Present status and future of ethanol industry

1
USE OF ALTERNATE SUGAR PROCESSING INTERMEDIATES
AND SUPPLEMENTARY CROPS FOR AUGMENTING ETHANOL
SUPPLY   R. V. Godage1, D. A. Patil2 and S. V.
Patil3
Vasantdada Sugar Institute, Manjari (Bk.),
Pune 412 307, India. Author for correspondence
sanjay01356_at_hotmail.com
2
WHY ALTERNATE/SUPPLEMENTARY RAW MATERIALS ?

• International crude price has crossed 100 per
  barrel.
• The world ethanol production has reached to 62.03
  Billion liters in 2007 and expected to increase
  to about 100 Billion liters by 2012.
• Indian total ethanol demand is projected to reach
  5.920 Billion liters in 2010 at 10 and 5
  blending rate of fuel ethanol in gasoline
  diesel, respectively.
• About 95 distilleries in the country are based
  on sugar cane molasses.

3

• Considering maximum projected sugar cane crushing
  in the country of 260.0 million MT (Molasses-
  11.70 million MT) in 2010, it would be possible
  to produce maximum 2.574 Billion liters of
  ethanol.
• This indicates that, cane molasses alone will not
  be sufficient to meet Indias increasing
  requirement of ethanol. To overcome this problem,
  it is possible to produce ethanol from variety of
  renewable agricultural sources such as various
  sugar processing intermediates, sugar beet, sweet
  sorghum, cereal grains etc.

4
Ethanol World Scenario World Total Alcohol
Production Year 2003-2007 (In Million Liters)

World Regions Years Years Years Years Years
World Regions 2007 2006 2005 2004 2003
EU Europe 5,112 4,647 4,229 3,835 3,885
Africa 695 633 608 584 540
N C America 27,399 20,867 16,875 14,969 12,706
Asia 7,225 6,534 5,920 5,994 6,535
Oceania 202 172 149 149 164
World Total 62,032 51,439 44,331 40,676 39,018
India 2,000 1,650 1,100 1,232 1,770
5
India-Gasoline Ethanol demand
Year Gasoline consumption (m.liters) Alcohol consumption for potable industrial (m. liters) E5 (m. liters) (Fuel ethanol) Total Demand of Alcohol _at_ E5 (m. liters) E10 (m. liters) (Fuel ethanol) Total Demand of Alcohol _at_ E10 (m. liters)
1 2 3 4 5 (34) 6 7 (36)
2006-07 9.27 1500 580 2080 1160 2660
2007-08 9.91 1575 620 2195 1240 2815
2008-09 10.61 1620 660 2280 1330 2950
2009-10 11.35 1700 710 2410 1420 3120
projected , m million projected , m million projected , m million projected , m million projected , m million projected , m million projected , m million
6
Estimated Indian Ethanol demand
Sr. No. Particulars Requirement of Alcohol (Million Lit.)
1 Industrial PotableE10 2815
2 Industrial PotableE5E5(D) 4880
3 Industrial PotableE10E5(D) 5615
4 Industrial PotableE10E10(D) 8285
7
ALTERNATE SUGAR PROCESSING INTERMEDIATESCase
Study Crushing capacity 4000 TCD
Distillery capacity 60 KLPD Sugar price Rs.
11.50/kg Ethanol price Rs. 21.50/Liter
Bagasse price Rs. 250.0/MT Pol Cane
13.23 All data on per day basis
8
Conventional route (Per day basis)
9
Two massecuite/B-Heavy molasses route (Per day
basis)
10
Total secondary juice route (Per
day basis)
11
Partial secondary juice route (Per day basis)
12
Total mixed juice route (Per day basis)
13
Partial mixed juice route(Per day basis)
14
Comparative Sugar and Ethanol Production
15
Comparative Ethanol Yields
16
Comparative Revenue Generation(Rs. Lac)
17
Expenditure, (Rs./MT)
18
 
Expected cane price, (Rs./MT)
   
19
Maximum Production (180 days)
20
SUPPLEMENTARY CROPS

• Tropical Sugar Beet
• New varieties suitable for tropical regions.
• Sugar content 12-18 .
• 5 to 6 months crop.
• Less water requirement.
• High salt tolerance.
• Constitutes 22.02 of world sugar production.
• Used for production of sugar, ethanol and
  cattle feed.
• Additional supply of raw material to sugar
  mills after
• sugarcane crushing season.

