of Bio Diesel per Day,from multi feed stock viz
Jatropha, Pungan seeds etc.
The company is now promoting aforestation by providing Pungam
seedlings to needy farmers, Panchayats and Schools etc for greening their
wastelands and provides an assured income to them by harvesting
Pungam seeds under buy back arrangement.
26. The Sugar Unit is a new addition into the
Bannari Group. It is a new Integrated Sugar
Complex comprising of 3600TCD Sugar and
25MW Co-generation Plants.
The new 25MW Co-generation power plant has
been synchronized withTamilnadu Electricity
Board Grid .
The Unit has crushed 10.43 LakhsTonnes of
Cane during the FinancialYear 2012-13.The Co-
Generation plant has produced 1372.10 Lakhs
Units of power and exported 1016.42 Lakhs
Units to the state Grid.
