SISSTA SEMINAR 2024 - Technical Papers Only

SISSTA, SEDL & PONNI SUGAR - Joint Seminar at Tiruchengode, 2024
Lowest Steam Consumption at a Sugar Plant of

Uttar Pradesh (Dewan Sugars Limited)
Vivek Verma1, Ashok Kumar Nanda2
1
Managing Director, Spray Engineering Devices Limited, Mohali, Punjab, India
2
President-Sugar, Spray Engineering Devices Limited, Mohali, Punjab, India
vivek.verma@sprayengineering.com
Abstract Keywords: Evaporation, crystallisation, steam

demand, capacity expansion, steam reduction,
Sugar industry plays very important role in global
falling film evaporator, mechanical circulator, spray
energy consumption, and it is one of the most
continuous pan, batch pan, bleeding
energy consuming industries. Increasing trend in
setting up of new sugar industries and capacity Introduction
enhancement of existing sugar plants in India is
Energy remains one of the critical
alarming to energy requirement. These industries
challenges of the future in sugar sectors.
consume considerable amount of energy for
production viz a viz generate the energy as
Businesses need to strike the balance between
cogeneration. The energy conservation in such operational efficiency and sustainable
plants is paid less attention as compared to that in development. With soaring energy prices and
developed countries. Also, there is a need to promote increased scarcity of natural resources,
recycle economy, energy generation, facilitating pinpointing energy efficienciesfrom planning
technological progress, reduce consumption, and to manufacturing to operations, makes good
protect the environment. Hence, energy efficiency business sense (1, 2). One way of reducing
and conservation should be viewed as new source energy costs is to become more energy
of energy along with energy cogeneration. Energy efficient to optimise existing resources and
efficiency improvement measures in sugar mills is
plan the right investments in new
done in the change in bleeding arrangement and
technologies (2). This will help manage
incorporation of energy efficient products &
operating costs and provide better delivery of
technologies in sugar processing units during
services to customers while reducing
heating, evaporation and concentration and waste
heat recovery system. Dewan Sugars Ltd., environmental impacts and mitigating risk
Moradabad, U.P.was established and cane crushing (5). Factory and measurement data are
trial season was conducted in 1999-2000 for the analysed using concept of mass and energy
crushing capacity 3500 TCD. Initially plant balance to indicate potential independent
capacity was 3500 TCD and expended upto 8000 variables that effects on higher energy
TCD in four phase and reduced steam successfully demand (3). The sugar industry represents
from 48-50% to 27-28% on cane using energy one of the most important economic activities
efficient evaporation and crystallisation technologies that consume higher quantity of energy (4, 5,
at low temperature processing along with change in 6). Steam is used in nearly every industry,
bleeding arrangements. Installation of low delta
and it is well known that steam generators
temperature equipment like plate heat exchangers,
and heat recovery boilers are vital to power
direct contact heaters, falling film evaporators,
and process plants (3, 5, 6). It is no wonder
spray continuous pans, honeycomb calandria batch
that with rising fuel and energy costs
pans, waste heat recovery system and complete
automation system during the crushing season engineers in these fields are working on
2022-23, Dewan sugar has expended the crushing innovative methods to generate electricity,
capacity from 6600 TCD to 8000 TCD with reduced improve energy utilization in these plants,
27-28% steam demand after adding/modifying and recover energy efficiently from various waste
upgrading the machineries and equipment. gas sources, by products, and simultaneously
1
Lowest Steam Consumption at a Sugar Plant of Uttar Pradesh (Dewan Sugars Limited)
Vivek Verma, Ashok Kumar Nanda
minimize the impact these processes have on expansions and modifications are described
environmental pollution and the emission of below in details.
harmful gases to the atmosphere (2). Energy
Phase-1: Crushing plant capacity
consumption in sugar plants depends on
expansion from 3500 TCD to 4500 TCD
various factors such as its capacity, steam
and reduction in steam consumption
generation parameters, vintage, equipment
35% from 48% on cane
used etc (1). Analysis of the energy
consumption pattern in the sugar mills In the first phase of plant expansion and
reveals that there exists significant scope for reduction in steam consumption, this plant
improving the energy efficiency the Indian was suffering from problems due to inefficient
Sugar Industry (6). The major reason for the machinery utilization. Maintenance cost and
high energy consumption in the industry is operating expenses were huge due to which
the presence of large number of folds, small there was no investment made in
capacity sugar mills which have no invested modernization/upgradation of various existing
much over the years in modernizing or equipment. To overcome the financial loss, the
upgrading various obsolete process equipment Dewan management was decided to undergo
(4, 5). This steam energy is divided into two expansion and modification of the plant
parts, the first part is used in the steam as without addition of boiler and turbine capacity
heat energy, which is in the form of steam in first phase.In this phase, following energy
and hot water (6). The steam energy is used saving equipment have been added and
in the production process from cane crushing bleeding scheme have been changed.
using the sugar cane preparation stage before • 2 nos. of tubular falling film evaporators
the container is chopped, the sugar cane is (FFEs) of heating surface 3000 m2 each
clarified by using steam from the heat
exchanger and boil syrup. The second part is • Direct contact juice heater
used for power generation (4, 5, 6). Steam is • Waste heat recovery system
used to drive turbines and power generators
• Molasses conditioner
into production or sales processes.
• Condensers with automation
Technology for expansion and steam
• Instead of 1st effect, all vacuum pans
saving
are operating on 2nd vapour
Dewan Sugars Limited is a public
incorporated on September 1983 and cane Dewan sugar has successfully achieved
crushing trial season was conducted in and performed well with the crushing plant
1999-2000 for the crushing capacity 3500 TCD capacity expansion from 3500 TCD to 4500
and 48-50% steam demand. TCD and reduction in steam consumption 35%
on cane from 48% on cane in the crushing
For first time expansion and modification season 2018-19 with existing boiler capacity
at Dewan Sugar in crushing season of 80 ton.
2017-18and continued expansion was
completed upto crushing season 2022-23, Phase-2: Crushing plant capacity
various additions of energy saving equipment expansion from 4500 TCD to 5500 TCD
and amendments in the existing scenario have and reduction in steam consumption
been done for energy efficiency without 32.5% from 35% on cane
disturbing the existing equipment, expansion After seeing the benefits of the sugar
and technologies in four phases as per plant, the Dewan management was very
suitability of the Dewan management. These pleased and decided to undergo expansion and
2
modification of the plant without addition of • Vertical Spray Continuous Vacuum Pan
boiler and turbine capacity in second phase.In (SCP®) of 5 nos. of chambers of capacity
this phase, following modern energy saving 55 t/h on ‘C’ massecuite
equipment have been added.
• Vacuum sugar melter of capacity of 50 t/h
• 2 nos. of tubular falling film evaporators
• Instead of 3rd effect, all vacuum pans
of heating surface area 4000 m2 each
are operating on 4th vapour
• Direct contact juice heaters This sugar plant has successfully
• Plate heat exchanger achieved and performed well with the
expanded crushing capacity from 5500 TCD to
• Addition of chambers in waste heat
6600 TCD and reduction in steam
recovery system
consumption 30% from 32.5% on cane in
• Vertical Spray Continuous Vacuum Pan crushing season 2021-22 as fig. 1 with
(SCP®) of 5 nos. of chambers of capacity extended boiler capacity 95 ton.
55 t/h on ‘B’ massecuite
• Instead of 2nd effect, all vacuum pans