21
SUGAR BEET CROP YIELD
Varieties Root wt (MT/ha)
HI 0064 110.7
Dorotea 107.64
Posada 106.11
22
Average Composition of Sugar Beet

Parameters Sugar beet
Water () 73 76.50
Dissolved solids () 23.50 27.0
Sucrose () 16 18
Water insoluble (Marc ) 4 - 5
23

• CHARACTERISTICS OF SUGAR BEET JUICE

Parameter Sugar beet juice
pH 6.0 6.5
Reducing Sugars () 0.2 - 0.3
Total reducing sugars () 15.0 -16.0
Unfermentable sugars () 0.2 0.3
Fermentable sugars () 14.8 15.7
Alcohol (as R.S.) Yield- (Lit./MT of sugar beet) 89.0 94.0
24
Sugar beet roots
Process flow diagram of Ethanol manufacturing
from sugar beet juice
Beet weighment
Beet washer
Wash water to field
Water
Beet slicer
Beet Diffuser
Exhaust steam
Diffused Juice
Diffused pulp
Screening
Pulp press
Suspended matter
Juice evaporation syrup cooling
Pulp for cattle feed
Low brix juice to diffuser
Syrup weighment
Water Yeast
Fermentation
CO2
Bio-methanation or Bio-composting
Primary distillation (R.S.)
Sp. wash
Steam
Ethanol
Dehydration
25
Case Study

Sugar beet Crushing capacity TBD 500
Sugar beet crushing plant cost 500 TBD (Wash water pump, beet conveyer, beet washer, beet slicer, cosset conveyer, diffuser, pulp press Evaporation unit etc.) Rs. Lac 1150.0
Existing Distillery Capacity KLPD 45
Ethanol price Rs./Lit. 21.50
Fusel oil price Rs./Lit. 28.00
Beet Pulp price Rs./MT 500.00
Compost price Rs./MT 250.00
26
Case Study 500 TBD to connect with existing 45
KLPD Distillery Unit
Particulars Unit Value
Sugar beet processing per day TBD 500
Net working days Days 60
Total beet processing MT 30,000
Alcohol yield Lit/MT 90
Total alcohol production (94.68 v/v) Lits. 27,00,000
Total Ethanol production (100 v/v) Lits. 25,47,170
Fusel oil Lits. 8,197.2
Beet Pulp (20 on beet) MT 6,000
Spent wash production M3 27,000
Spent wash recycle (30) M3 8,100
Spent wash outlet M3 18,900
27
Particulars Particulars Unit Value
Press mud requirement Press mud requirement MT 7,560
Compost production Compost production MT 5,117
Realization Realization (Rs. Lac)
Ethanol Rs./Lit. 21.50 547.64
Beet Pulp Rs./MT 500 30.00
Fusel oil Rs./Lit. 28.00 2.30
Compost Rs./MT 250 12.79
Total (A) 592.73
28
Particulars Unit Value
Processing cost (Rs. Lac)
Beet to syrup conversion cost Rs./MT 80.00 24.00
Syrup to Ethanol cost
Steam ( 2.6 kg/lit. of ethanol) Rs./MT 500 33.11
Power (6850 units/day) Rs./Unit 1.65 6.78
Water (4 lac lits./day) Rs./10M3 9.00 0.22
Chemicals Rs./Lit. 0.20 0.05
Insurance 0.025 2.88
Repair Maintenance 1.50 17.25
Interest on working capital 0.41
29
Particulars Unit Value
ETP (Rs. Lac)
Press-mud requirement Rs./MT 50.00 3.78
Cost of culture Rs./Kg 30.00 2.27
Cost of Diesel (100 Lit./day) Rs./Lit. 40.00 2.40
Total (B) 93.15
Fixed Cost
Depreciation 140.00
Interest on Term loan 52.44
Interest -Own contribution 7.94
Total fixed cost Total C 200.38
Total processing cost Total D (BC) 293.52
30
Particulars Unit Value
(Rs. Lac)
Gross profit Total E (A-D) 299.21
Add Depreciation F 140.00
Total cash Accrual G (EF) 439.21
Less Term loan H 207.00
Cash Available for beet cost I G-H 232.21
Sugar beet cost- Rs./MT 774.03
31
Sweet Sorghum (Sorghum Bicolor (L.) Moench)

