Prospects of Ethanol & its Costing

BY

NARENDRA MOHAN
DIRECTOR
NATIONAL SUGAR INSTITUTE, KANPUR
 NATIONAL SUGAR INSTITUTE, KANPUR

Sugarcane – Source of Green Energy

JUICE SUGAR

BAGASSE Ethanol

LEAVES & TOPS CO-GENERATION

OF ELECTRICITY

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Ethanol….
The“ Solar Energy In liquid Form”.

When we want plant see to grow equal

amount of biomass to renew what burnt for
energy, the planted biomass consumes equal
quantity of CO2 which is released during
burning, no more –no less.

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IMPORTANCE OF ETHANOL
1.VALUE ADDITION: Production & sale of Ethanol is much more
profitable than selling molasses as primary by product.
2. EBP SUCCESS: To cope up with the requirement of Ethanol @
approx. 2.68 billion liters for E-10 programme.
3. STABILIZED SUGAR PRODUCTION: To balance demand-supply
position of sugar by diverting intermediate process liquors
for ethanol production.
4. ENVIRONMENT PROTECTION: Clean and green form of
renewable energy, avoiding use of fossil fuels.

5. FOREX ISSUES : To save foreign exchange required on import

of crude oil.
……..& energy security
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Revenue through sale of primary by-product (Standalone Sugar

Units- conventional route)
(per ton of sugarcane)
Sl. By-product Quantity Rate Revenue
No. (ton) (per ton) (Rs)
(Rs.)
1. Bagasse saved @ 0.070 1600.00 112.00
7.0% on cane*
2. (per ton of sugarcane)
Molasses @ 4.5% 0.045 5000.00 225.00
on cane
3. Press Mud 3.5% 0.035 250.00 8.75
on cane
TotalRs.345.75 per
ton of sugarcane
*Average bagasse % cane: 30 and considering installation of low to medium i.e. Rs. 34.50 per
pressure boilers of 32 kg/ sq cm g to 45 kg/sq cm g working pressure having qtl of sugarcane
bagasse : steam generation ratio as 2.2 to 2.3 only. Power generation through
back pressure turbines to meet sugar plant requirements only.

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Revenue through value addition (Integrated Sugar Complexes-
considering High Pressure Co-generation & Ethanol production)
(per ton of sugarcane)
Sl. By-product Quantity Value added Rate Revenue Addl. Cost of Net Revenue
No. (ton) product (Rs) (Rs) conversion (Rs.)
1. Bagasse saved 0.09 Power: 43.3 6.25 270.60 Rs. 2.00 per Rs. 184.00
@ 9.0% on Units* Per Unit unit i.e. Rs.
cane* 86.60
2. Molasses @ 0.045 Ethanol: 10.6 42.00 445.20 Rs. 10.00 per Rs. 339.20
4.5% on cane liters# Per liter liter i.e. Rs.
106.00
3. Press Mud 0.035 Press Mud: 25.00 8.75 ------- Rs.
3.5% on cane 0.035 ton Per qtl. 8.75
* Average bagasse % cane: 30 and considering installation of high Total Rs.531.95
pressure boilers of 87 kg/ sq cm g to 110 kg/sq cm g working per ton of
pressure having bagasse : steam generation ratio as 2.5 to 2.6 only. sugarcane
Power generation through Condensing/Condensation-Extraction or
i.e. Rs.
in combination with back pressure turbines to meet sugar plant
requirements and surplus for exports. 53.00 per
qtl of cane
# Considering an average yield of 235 liters of ethanol per ton of
molasses.

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.
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SUGAR-ETHANOL BALANCE
# We are producing sugar more than the domestic
requirement.

# Availability of Ethanol through conventional route is less

than requirement for the desired 10% blending
programme.

# There is need to balance Sugar-Ethanol production to

have stable sugar availability for domestic consumption
and required quantity of Ethanol for EBP 10.

# Such balance through Flexi Sugar Factories is desirable

for sugar supply-demand balance and EBP success.
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 RAW MATERIALS FOR ALCOHOL PRODUCTION
Simple
Sucrose Cane juice ; Beet
juice; Molasses
Single Stage Hydrolysis

Moderate Cassava; wheat

Starch rice; sorghum;
Complex millets
Two Stage Hydrolysis

Most Complex
Bagasse; wheat &
Cellulose Lignin
Pretreatment Followed by Liquefaction
rice straw; grass
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Hemicellulose
 NATIONAL SUGAR INSTITUTE, KANPUR

World Ethanol production by feedstock

NATIONAL SUGAR INSTITUTE, KANPUR

Total Ethanol= 105 billion ltrs

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 NATIONAL SUGAR INSTITUTE, KANPUR

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
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 NATIONAL SUGAR INSTITUTE, KANPUR

Installed Capacity Base….