are operating on 3rd vapour
This sugar plant has successfully

achieved and performed well with the
expanded crushing capacity from 4500 TCD to
5500 TCD and reduction in steam
consumption 32.5% from 35% on cane in the
crushing season 2020-21 with existing boiler
capacity of 80 ton.

and reduction in steam consumption
30% from 32.5% on cane Fig. 1: Actual image of FFEs and SCP®
After seeing the performance and after 3rd phase expansion of the plant
benefits of the sugar plant, the Dewan
management was again decided to expand and Phase-4: Crushing plant capacity
modifying of the plant capacity without in expansion from 6600 TCD to 8000 TCD
third phase. In 3rd phase, following modern and reduction in steam consumption
energy saving equipment have been added 27% from 30% on cane in crushing
with some modifications. season 2022-23
• 2 nos. of tubular falling film evaporators Pleased by the performance and

of heating surface area 5000 m2 each economic benefits of the plant, the Dewan
management was very glad and again decided
• Direct contact juice heaters to expand the plant capacity and reduce the
steam consumption in 4th phase. In this
• Plate heat exchanger
phase, following modern energy saving
• Addition of chambers in waste heat equipment have been added with some other
recovery system modification and upgradation.
3
• 2 nos. of tubular falling film evaporators 85 t/h. This will be sufficient for the
of heating surface area 6000 m2 each enhanced crushing capacity steam
consumption.
• Vertical Spray Continuous Vacuum Pan
(SCP®) of 6 nos. of chambers of capacity • DSL had installed a new 10 MW back
80 t/h on ‘B’ massecuite pressure Turbo-Alternator set. The
enhanced crushing capacity requires
• Replacement of 2 nos. of batch pan of
around 7.5 MW power.
capacity 80 t/h with one number of new
batch pan capacity of 100 t/h of SED’s • DSL power plant had been equipped with
designed which is operating on low 11 KV Alternator. DSL installed the
temperature vapour i.e. 85 − 88°C required step-down transformers and
HT/LT switch gears to connect the HT
• All vacuum pans (continuous and
electrical system with the LT electrical
batch type) are operating on 5th
system available in the plant to have a
vapour
seamless use of power produced for the
The strength of the new addition of plant plant equipment.
and machinery are detailed below.
Boiling House
Milling Section • DSL boiling house is added with new clear
• Dewan Sugar Limited (DSL) had installed juice PHEs, juice clarifier of 30’ diameter
to add one no. 42x84 size ULKA 5-roller one no., 2 nos. of 6000 sqm heating
mill as the last mill to the existing milling surface FFEs, 1 no. – SCP® for C-Pan,
tandem of 4 mills having 36 × 78 mill vertical crystallizer 500 MT capacity for
sizes. With this addition it becomes a c-massecuite cooling, centrifugal machines,
5-mill tandem and more than sufficient for modified vapor bleeding scheme revised
crushing capacity of 6600 TCD. for 27% steam consumption.
• DSL had modernized its existing boiler • In addition to this plant upgradation,
with capacity addition from 77 t/h to necessary energy efficient equipment was
Fig. 2: Actual image of evaporators and vacuum pans after expansion in 4th phase
4
also erected to stabilize/optimize the addition and modification of available and

energy consumption for crushing 6600 proven innovative technologies, products and
TCD with ease. solutions.With the use of modern innovative
principles, sugar mills can reduce the steam
• DSL with all above additions stands high
consumption and subsequently able to achieve
in energy efficiency & overall plant
tremendous bagasse and energy saving. The
efficiency.
optimization of energy consumption in sugar
• Most of proposed equipment is vertical factories can also be important to evaluate the
installation (DCH, FFEs and SCP®) cost of process steam demand reduction. The
reducing expenditure on civil structure. decision of best the technology to be
DCH, FFEs, SCP® are fully automatic implemented in the energy reduction in
system with DCS. process system depends on the quantity of
steam consumed by the process and the
• High Flexibility in operating capacity
analysis of both systems must be made
without incurring extra cost.
together looking for the better alternative for
• User friendly, easy to automate and the factory. After achieving the performance
operate. of 30% on cane during season 2021-22 at
Dewan Sugar plant in Uttar Pradesh, IPL
In the history of the sugar plants, the
(Rohana & Titawi), Tikaula Sugar, BHL-Palia,
Dewan Sugar plant is the first sugar plant of
Kinauni, Dalmia-Nigohi, Ramgarh,
Uttar Pradesh even of India also, that all the
Jawaharpur, KM Sugar and many more sugar
vacuum pans (continuous and batch) for A, B,
plants adopted the scheme and reduced the
C boiling is operating with 5th vapour of
steam demand by 14-18% on cane, second
evaporators now.
phase for further reduction of steam/power in
Conclusion these plants are in progress.
In this study, the performance Acknowledgement
parameters of this sugar mills were analysed Authors are thankful to Shri Gaurav
with the aim of key-selected parameters which Dewan (Managing Director) and his technical
enable to test commonly stated theories for team for continuous support, faith and
energy efficiency improvements in sugar mills confidence on SED Land remains association
towards real operation parameters. The sugar with Spray Engineering Devices Limited
mill is the most energy-consumed industry (SEDL), Mohali, Punjab, India.
sector which currently consumes steam on
average 40-41 % on cane that steam demand
can be reduced up to 26-27% on cane after
The phase wise performance of the plant in tubular form is given below:
Parameters Phase-1 Phase-2 Phase-3 Phase-4