• Short duration crop (120 140 days).
• Cheaper to grow.
• Less water requirement than any other crop.
• Has a good tolerance to wide range of climatic
  soil
• conditions.
• This crop can be taken twice in a year.
• The quality of Rectified Spirit obtained is
  superior.
• The effluent volume can be reduced to 3 lit/lit.
• Sweet Sorghum is grown in Africa, South
  Central
• America, China, India, Pakistan and United
  States.

32
SOWING AND HARVESTING

• 7 Varieties in Kharip Season 7 Varieties in
  Rabi season.
• RSSV-9 From MPKV, Rahuri.
• SSV-84, ICSV-93046, ICSV-700, NTJ-2, SPV-472
  S-35 From
• ICRISAT, Hyderabad.
• Sown at V.S.I. Farm by dibbling method.
• 6 Irrigations at an intervals of 20 days.
• NPK Fertilizer doses of 120, 60 60 kg/ha were
  given.
• The crop was harvested at an intervals of 10
  days i.e. 100 days, 110
• days, 120 days, 130 days from sowing.

33
COST OF CULTIVATION FOR S. SORGHUM
Sr.No. Particulars 1 ha. Cost Rs.
1. Preparatory Tillage Ploughing, Harrowing, Cleaning Collection, layout preparation etc., 3245.40
2. Cultivation Plant Protection Seed cost, dibbling labour, Fertilizers Its application Weed Control Irrigation Charges Plant Protection 3350.50 1455.00 825.40 1112.40 1603.40
3. Supervision Charges 10 on above 1159.21
4. Total cost of cultivation 12751.31
34
SWEET SORGHUM PLOT AT VSI
35
ANALYSIS OF RAW AND CLARIFIED JUICE
Sr.No. Particulars Raw Juice Clarified juice
1. 0 Brix 16.97 - 19.65 16.32 - 19.36
2. pH 4.84 5.10 7.04 8.66
3. Reducing Sugar () 1.0 1.88 0.98 2.29
4. Total Reducing Sugar () 12.97 15.73 13.12 15.99
5. Calcium Oxide (CaO) PPM 1185 1960 1120 1875
6. Magnesium (MgO), PPM 58 70 40 65
7. Phosphate (P2O5), PPM 850 1150 70 100
8. Starch, PPM 772 5521 775 4317
9. Polyphenols, PPM 475 1125 512 981
10. ?- Amino Nitrogen, PPM 27 121 17 83
11. Aconotic Acid, v/v 1.04-1.36 0.93-1.32
36
S. SORGHUM STALK AND JUICE ANALYSIS
Sr.No Particulars Analysis Report
1. Pol in stalk 8.78 11.39
2. Fiber in stalk 12.30 18.58
3. Juice Purity () 64.21 69. 47
4. Mud volume in juice () 48.7 65.80
ALCOHOL YIELD ALCOHOL YIELD ALCOHOL YIELD
1. Fermentable Sugar in stalk (subtract 2.5 sugar loss in baggase), Kg/ha. 2720.60 5270.90
2. Alcohol Yield (Expected) Lit./Ha (F.E. 90, D.E.-98.5, Alcohol - 94.68) 1640.80 3178.27
3. Alcohol Recovery (B.L. /MT of stalk) 49.69 63.07
37
Economics of Ethanol Production From Sweet Sorghum
Sr. No Particulars Considering 40 T/ha Considering 40 T/ha
Sr. No Particulars Per Day Month
A. Ethanol Production Land Requirement Ethanol Production Land Requirement Ethanol Production Land Requirement
1. Distillery Capacity, lit. 30,000 9 Lac lit
2. S. S. Stalk Required, Tons 600 18000
3. Sweet Sorghum Stalk Yield,MT/Ha 40 40
4. Ethanol Yield, liters/MT S.S.Stalk 50 50
5. Land Requirement for Sowing 15 ha 450 ha
6. Seed Required for Sowing (Considering 10 kg/ha) 150 (37.5 Acre) 4500 (1125Acre)
B. Production Production Production
