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Sugar
Turning into white gold?
27 February 2021
INDIA | SECTOR UPDATE
The sugar sector is known for its cyclical nature. However, it has seen structural changes
with: (1) rational alterations in the government’s policies, and (2) flexibility provided, as Vikram Suryavanshi, Research Analyst
diversion of surplus cane and B-heavy molasses is now allowed to produce ethanol that (022 6246 4111) vsuryavanshi@philipcapital.in
can be used for blending with petrol. In addition, differentiated pricing for ethanol (based
on raw material) is quite attractive and has the potential to significantly reduce the
cyclical nature of the sector because of the sustainable business model it provides for
sugar mills.
Ethanol supply from sugar mills can meet c.15-18% of the blending target
The government has fast-forwarded its 20% ethanol blending target to 2025 from 2030
earlier; this will require additional distillery capacity addition of c.5bn-7bn litre per annum
(capital expenditure of c.Rs 150-210bn needed from sugar mills) and diversion of c.10-12%
of cane juice directly into ethanol. Conversion of B-heavy molasses into ethanol will
generate c.6bn litre distillery output, which is sufficient for 12-14% blending. We believe
sugar mills will shift to flexible business model with higher production of ethanol due to
secure demand, attractive pricing, and a balancing out of the sugar cycles.
Sugar Cane
=
Sugar
+
Power and Ethanol
+
Biogas and Fertilizer
2022
2000
2001
2002
2003
2004
2005
2006
2007
2008
2010
2011
2012
2013
2014
2015
2016
2017
2018
2019
2020
2021
250
200
150
100
50
0
2005
2016
2000
2001
2002
2003
2004
2006
2007
2008
2009
2010
2011
2012
2013
2014
2015
2017
2018
2019
2020
2021
Source: PhillipCapital India Research, Industry, ISMA
MSP since 2018 has restricted downside to the price even in a surplus scenario
Closing inventory Domestic sugar price
45 25
Price drop 18% with Stable prices dispite highest
40 higher inventory inventory in history
35 20
30
15
25
20
10
15
10 5
5
0 0
SS2014 SS2015 SS2016 SS2017 SS2018 SS2019 SS2020 SS2021
The minimum selling price also helps mills to garner better realizations during periods
of lower international prices, protecting the profitability in sugar segment. To reduce
surplus, the government has also provided financial incentives, which help mills to
export sugar.
Sep-20
Feb-21
Jun-20
Nov-20
Dec-20
Jul-20
Oct-20
Apr-20
Aug-20
Mar-20
May-20
Jan-21
Source: PhillipCapital India Research, Industry
7.00
6.00
5.00
4.00
3.00
2.00
1.00
0.00
SS2016
SS2021
SS2014
SS2015
SS2017
SS2018
SS2019
SS2020
SS2022
SS2023E
Ethanol prices are now associated with domestic prices, and de-linked from crude
50.0 Domestic ethanol price (Rs/ltr) Crude Price ($/bbl)-RHS 100
45.0 90
40.0 80
35.0 70
30.0 60
25.0 50
20.0 40
15.0 30
10.0 20
5.0 10
0.0 0
2014 2015 2016 2017 2018 2019 2020 2021
Sugar cane is fast becoming an energy crop Sugar cane is now regarded as an
Sugar cane is now regarded as an energy crop, with a renewed focus on ethanol energy crop with a renewed focus on
blending and power generation from bagasse, as well as waste from distilleries. Some ethanol blending and power generation
sugar mills are using distillery waste and press mud for biogas generation. from bagasse, as well as waste from the
distillery
Revenue generation from a tonne of cane crush increases if sugar mills shift to an
integrated business model and higher ethanol production. Revenue per tonne of cane
crush is higher by c.10% with integrated model using C-molasses for ethanol and
power generation form bagasse. The per tonne realization increase even more with
increased production of ethanol – 15% higher in case of diversion of B-heavy
molasses to ethanol and c.20% higher in case of direct conversion of juice to ethanol
due to the attractive ethanol prices that the government has fixed.
Different sugar business models are now available (Revenue - Rs / tonne of cane)
Sugar Power Press mud Ethanol
5000
4500
4000
3500
3000
2500
2000
1500
1000
500
0
Conventional Integrated B-Heavy Juice to Ethanol
With realistic policy support and commitment for ethanol blending from the
government, the success story of ethanol blending in Brazil can be replicated in India.