Crushing Season 2017-18 2020-21 2021-22 2022-23
Plant Capacity
3500 to 4500 TCD 4500 to 5600 TCD 5600 to 6600 TCD 6600 to 8000 TCD
Expansion
Reduction in Steam 35% from 48% on 32.5% from 35% 30% from 32.5% 27-28% from 30%
Consumption cane on cane on cane on cane
Boiler Capacity 80 Ton 95 Ton
5
References 4. Increased rankine cycle and evaporators

efficiency to reduce more power to crush more
1. Report of the task force on the sugarcane and
with 25% steam consumption, A K Mishra and
sugarcane industry, March 2020, NITI Aayog,
Vivek Verma, Proceedings of 10th Joint
Government of India, 01-87.
Convention of STAI & DSTA, (2011), 45-48.
(10_Report_of_the_Task_Force_on_Sugarcan_
and_Sugar_Industry_0) 5. Innovation in the area of energy efficiency and
conservation in sugar industry, A K Nanda,
2. Indian Sugar Industry: Towards Self-reliance Vivek Verma and G P S K Deekshitlu,
for Sustainability, S. Solomon and M. Swapna, Proceedings of 67th Annual Convention of
Sugar Tech. 2022; 24(3): 630–650. STAI, 2006, 54-75.
3. Modern innovation to reduce energy 6. Conservation of steam in sugar industry
consumption, Vivek Verma, 50th Year Golden experience of GMR Industries Limited, G. M.
Jubilee Souvenir, National Federation of Raju, D.R. Reddy, S.S. Rao and Vivek Verma,
Cooperative Sugar Factories, New Delhi, 2010, Proceedings of 67th Annual Convention of
101-117. STAI, 2006, 84-99.
6
Reduction of Steam Demand in Sugar Processing of Jai

Bhavani at a Glance
Vivek Verma1, Tekale D.K.2, Ranjit Shivaji Atkale3, Dilip Kore S.4
1
Managing Director, Spray Engineering Devices Limited, Mohali, Punjab, India
2
General Manager, Jai Bhavani Sahakari Sakhar Karkhana Ltd., Georai, Maharashtra, India
3,4
Sugar Business, Spray Engineering Devices Limited, Mohali, Punjab, India
Abstract by-products are potential sources of energy.

The sugar industries play a significant role in Sugarcane is a rich source of energy and the
India’s agricultural economy and renewable energy energy ratio for input to output is higher for
sector of the sugar industries can contribute a lot sugarcane than for any other agricultural crop
for energy conservation in the form of steam, power, (1). Sugarcane, being a renewable crop gives
fuel and water management. Sugar industries use a lot of renewable energy resulting in
steam at low pressure for sugar processing and
reduction of greenhouse effect (1). Energy
some of the plants still use medium pressure steam
for sugar processing. Process steam utilization is
conservation in the sugar industry contributes
exceeding 42-48% on cane for sugar manufacturing to majorly steam, power, fuel and water
in some of the sugar plants in India and there are management (1, 2). Presently, a lot of heat
huge possibilities of reducing the process steam and energy are used during processing in
consumption to a level less than 25% on cane and heating and cooling, evaporating and
sugar factories can be designed to operate without
concentrating the juices and intermediate
boiler. Energy needs are increasing day by day in
sugar products (1, 3). Some factories use
India and this ever-increasing demand can be met
out by means of implemented energy saving medium pressure steam for sulphur burning,
methodologies as much as possible. For this energy pan washing, sugar drying, melting and
saving, the project at Jai Bhavani Sahakari Sakhar molasses heating and centrifugal station.
Karkhana Ltd., Georai, Maharashtra was taken for Many sugar factories use a large quantity of
detailed case study. The initial plant capacity was steam per ton of cane for sugarcane
2500 TCD with 54% steam consumption and after
processing (3,4, 5). There is a need for the
addition of some energy efficient modern equipment
sugar factories to reduce their steam and
and modification in the existing bleeding scheme,
the plant capacity was expanded to 5000 TCD with power consumption mostly at evaporation and
reduced steam demand 30% on cane. This paper concentration processes using energy efficient
brings out the reduction in steam consumption equipment addition and modification the
possibility in the process area of the sugar existing bleeding scheme of Jai Bhavani SSK,
industries. The steam reduction measures that could Maharashtra in two phases. The continued
be adopted in the sugar plants are factory specific
demand for an increase in capacity and
and it is necessary to have a detailed study of the
reduction in steam efficiently has led to the
sugar factory and come up with the possible
reduction areas for adoption. development of energy efficient products and
cost-effective innovative solutions for the
Keywords: Energy efficiency, evaporation and sugar plants (4, 5). These developments for
concentration, falling film evaporator, mechanical
energy efficiency have changed the energy
circulator, batch pan, direct contact heater, mill,
bleeding scheme scenario of the sugar industries and created
the thrust towards better energy efficiency.
Introduction Jai Bhavani SSK, Georai, Maharashtra
Today, the sugar industry is viewed as was commissioned in 1977-78 and unable to
energy industry as all the products and meet out the power as well as fuel
7
Reduction of Steam Demand in Sugar Processing of Jai Bhavani at a Glance
Vivek Verma, Tekale D.K., Ranjit Shivaji Atkale, Dilip Kore S.
requirement for the sugarcane crushing and equipment but to overcome the financial loss,
processing with traditional setup. Initially the Jai Bhavani management was decided to
plant capacity was 2500 TCD with 54% steam undergo expansion cum modification of the
consumption and electrically unbalanced. This plant without addition of boiler and turbine
factory was balanced in two phases with capacity in first phase. It was expanded by
steam saving by addition of energy efficient considering power consumption 20 ton of cane
equipment like direct contact juice heaters with replacement of DOL starters at variable
and duplex type condensate heaters for juice loads by VFD such as boiler feed pumps, ID/FD
heating, falling film evaporators, new design fans, juice pumps with automation & injection
honeycomb calandria type vacuum pans. pumps. All six mills’ turbines were replaced by
electric motors. In this expansion and
expansion from 2500 TCD to 3600 TCD modernization of first phase as per table 1, the
and reduction in steam consumption following parameters have been proposed in the
36% on cane from 54% on cane replacement of the existing equipment or
addition of the energy saving scheme:
This plant was suffering from problems
due to inefficient machinery utilization and The evaporator configuration or the
unable to meet the cane price. Maintenance vapour bleeding arrangement of existing 2500
cost and operating expenses were huge due to TCD plant capacity and 54% steam demand
which there was no invested made in have been shown in fig. 1 and fig. 2
modernization/upgradation of various existing respectively.
Table 1: Parameters for existing 2500 TCD

plant capacity and proposed for expansion of 3600 TCD in phase 1
Sr. Existing scenario Proposed scheme