1. Gross Distillation Capacity: +6.25 Billion Liters per
annum, including grain.
2. About 74% installed capacity is molasses based and
26% grain based.
3. Ethanol Production Installed base: Approx. 2.25 Billion
Liters per annum.(156Units)
in KLPA

S.No. EtOH capacity EtOH capacity EtOH capacity Total

(units attached (units attached (Stand alone
with Private Sugar with Co-operative units)
Mills) Sugar Mills)

1. 1424850 576600 237300 2238750

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 NATIONAL SUGAR INSTITUTE, KANPUR

OVERVIEW OF SUGAR & MOLASSES

PRODUCTION
S.No. Sugar No. of Sugarcane Sugarcane Sugar Molasses
Season Sugar produced Crushed Produced Produced
factories (Lakh (Lakh (Lakh (Lakh
in tonnes) tonnes) tonnes) tonnes)
operation
1. 2010-11 507 3423.82 2398.07 243.94 109.70

2. 2011-12 529 3610.36 2569.75 263.42 118.24

3. 2012-13 526 3411.99 2505.98 251.40 117.44

4. 2013-14# 509 3483.84 2360.20 245.54 108.50

#Provisional

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 NATIONAL SUGAR INSTITUTE, KANPUR

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 Molasses available Estimated Alcohol
Production (Lakh for alcohol Production
tonnes) production (Lakh Potential (Crore
tonnes) liters)
2011-12 118.24 112.33 263.98

2012-13 117.44 111.57 262.19

2013-14 108.50 103.08 242.24

2014-15# 124.82 118.60 278.70

# Provisional

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 NATIONAL SUGAR INSTITUTE, KANPUR

SECTOR-WISE REQUIREMENT/AVAILIBILITY OF ALCOHOL

In crore liters
S.No Particulars 2011-12 2012-13 2013-14 2014-15
(Estimated)
1. Requirement for potable liquor industry 153.2 157.0 220.0 230.0

2. Requirement for chemical and other 104.3 88.5 80.0 80.0

industrial uses
3. Total requirement for potable liquor & 257.5 245.5 300.0 310.0
Chemical Industry
4. Less Grain alcohol usage for potable liquor 52.5 75.0 140.0 150.0
5. Net requirement for potable liquor & 205.0 170.5 160.0 160.0
Chemical Industry (molasses based alcohol)
6. Net availability of alcohol for EBP 58.98 91.69 82.24 118.70
7. Less 5% loss on de-hydration 2.95 4.58 4.11 5.94
8. Net availability of Ethanol for EBP 56.03 87.11 78.13 112.76
(0.56 (0.87 (0.78 (1.13 Billion
Billion Billion Billion liters)
liters) liters) liters)
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 NATIONAL SUGAR INSTITUTE, KANPUR

….so we need
1. Ethanol capacity to be raised from
2.25 billion liters/annum to say
2.75 billion liters

2. Use of alternate sources for

alcohol/ethanol production to cope
up with EBP 10……..to meet
shortfall of about 1.5 billion
liters/annum.

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 NATIONAL SUGAR INSTITUTE, KANPUR

Other process liquors for alcohol production

Cyclic nature of the Indian Sugar Industry and various
other factors effect the availability of molasses for
ethanol production. Thus, there is need to look for
other feed stocks to cope up with ethanol requirements
for EBP10, and as far as sugar factories are concerned
following may be the alternatives:

1. Ligno-cellulosic Ethanol from bagasse.

2. Directly from sugarcane juice.
3. Diversion of Secondary juice.
4. Diversion of Filtrate (filtered juice).
5. Diversion of B-Heavy Molasses.
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DIVERSION OF B HEAVY MOLASSES 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….

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 NATIONAL SUGAR INSTITUTE, KANPUR
Chemical Composition of B- Heavy and Final Molasses

S.No PARAMETERS B-HEAVY FINAL

MOLASSES MOLASSES
1 Reducing sugars (g %) 4-16(10) 10-16(13)

2 Total Reducing sugars (g %) 50-89(54) 40-50(45)

3 UFS (g %) 2.00-3.00(2.5) 4.00-6.00(5.0)

4 Volatile fatty acids (ppm) 2000-2500 3400-4000

5 pH 4.8-6.0 4.8-6.0
 NATIONAL SUGAR INSTITUTE, KANPUR

Fermentative Production of Alcohol from Intermediate Molasses

S.No PARAMETERS B-HEAVY FINAL

MOLASSES 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 ) 296.8 235.5

 Comparison of data of B-heavy molasses and final molasses trial done at
Dhampur Distillery

S.No. Particulars Units FM BH

1. Molasses Consumption Qtls 7500 7950
2 Total Production (95 %) Litre 188201 224096
3 Ethanol Production Litre 159000 198237
4 Spent Wash Generation Litre/Litre 8.6 6.99
5 Fusel Oil Litre Nil NIL
6 Steam Consumption kg/l Tons 2.14 1.83
7
8
9 MEE(Feed Rate-960
M3)(Exhaust) Tons 202 U/Cleaning
10 ENA Kg/Litre 1.8 1.8
11 Power Consumption kw/l kwh 0.096 0.074
12 Fermentation Efficiency % 88 89.7
13 Distillation Efficiency % 97.6 97.6
14 Yield Litre/Ton 225 281.8
15 Loss on Spent Wash NIL NIL
16 Loss in Spent Lees NIL NIL
17
Storage Deterioration Unit/6 month 2.5 3.5
18 Molasses TRS % 44.1 52.1
19 Unfermentable Sugar % 6.28 Data NA
20 Volatile Acids mg/litre 5143 4971
Sl. No. Particulars Units Three Massecuite Two Massecuite
Boiling Boiling