1. Ethanol Production, lac lit 0.30 9.0
2. Bagasse Production, Tons ( 28 0n S. Sorghum Stalk Crushed) 168 5040
3. Tops leaves for fodder, MT 255 7650
38
Economics of Alcohol Production From Sweet Sorghum
Sr.No Particulars Months (30 Days )
C. Expenses Per Month ( Rs. Lac ) Expenses Per Month ( Rs. Lac )
1. Harvesting Transporting (_at_ Rs.250/Ton) 45.00
2. Processing to Syrup _at_ Rs.8.25/lit of Ethanol 74.25
3. Syrup to Ethanol_at_ Rs. 3.75/ of R. S. 33.75
Total Expenses 153.00
D. Receipts Per Month( Rs. Lac ) Receipts Per Month( Rs. Lac )
1. Ethanol 9.0 lac lit _at_ Rs. 21.50/lit 193.50
2. Bagasse 5,040Tons _at_ Rs.500/Ton 25.20
3. Tops leaves for fodder _at_Rs.500/T. 38.25
Total Receipts 256.95
E. Gross Profit ( Rs. Lakh) 103.95
39
Economics of Alcohol Production From Sweet Sorghum
Sr.No Particulars Months (30 Days )
1. Price that can be paid to the farmers after deducting 10 Manufacturers Margin Rs.519.75/MT
2. Price that can be paid to the farmers after deducting 10 Manufacturers Margin Rs.20,790/ha/crop
3. Additional Benefit from sale of grains _at_ Rs.6000/MT X 1. 5 MT/ha Rs. 9,000/ha/crop
4. Assumed cost of cultivation. Rs. 12,750/ha
5. Total Benefit to the Farmer ( Sr.No. 2 Sr. No. 3 Sr.No. 4) Rs. 17,040/ha/crop
40

• Conclusion
• Conventional molasses route is most economical.
  However, it can not fulfill the increasing
  ethanol demand of the country. It would also
  result in increasing the sugar stocks.
• Route that can be used will be determined by the
  prevailing prices of sugar and ethanol at that
  time.
• Excess sugar can be diverted to ethanol
  production. However, at the same time there is a
  need to create additional demand for ethanol by
  initiating minimum 10 blending with petrol.
• Though whole cane juice route is showing maximum
  returns under prevailing prices of sugar and fuel
  ethanol, it can not be a practicable approach due
  to the constraints of average distillery
  capacities in our country.
• B-Heavy molasses route can be the next choice
  after conventional route as switch over is fast
  with better sugar quality and no capital
  investment.

41

• Though partial secondary juice route is also
  showing higher returns, it would require
  additional investment.
• Higher the price of ethanol and comparatively
  lower the price of sugar, other routes will
  become viable.
• B-Heavy molasses can be stored where as secondary
  juice or mixed juice can not be stored.
• Indian sugar mills need to develop flexible
  approach to shift from sugar to ethanol or
  vice-versa as per the market demand.
• Ethanol Cogeneration with their rapidly
  increasing demand present an opportunity to
  reduce sugar stocks, provide diversification
  supply a steady income stream to protect the
  bottom line.
• Sugar beet and sweet sorghum are potential crops
  for ethanol production. More R D is needed to
  establish suitable varieties under Indian
  conditions.

42
Thank You