Performance parameters
No. (2500 TCD) (3600 TCD)
1 Crushing Rate (24 h) 104.16 TCH 150 TCH
2 Steam available from Boiler 75 TPH 55 TPH
3 Total Steam Generation Capacity 75 TPH 75 TPH
STEAM DISTRIBUTION / CONSUMPTION
1 Turbo generator (2.5 + 1.5) MW Plant load 2.3 MW 28.75 t/h 46.00 t/h
2 Fibrizer Turbine 1000 BHP (80 % average load) 8.57 t/h 8.57 t/h
st
3 Mill Turbine No. One 300 BHP (80% average load) for 1 Mill 3.62 t/h Nil
nd
4 Mill Turbine No. Two 600 BHP (80% average load) for 2 6.62 t/h Nil
and 3rd Mill
5 Mill Turbine No. Three 600 BHP (80% average load) for 4th 6.62 t/h Nil
and 5th Mill
6 Mill Turbine No. Four 300 BHP (70% average load) for 6th Mill 3.56 t/h Nil
7 Steam for Distillery 4.0 t/h 4.0 t/h
8 Total Exhaust Steam available for Process 61.74 t/h 54.57 t/h
9 Misc. use of high press steam 7 bar@3% 3.4 0.5
10 Process Steam Consumption 54 % 36%
8
Fig. 1: Vapour bleeding arrangement of existing plant capacity 2500 TCD and 54% steam consumption
Fig. 2: Proposed vapour bleeding arrangement for expanded plant capacity

3600 TCD and reduction in steam demand 36% on cane in phase 1
9
Highlight of factory parameters is given • Flash heat recovery system (CIGAR®)

below after modernization installed.
1 Plant Capacity : 3600 TCD (150 TCH) • Mechanical circulator for all batch pans.
st th
2 Milling Tandem : 5 Mills (1 & 5 Mills 30’
× 60’ and 2nd, 3rd & 4th • Condenser automation with VFD for
Mills 30’ × 60’) injection pump.
3 Boiler Capacity : 20 t/h @ 21 kg/cm2 - 2 Nos.
35 t/h @ 21 kg/cm2 -1 No. • Evaporator body isolation arrangement for
4 Turbine Capacity : 2.5 MW and 1.5 MW avoiding general cleaning.
5 Juice Heater : Tubular and Direct Contact
• DCH for raw juice & sulphured juice final
Juice Heater (DCH)
heating.
6 Evaporator : Falling Film Evaporators
and Existing Robert
• Compartment modifications of existing
7 Vacuum Pans : Batch Pans with
tubular juice heaters.
Mechanical Circulators
8 M/c. Boiling Scheme : 3 M/c. Boiling • Addition of honeycomb type calandria
9 Final Product : White Plantation Sugar batch pan 60 ton/strike capacity for
10 Steam : 36% on cane A-massecuite.
Consumption
The expansion and modernization of the
The list of new added equipment with plant in crushing season 2021-22, the sugar
modifications and alterations are given plant achieved 36% steam consumption with
below: enhanced plant crushing capacity 3600 TCD
• All mill turbines removed & DC motors and it was balanced on 4 MW turbine
installed. generation. The achieved results of crushing
season 2021-22 and existing parameters of old
• 2 nos. of falling film evaporator (FFEs) of crushing season 2014-15 are given in table 2.
heating surface area 2400 m2 each are The actual plant image in the first phase
added for second and third effect. modification is shown in fig. 3.
Table 2: Parameters before and after modification with addition of new equipment in phase 1
Sr. Before Modification Season After Modification
Particular
No 2014-15 Season 2021-22
1 Cane Crushing Capacity 2500 TCD 3600 TCD
2 Total Cane Crushed 281101.00 tons 6200804.24 tons
3 Number of Days 139 days 202 days
4 Power Generated 3935414.00 kWh 12398775.00 kWh
5 Power consumption per TCH Sugar 14 TCH 18.62 TCH
6 Power consumption per TCH Sugar + Distillery -- 20-21 kWh
7 Bagasse Generated 75025.85 tons 175015.51 tons
8 Bagasse used for Sugar 75025.85 tons 98813.80 tons
9 Bagasse used for Distillery -- 20072.72 tons
10 Bagasse saved % on cane Nil 8.65 % on cane
11 Reduction in Steam Consumption -- 18 % on cane
10
Fig. 3: Actual plant image after modification and addition of new equipment in phase 1
• Existing 1st & 5th mill replaced by 33’ ×

66’ with planetary gear box & AC motor.
and reduction in steam consumption • Existing Mill No. 2 replaced by 36’ × 72’
30% on cane from 36% on cane with planetary gear box & AC motor.
In off-season 2022, the Jai Bhavani • Installation of One New Rotary Juice
management decide for further expansion of Screen of size 1800 mm × 4500 mm.
the plant from 3600 TCD to 5000 TCD with
• All three boilers were repaired & its ID,
reduced steam consumption 30% on cane. For
FD & SA fans were also replaced hence
this phase 2, some modification, addition and
total capacity of Boiler reached to 85 TPH.
alteration have been done in the plant. The
cane density enhancer in between the first • The new Turbine of 8 MW installed to
feeder table & second feeder table is installed improve the turbine efficiency and meet
for leveling the cane and due to this density out the entire power demand of complex.
of cane blanket was increased. This helped a
• Condensate heat recovery in two steps
lot to avoid the civil and mechanical work of first as SJ Heating followed by RJ heating
increase in cane carrier width as well as all was implemented.
existing preparatory devices are retained as it
is. Sugarcane crushing achieved up to 5500 • Replacement of Juice/Syrup sulphiters &
addition of Clarifier, Vacuum Filter,
TCD on existing carrier width of 1500 mm
Centrifugal Machine for ‘A’ massecuite
and cane carrier length increased by 14 meter
curing, hopper battery & sugar weighing
and height increased by 300 mm. Some other
duplex machine.
modifications have been made as per below.
• Added two more Falling Film Evaporators
• Fibrizer existing steam turbine drive (FFEs) of heating surface area of 4000 m2,
replaced by 1000 HP 750 RPM, 11 KV HT vapor bleeding from 4th effect of
motor at both sides. evaporator to pan was practiced.
11
Fig. 4: The evaporator configuration or vapour bleeding scheme for 3600 TCD to 5000 TCD
expansion with reduction in steam demand 30% on cane from 36% on cane in phase 2
• From syrup concentration three more bodies configuration of vapour bleeding scheme is
were kept in operation & vapour bleed to shown in figure 4.
RJ Final & SJ Heating from this bodies. Highlight of plant in phase 2 after
modernization is given below:
• Old design batch pan of capacity 40 MT was
replaced by highly efficient honey comb type 1 Plant Capacity : 5000 TCD (225 TCH)
80 MT batch pans with circulators. 2 Milling Tandem : 5 Mills
1stand 5th Mill 33’ × 66’
• The present Distillery is in operation with 2nd Mill 36’ × 72’
steam requirement 10 TPH and power 3rd and 4th Mill 30’ × 60’
requirement 800 to 1000 kWh from 3 Boiler Capacity : 25 t/h @ 21 kg/cm2 - 2 Nos.
35 t/h @ 21 kg/cm2 - 1 No.
existing boiler & turbine.
4 Turbine Capacity : 8 MW Back Pressure
The expansion and modernization of the 5 Juice Heater : Tubular Type and DCH
plant in in phase 2, the sugar plant achieved 6 Evaporator : FFEs & Existing Robert
30% steam consumption with expanded plant Type
crushing capacity 5000 TCD in crushing 7 Vacuum Pans : Batch Pans with
season 2022-23 and was balanced on 8 MW Mechanical Circulators
turbine generation. The evaporator