The production of bio-ethanol from sugarcane is most efficient and economical and
both countries are among the larger producers of sugarcane worldwide.
62.65
Cane 59.48
59.10
57.61
B-Heavy 54.27
52.43
45.69
C- molasses 43.75
43.46
Additionally, sugar mills are getting better realizations per tonne of cane crushed
with conversion of B-heavy molasses into ethanol instead of extracting additional
sugar. This conversion will also help to reduce sugar production and reduce demand-
supply imbalance in the country.
As per our analysis, break-even ethanol price from B-heavy molasses is around 1.4-
1.6x of sugar price, based on process efficiency. For direct conversion of juice into
ethanol, price breakeven is at 1.8-1.9x of sugar realizations. At current domestic
sugar price of Rs 31 per kg and ethanol realization from B-heavy molasses at Rs 57.61,
sugar mills garner additional revenues of Rs 85-100 per tonne of cane crushed (see
chart below).
Breakeven analysis for sugar and ethanol production Additional benefit from B-heavy; ethanol @ Rs 57.61/litre
5500 Revenue (sugar + ethanol) with normal crushing 250 Additional benefit to sugar companies
B-Heavy to molasses
200
5000
150
4500
100
2500 -150
24 26 28 30 32 34 36 38 40 42 44 24 26 28 30 32 34 36 38 40 42 44
Sugar Price (Rs /Kg) Sugar Price
(Rs /Kg)
Source: Industry, PhillipCapital India Research
The distillery capacity that sugar mills need (ethanol yield litre/tonne of cane)
80 7-8X
70
60
50
40
30 2X
20
10
0
C-molasses B-Heavy molasses Cane Juice
The diversion of B-heavy molasses into ethanol and around 10% diversion of cane
directly into ethanol has the potential to balance demand-supply in the domestic
sugar market. Sugar production can be managed at 24-26mn tonne per annum and
ethanol supply can be increased from 2.8bn litre per annum to touch 7.6bn litre per
annum, sufficient for 15-18% blending, assuming 2-3bn litre requirement from the
chemicals and liquor industries.
As per our analysis, c.65-70% of ethanol supply can come from two states, each
contributing c.35% of total ethanol supply from sugar cane in the country. Ethanol
supply from Maharashtra can be increased to c.2.7bn litre annually (from c.1bn litre
at present) and so also can supply from Utter Pradesh.
The Government is targeting ethanol supply of c. 12bn ltr by 2025 out of which c.9bn
ltr would be required for 20% blending with petrol and remaining 3bn ltr would be
required for chemical and liquor industry.
Ethanol supply and usage for 20% blending target in 2025 (bn ltr)
10
9
8
7
6
5
4
3
2
1
0
Sugar based Grain based Blending Other use
Supply Usage
Sugar mills are expected to supply c.7bn ltr while remaining c.5bn ltr will be supplied
by the grain-based distilleries. The diversion of c.5-6mn tonne sugar would balance
the demand supply for the sugar sector and help in reducing the inventory and
storage cost along with better realization for sugar which will facilitate timely
payment to sugarcane farmers.
Annexures
ABC of molasses
At the sugar factory, cane juice is heated and is treated with sulphur and lime for
removing colour and impurities.
During crystallization, with the centrifugal process, non-crystalized sugar waste is
generated – known as molasses.
o A molasses (first molasses) is an intermediate by-product resulting from first
sugar crystal extraction (A sugar), from the initial processing.
o B molasses (second molasses) contains less sugar and does not
spontaneously crystallize. These molasses have c.65% sugar. B-heavy yield
from sugar cane can be 6-8% of cane crushed. One tonne of B-heavy
molasses can give 300-330 litres of ethanol.
o C molasses (final molasses, blackstrap molasses) is the end by-product of
processing. It still contains considerable amounts of sucrose (approximately
32-42%). C heavy has c.40% sugar. C molasses does not crystallize and can
be stored in liquid form. C-molasses yield from sugar cane is 3.5-4.0% of
cane crushed. One tonne of C-molasses gives 230-260 litre of ethanol.
Now spent wash is heated and concentrated to use as fuel for boiler and used for
seam and power generation with incineration technology. Zero liquid discharge can
be achieved through Eco –friendly which is also energy efficient. Waste potash rich
ash is saleable, generates good revenue and also eliminates disposal problem and
reduction in overall production cost per litre of alcohol.
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