1 Cane Ton 1 1
2 Recovery % Cane 10.37 8.81
3 Quantity of Sugar Produced Kg 103.70 88.15
4 Sugar Price Rs. / Kg 29 29
5 Gross Revenue from Sugar Rs. / Ton Cane 3007 2556
6 Conversion Cost Rs. / Kg 5.75 5.75
7 Net Revenue from Sugar Rs. / Ton Cane 2411 2049
8 Molasses % Cane 4.5 6.58
9 Quantity of Molasses Produced Kg 45 65.8
10 Ethanol Production Rate Litres per Ton of 223.25 294.50
Molasses
11 Quantity of Ethanol Produced Litres 10.05 19.38
12 Ethanol Price Rs. / Litre 42 42
13 Gross Revenue from Ethanol Rs. / Ton Cane 422 814
14 Conversion Cost Rs. / Litre 10 9.5
15 Net Revenue from Ethanol Rs. / Ton Cane 321 630
16 Power Export KWh 71.78 73.93
17 Power Price Rs. / KWh 6.25 6.25
18 Gross Revenue from Power Rs. / Ton Cane 449 462
19 Conversion Cost Rs. / KWh 2 2
20 Net Revenue from Power Rs. / Ton Cane 305 314
21 Press Mud % Cane 3.5 3.5
22 Quantity of Press Mud Produced Kg 35 35
23 Press Mud Price Rs. / Kg 0.26 0.26
24 Net Revenue from Press Mud Rs. / Ton Cane 9 9
25 Total Net Revenue Rs. / Ton Cane 3047 3003
26 Difference Rs. / Ton Cane -44
 3200
FINAL MOLASSES VS B-HY MOLASSES 3150
3100
ETHANOL PRICE @ RS. 42 / LITRE
3091
3047

3000 3002
2943
FM B HY
NET REVENUE IN RS.

2900 2914
2839

2826
2800
2736

2738
2700 2650

2600 2562 2632

2528
2500
24 25 26 27 28 29 30
SUGAR PRICE IN RS./KG 22
 3300
FINAL MOLASSES VS B-HY MOLASSES
ETHANOL PRICE @ RS. 47.5 / LITRE 3201
3200
3188
3097
3100
FM B HY 3099
3011
NET REVENUE IN RS.

3000 2993
2923
2900 2890
2835

2800 2747
2786
2700 2659
2682
2600
2578

2500
24 25 26 27 28 29 30
SUGAR PRICE IN RS./KG 23
 NATIONAL SUGAR INSTITUTE, KANPUR

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.
 Sugar of better quality – no need to recycle molasses of
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
 However, the economics of B Heavy diversion shall be
dependent upon the price of the Sugar vis a vis
Ethanol. 24
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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.
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Feedstock for Ethanol Production

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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 60-75 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.
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Fermentative production of alcohol from Sugar Beet Juice

S.No PARAMETERS RESULT

1 Qty of sugar beet 3k g

2 Final volume of juice 5L

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 101.6 litre/ ton

 NATIONAL SUGAR INSTITUTE, KANPUR

SWEET SORGHUM
I

India is the second largest producer of 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 of alcohol.
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Fermentative production of alcohol from
sweet sorghum
1. Quantity of sweet sorghum stalk 2.5 kg
2. Volume of juice 1.0 liter
3. TRS content 17.9%
4. Unfermentable sugars Nil
5. Theoretical ethanol yield (% v/v) 11.52
6. Practical ethanol yield (% v/v) 11.17
7. Fermentation efficiency 96.96
8. Ethanol in 1 liter juice 111.7 ml
9. Ethanol in 1000 liters juice 111.7 liters
10. Ethanol yield (liter/ton of sweet sorghum stalk) 44.68
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CASSAVA

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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.
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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
 NATIONAL SUGAR INSTITUTE, KANPUR
SO, ETHANOL MATTER US IN INDIA ….AND WE
HAVE TO WORK ONE
# DISTILLERIES ATTACHED TO SUGAR FACTORIES AND
PRODUCING ALCOHOL ONLY (21 NOS.),

# DEVELOPING FLEXI SUGAR FACTORIES AND BIO-REFINERIES.

# ADOPTING ALTERNATE MEANS OF ETHANOL PRODUCTION

VIZ. DIVERSION OF INTERMEDIATE PROCESS LIQUORS & USE OF
OTHER FEED STOCKS.

# PRODUCTIVITY IMPROVEMENT BY IMPROVEMENT IN PLANT

EFFICIENCY

# BALANCING SUGAR & EtOH PRODUCTION AS PER DEMAND

AND ECONOMICS.
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Jai Hind…………

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