12
8 M/c. Boiling Scheme : 3 M/c. Boiling • The new Juice Sulphitor 320 HL & Syrup
9 Final Product : White Plantation Sugar Sulphitor 105 HL are added.
10 Steam Consumption : 30% on Cane
• A new Vacuum Filter of 14 × 28 is added
The list of addition of new equipment in with all accessories.
phase 2 for plant capacity expansion and
reduction of steam consumption with all • One spray pump 3200 m3/h is added along
modifications and alterations are described below. with modification of spray pond.
• Fibrizer turbines removed & AC motors • New B & C Sugar Melter of 30 t/h is
installed 1000 HP 750 RPM, 11 KV HT added.
motor at both sides.
• A new batch type Machine for
• 2 nos. of FFEs of heating surface area of
A-Massecuite curing of capacity 1750
4000 m2 each as first and second effect.
kg/charge with pugmill is added.
• Installation of Condensate Duplex Type
Heater for SJ1 & RJ1. • A new hopper battery of 30 TPH is added
along with duplex type weighing machine.
• 1 no. of new Batch Pan 60 ton added and
existing batch pan 40 ton replaced with In this expansion cum modernization of
new batch pan 80 ton. the sugar plant achieved 30% steam
consumption with capacity 5000 TCD and
• Evaporator body isolation arrangement for
balanced on 8 MW turbine generation. The
avoiding general cleaning.
results achieved are tubulated in table 3 and
• A new clarifier of 2200 HL is added to actual plant image after modification in fig. 5
the existing civil foundation. in phase 2 are given below.
Table 3: Comparison of the parameters of phase 1 and phase 2
Phase-1 (Before After Modification

Sr. No. Particular
Modification) in phase-2
1 Cane Crushing Capacity 3600 TCD 5000 TCD
2 Total Cane Crushed 6200804.24 tons 619878.159 tons
3 No. of Days 202 days 134 days
4 Power Generated 12398775.00 kWh 14623936.00 kWh
5 Power consumption per TCH Sugar 18.62 TCH 22.60 TCH
6 Power consumption per TCH Sugar + Distillery 18.58 TCH 23.59 TCH
7 Bagasse Generated 175015.51 tons 177427.982 tons
8 Bagasse used for Sugar 98813.80 tons

95533.251 tons
9 Bagasse used for Distillery 20072.72 tons
10 Bagasse Saved % on cane 8.65 13.25
11 Reduction in Steam Consumption 18 % 5.96%
13
Fig. 5: Actual plant image after modification and addition of new equipment in phase 2
After addition of energy efficient modern sugar plant mainly the expansion from 2500
equipment, alternation and modification in TCD to 5000 TCD and reduction in steam
the existing bleeding scheme by Spray consumption 30% on cane from 54% of phase
Engineering Devices Limited, Mohali, this -1 and phase-2 are given in table 4 with other
plant is performing satisfactory continuously parameters also.
as per proposed parameters. A summary of
performance parameters of the Jai Bhavani
Table 4: Summary of performance parameters of phase 1 and phase 2
Sr. No Parameters PHASE-1 (3600 TCD) PHASE-2 (5000 TCD)

1 Crushing rate (24 hours) 150 TCH 225 TCH
2 Steam available from boiler 55 TPH 65 TPH
3 Total steam generation capacity 75 TPH 85 TPH
STEAM DISTRIBUTION /CONSUMPTION
1 Turbo generator Installed 2.5 + 1.5 = 4 MW 8 MW
2 Inhouse load 4 MW 5.5 MW
3 Steam required for Turbine 46 t/h 55 t/h
4 Fibrizer Turbine 1000 BHP (80 % average load) 8.57 t/h Nil
5 Steam for distillery 4.0 t/h 10.0 t/h
6 Through PRDS Nil 10.0 t/h
7 Total exhaust steam available for process 54.57 t/h 65.00 t/h,
8 Misc. use of high press steam 7 bar@ 3% 0.5 Nil
9 Process steam consumption 36 % on cane 30 % on cane
14
Conclusion technology for reduction in energy demand in

The present study shows that the the sugar plant is need of the hour and it
performance parameters of this sugar mill should be implemented for sustainability and
and analyzed with the aim of key-selected growth of the sugar plants.
parameters which enable to test commonly Acknowledgements
stated theories for energy efficiency
Authors are thankful to management
improvements in sugar mill towards real
and whole process engineering team of Jai
operation parameters. The initial plant
Bhavani for their continuous support and
capacity was 2500 TCD with 54% steam
cooperation during project implementation as
consumption and after addition of some
well as Spray Engineering Devices Limited,
energy efficient modern equipment and
Mohali, Punjab for technical data collections
modification in the existing bleeding scheme,
and compilation for this technical paper and
the plant capacity was expanded to 5000 TCD
sugar project.
with reduced steam demand 30% on cane. The
sugar mills are the energy-consumed industry References
sector which currently consumes steam on 1. Report of the task force on the sugarcane and
average 42-48% on cane that steam demand sugarcane industry, March 2020, NITI Aayog,
can be reduced up to 25% on cane or even Government of India, 01-87. (10_Report_of_
below after addition and modification of the_Task_Force_on_Sugarcan_and_Sugar_Ind
ustry_0)
available and proven innovative technologies,
products, and cost-effective solutions. The 2. Energy conservation in sugar industries, A.N.
Pathak, J. of Scientific and Industrial
sugar plants can be managed and operate
Research, 1999, Vol. 58, 76-82.
without boiler also. With the use of modern
3. Modern innovation to reduce energy
innovative principles, sugar mills can reduce
consumption, Vivek Verma, 50th Year Golden
the steam consumption and subsequently able Jubilee Souvenir, National Federation of
to achieve tremendous bagasse and energy Cooperative Sugar Factories, New Delhi, 2010,
saving. The optimization of energy 101-117.
consumption in sugar factories can also be 4. Increased rankine cycle and evaporators
important to evaluate the cost of process efficiency to reduce more power to crush more
steam demand reduction. This factory’s with 25% steam consumption, A K Mishra and
Vivek Verma, Proceedings of 10th Joint
achievement for lower energy consumption
Convention of STAI & DSTA, (2011), 45-48.
with respect to the capex is a clear indicator
5. Innovation in the area of energy efficiency and
on how we can improve the bottom line of the
conservation in sugar industry, A K Nanda,
sugar plants so that it become profitable on Vivek Verma and G P S K Deekshitlu,
sustainable basis. The right decision for Proceedings of 67th Annual Convention of
selection and adoption of the suitable STAI, 2006, 54-75.
15
Maximizing Energy Efficiency through Cogeneration
Chandrasekaran R., Sakthivel P.C., Anand M.

(DGM-Engineering), (AE-Instrument), (AE-Electrical) Ponni Sugars Erode Limited, Tamil Nadu.
rc@ponnisugars.com
Abstract Sugars maximizes energy utilization while

This paper delves into the implementation and impact minimizing waste, aligning with their
of cogeneration technology at Ponni Sugars (Erode) dedication to sustainable practices. The
Limited, a leading player in the sugar industry. integration of bagasse into their cogeneration
Cogeneration, or combined heat and power (CHP), is operations not only enhances energy
a proven technique for maximizing energy efficiency independence by reducing reliance on fossil
by simultaneously producing electricity and useful fuels but also plays a pivotal role in
heat from a single fuel source. The study highlights mitigating greenhouse gas emissions.
Ponni Sugars’ adoption of cogeneration, exploring its
Economically, leveraging bagasse offers
benefits in terms of energy savings, cost reduction, and
tangible benefits, including cost savings from
environmental sustainability. Through a detailed
analysis of the cogeneration system’s design, operation, reduced external fuel procurement and
and performance, this paper provides insights into revenue generation through surplus electricity
best practices for optimizing energy efficiency in sales. Moreover, Ponni Sugars’ adherence to
similar industrial settings. regulatory frameworks incentivizing
renewable energy usage further underscores
Introduction the strategic significance of biofuel
Cogeneration presents a promising integration. In essence, the incorporation of
solution for improving energy efficiency in bagasse into their cogeneration endeavours
industrial processes by harnessing waste heat not only drives efficiency and economic
for additional power generation. Ponni Sugars prosperity but also underscores Ponni Sugars’
(Erode) Limited, recognizing the potential unwavering commitment to environmental
benefits of cogeneration, has invested in this stewardship within the sugar industry.
technology to enhance its operational
efficiency and sustainability. This paper Operational Strategies
examines the cogeneration system deployed at Effective operation of the cogeneration
Ponni Sugars, focusing on its design system involves optimizing various parameters,
principles, operational strategies, and including steam pressure, temperature, and
performance outcomes. flow rates. Ponni Sugars employs advanced
control systems and monitoring tools to ensure
Cogeneration System Overview efficient operation and maximize energy output.
Ponni Sugars (Erode) Limited’s Additionally, the system is integrated with the
cogeneration system stands as a testament to sugar production process to align power
their commitment to sustainability and generation with plant demand, further
enhancing overall efficiency.
efficiency in the sugar industry. This system,
comprising high-efficiency turbines or engines Implemented Energy Saving Techniques
alongside heat recovery equipment like heat in Our Plant.
exchangers and boilers, exemplifies their
innovative approach to energy management. Objective 1: Enhancing Efficiency
At the heart of this operation lies the through Automation of Alternator
utilization of bagasse, a by-product of sugar Coolers Control Valves
production, as a renewable fuel source. By Our Factory has a 19 MW synchronous
harnessing this abundant resource, Ponni generator with water cooling system. Four
16
water coolers installed with a capacity of efficiency. This automation initiative seeks to
40 m3/hr each. Initial design required minimize manual intervention, thereby
120 m3/hr cooling water for 100% generator reducing energy consumption and improving
output. Site conditions led to increased cooling productivity. Additionally, implementing
water utilization of 160 m3/hr. automated sealing air control will bolster
Coolers kept fully open regardless of safety measures and ensure compliance with
power generation for risk mitigation.Added regulatory standards. By automating this
two pneumatic control valves and a bypass critical aspect of boiler operations, our
system. Control valves respond to winding company aims to optimize combustion
temperature for automatic regulation. Manual conditions, increase reliability, and achieve
intervention and operation eliminated for greater operational excellence.
optimized water inlet.
Benefits achieved
• Achieved energy savings in cooling water
Benefits achieved
pumping system: 83 kWh/day.
As a result of this automation, Ponni
• As a result of this automation, Ponni Sugars anticipates annual savings of Rs 1
Sugars anticipates annual savings of Rs lakh.
1.32 lakh.
Objective 3: Silo Door Automation system
Objective 2: Automation of Sealing Air Our factory has a 95 TPH travelling
and Coal Spreader Air Flow Control grate type bagasse fired boiler (installed in
In our company’s operational framework, 2012). Designed to use bagasse, bagasse pith,
sealing air control lacked automation, and coal as fuels. Initially had manual fuel
resulting in inefficiencies and performance feeding system for the designed fuels. Faced
limitations. The objective is to introduce issues during operation with various fuel
automation to regulate sealing air flow with sizes, including fuel feeder shaft cuts (4-5
precision, aiming to enhance operational occurrences per month).
17
Identified root cause: Fuel compression Objective 4: Implementation of Fan-less

during fuel silo levelling with different fuel Cooling Tower
sizes. Our objective is to replace the current
We demonstrated operational excellence cooling system, which relies on four electric
by implementing changes: fans, with a fan-less cooling tower. The
existing setup consumes excessive power,
• Replaced manual fuel feeding doors with leading to inefficiencies and higher energy
electrically actuated ones. costs. By transitioning to a fan-less design, we
• Silos equipped with level sensors for anticipate significant energy savings, reduced
monitoring fuel levels. maintenance needs, and enhanced reliability.
This shift aligns with our sustainability goals
• Silo level feedback controls actuation of
and demonstrates our commitment to cost
fuel feeding doors.
reduction and environmental stewardship
• Front-end fuel conveyor speed adjusted
based on silo level to maintain balance.
Multiple fuel feeding points on-site, all
controlled through automation.
Benefits achieved
As a result of this automation, we
anticipate annual savings of Rs 2.5 Lakhs
Objective 5: Improved Energy Efficiency

through Steam Utilization Optimization:
(9 ATA extraction steam utilized for TG

gland sealing and steam ejector)
By utilizing 9ATA extraction steam from
the turbine generator (TG) for gland sealing
Benefits achieved and steam ejector purposes instead of
• Consistent main steam pressure due to 110-9ATA live steam, significant energy
proper fuel feeding. savings have been achieved.
• Reduced wear and tear of conveying and For the steam ejector operating with
feeding equipment. 9ATA bleed, 1 ton per hour (24 tons per day)
As a result of this automation, Ponni of steam at 10 kg/cm2 and 180°C is utilized,
Sugars anticipates annual savings of Rs 65000 totalling 5976 tons (5,976,000 kg) over 249
days. This results in an energy saving of
3,950,136,000 kcal, equivalent to 1580.05 tons
of fuel.
18
at steam pressure and temp is 105 kg/cm2

and 520 deg Celsius with running days of 249
Total steam quantity utilized
⎛ Total quantity ⎞ ⎛ No of days ⎞

=⎜ ⎟×⎜ ⎟
⎝ of steam perday ⎠ ⎝ operation ⎠
= 24 × 249
= 5976 tons of steam (which is 5976000 kg of steam)
Therefore, the energy saved is (energy of

Similarly, for the steam ejector operating steam × qty of steam)
with main steam, 1 ton per hour (24 tons per
day) of steam at 105 kg/cm2 and 520°C is = 5976000 × 816
utilized, totalling 5976 tons (5,976,000 kg)
= 4876416000 k cal
over 249 days. This yields an energy saving
of 4,876,416,000 kcal, equivalent to 1950.56 In terms of fuel saving
tons of fuel.
Total thermal Energy saved (Kcal)
Calculations =
⎛ Kcal ⎞
Fuel Calorific value ⎜ ⎟
Enthalpy of steam at above condition is ⎝ kg ⎠
661 k cal/kg
4876416000
=
Total steam quantity utilized 2500 × 1000
⎛ Total quantity ⎞ ⎛ No of days ⎞ = 1950.565 tons

=⎜ ⎟×⎜ ⎟
⎝ of steam per day ⎠ ⎝ operation ⎠
Total fuel saved is (Live Steam PRDS
= 24 × 249
consumption – 9ATA bleed consumption)
= 5976 tons of steam (which is 5976000 kg of steam) = 1950.56 − 1580.05 tons
Therefore, the energy saved is (energy of = 370.51 tons per year

steam × qty of steam)
This significant reduction in fuel
= 5976000 × 661 consumption underscores the efficiency and
cost-saving benefits
= 3950136000 k cal
In terms of fuel saving Benefits achieved

Energy Conservation: Utilizing 9ATA
Total thermal Energy saved (Kcal)
= extraction steam minimizes live steam PRDS
⎛ Kcal ⎞
Fuel Calorific value ⎜ ⎟ consumption, conserving energy resources.
⎝ kg ⎠
Cost Reduction: Lowering live steam
3950 × 136000
= PRDS usage directly translates to cost savings
2500 × 1000
for the company.
= 1580.05 tons
Environmental Impact: Efficient steam
Qty of Steam Used for Ejector with main utilization reduces greenhouse gas emissions,
steam = 1 Ton per hr (i.e., 24 tons per day) aligning with sustainability goals.
19
Operational Efficiency: Optimized steam zone temperature, and furnace temperature.

usage improves overall operational We developed logic where these five reference
performance and reliability. parameters work together to keep the single
parameter, steam pressure, constant.
Objective 6: Development of DCS logic
for boiler operation with multiple inputs "Improved DCS logic in maintaining
steady steam pressure with multi-fuel feeding
In 2012, we installed a 95 TPH
with different characteristics offers several
travelling grate type bagasse-fired boiler
advantages in terms of efficiency, emissions,
designed to use bagasse, bagasse pith, and
coal as fuels. However, due to a bagasse and overall power generation. Let’s delve into
shortage, we had to switch to alternative the specific benefits mentioned:
bio-fuels. After conducting trials with nearly
1. Constant Furnace Temperature:
150 different fuels, we narrowed it down to a
Stable furnace temperature, which is
minimum of 14 suitable fuels based on trial
crucial for optimal combustion efficiency.
results. Despite this selection, fluctuating
Fluctuations in steam pressure can lead
parameters in boiler operation persisted due
to the varying calorific values of the fuels. As to temperature variations, causing
a result, fuel consumption increased, leading incomplete combustion, increased fuel
to higher emissions of particulate matter consumption, and higher emissions.
(SPM).
2. Boiler Steam Flow Increment: The
Solution Provided: To streamline boiler boiler can maintain a consistent steam
operation, we focused on maintaining the flow rate, ensuring a steady supply of
main parameter as steam pressure, with steam for downstream processes. This
reference parameters including fuel silo level, consistency is essential for maintaining
O2 percentage in the boiler, superheater coil the desired operating conditions of
20
turbines, heat exchangers, and other the power plant. The new DCS logic
steam-driven equipment. minimizes abnormal alarms in the DCS,
ensuring smooth operation and reducing
3. SPM Reduction: SPM (Suspended
operator workload.
Particulate Matter) refers to fine
particles suspended in the flue gas. This 9. Enhanced Lifespan of Critical
new DCS logic helps to reduce SPM Equipment: The new DCS logic helps to
emissions by promoting complete reduce stress on critical equipment such
combustion and minimizing the as travelling grate, superheater coils,
formation of soot and ash particles. turbines and piping by maintaining
constant furnace temperatures. This
4. ESP Stable Operation: ESP
extends their lifespan, minimizing
(Electrostatic Precipitator) is a device
maintenance costs and downtime.
that removes particulate matter from
flue gas. Stable steam pressure ensures 10. Operators Can Concentrate on Other
consistent flue gas flow and properties, Works: With a stable furnace and fuel
allowing the ESP to operate at peak feeding due to constant steam pressure,
efficiency, effectively capturing and operators can focus on other tasks,
removing particulate matter. improving overall plant productivity and
efficiency.
5. Ash Quantity Reduction: By
promoting complete combustion and Objective 7: Adding Variable Frequency
reducing SPM emissions, the new DCS Drives (VFDs) to Existing Direct on Line
logic also contributes to a decrease in the (DOL) starters
overall ash quantity produced. This
Adding Variable Frequency Drives
reduction in ash minimizes disposal costs
(VFDs) to existing Direct On Line (DOL)
and environmental impact.
Starters involves retrofitting the motor control
6. Higher Power Generation: The system with VFDs to enable variable speed
combined benefits of efficient combustion, operation. This conversion allows for precise
reduced emissions, and stable steam flow control of motor speed and torque by
contribute to an overall increase in power adjusting the frequency and voltage supplied
generation. Improved DCS logic in to the motor, optimizing energy consumption
maintaining steady steam pressure ensures and enhancing operational efficiency. By
that the boiler operates at its optimal implementing VFDs, DOL systems can
capacity, maximizing energy output. achieve significant energy savings, reduce
mechanical stress on equipment, and extend
7. Steadiness in Auxiliary the lifespan of motors, making it a
Consumption: The new DCS logic helps cost-effective solution for improving overall
to reduce fluctuations in auxiliary power system performance and sustainability.
consumption, which is the energy used
to operate auxiliary equipment in the Fire Hydrant Jockey Pump: Installed a
power plant. This improves overall Variable Frequency Drive (VFD) to regulate
energy efficiency and reduces operating the speed and torque of the fire hydrant
costs. jockey pump, resulting in energy savings of
16,704 kWh/ annum.
8. Smooth Operation of DCS: The
distributed control system (DCS) Condensate Extraction Pump-2:
monitors and controls various aspects of Implemented a VFD for Condensate
21
Extraction Pump-2, leading to energy savings inefficiencies are promptly addressed through
of 17,400 kWh per annum. corrective measures to maintain optimal
system performance.
RO Plant High-pressure Pumps and CPU
DG Transfer Pumps: Installed VFDs for Benefits and Impact
the RO plant high-pressure pumps and CPU
The adoption of cogeneration technology
DG transfer pumps to optimize energy usage,
has yielded significant benefits for Ponni
contributing to energy savings.
Sugars, including reduced energy costs,
Bagasse Conveyor BC-2 & BC-3: Utilized enhanced reliability, and reduced
VFDs for Bagasse conveyor BC-2 & BC-3 to environmental footprint. By utilizing waste
enhance conveyor efficiency and reduce energy heat for power generation, the company has
consumption during operation. achieved higher energy conversion efficiencies
compared to conventional power generation
Wet Scrubber System Pumps:
methods. Moreover, the use of renewable
Implemented VFD installation for wet
biomass fuel aligns with Ponni Sugars’
scrubber system pumps to optimize their
commitment to sustainable practices and
operation and energy consumption while
environmental stewardship.
ensuring effective air pollution control.
Energy Efficient Air Compressor: Conclusion

Installed an energy-efficient air compressor, Ponni Sugars’ experience with
aiming to reduce energy consumption and cogeneration serves as a compelling example
improve overall compressed air system of how industrial facilities can improve energy
performance. efficiency and sustainability through
VFD for Hot Condensate: Installed a VFD innovative technologies. By leveraging
for hot condensate system, providing variable cogeneration, Ponni Sugars has not only
speed control and optimizing energy usage. reduced its reliance on conventional energy
sources but also positioned itself as a leader
Mechanical Spreader VFD: Implemented a
in environmentally responsible sugar
VFD for the mechanical spreader, allowing for
production. The lessons learned from Ponni
variable speed operation and enhancing
Sugars’ cogeneration journey offer valuable
energy efficiency.
insights for other industries seeking to
C1 and C1A Coal Screw Feeder: optimize energy usage and mitigate their
Introduced VFDs for the C1 and C1A coal environmental impact through integrated
screw feeders, optimizing their operation and energy solutions.
reducing energy consumption during coal
feeding processes. Acknowledgement
Author is very much thankful to M/s
Performance Evaluation
Ponni Sugars Management,
Through rigorous performance
monitoring and analysis, Ponni Sugars Shri N. Gopalratnam Chairman, Shri
evaluates the efficiency and effectiveness of its N. Ramanathan Managing Director, Shri K.
cogeneration system. Key performance Yokanathan President& CFO, Shri B.
indicators such as electrical efficiency, Chandrasekar Sr. Vice President
thermal efficiency, and overall energy savings (Operations) and Shri A. Ravikumar
are regularly monitored and benchmarked General Manager (Engineering) for their
against industry standards. Any deviations or valuable guidance in writing this article.
22
Energy Conservation Best Practices in the Sugar Industry

with Advanced Technology and Modern Equipments
Chinnappan N., Balakrishnan K., Saravanan V., Annadurai R., Sudalaikan S.
Executive Director, General Manager (Tech.), Dy. General Manager, - Sr. Manager (Process),
Sr. Manager (Co-gen), Dhanalakshmi Srinivasan Sugars Pvt. Ltd., Perambalur
Abstract Plant installed with 3500 TCD sugar

The Sugar Industry an agro based industry. The plant, 23MW co-generation and 60 KLD
second largest industries in India is consuming lot Distillery in the year 2009-10.
of energy in the form of steam, Power, water, fuel
and oil. Govt. of India setup BEE in March 2002 Mills - Two roller Mills – 4 nos. with
inline shredder with H.T. motors.
under the provision of Energy conservation act
2001. Government of India has published a gazatte Mill Drive - A.C. Motors, Donnely chute
th
notification S.O 2523(E) dated 6 June, 2023 that Gears - All Planetary
covers the industry consuming 10000 MTOE of
Motors - with VFD and energy efficient
annual energy or more to be categorised “designated
consumers” under the energy conservation act.
Boiling House
BEE has brought sugar sector to PAT (practice
achieve and trade) which is a regulatory instrument JHs - all DCH
to reduce specific energy consumption. Clarifier - SRT
Evaporators - FFE with CIP for cleaning
At this situation Energy reduction and energy
conservation plays an important role in sugar PANS - Vertical continuous pans with
sector. mechanical circulators
Crystallizers - one each R1, R2 and A
Energy conservation and energy reduction measures
massecuite. Vertical crystallizer
taken over the past 40-50 years in Indian Sugar
for B and C (one each)
industry is very significant. The actions required for
the future is discussed. Centrifugals - continuous for B and C
- Batch for A and Refinery
Key Words: Energy conservation and efficiency, massecuite
milling, evaporators, condensers tubular heater and
Hoppers - One fluedized bed with normal
DCH, Batch and continuous pans, vapour bleeding,
hoppers – 2 nos.
batch and continuous centrifugals. Hoppers driers,
cooling systems. Grading - Sizers with sugar bins
This factory is designed for 33 percent

Introduction
steam on cane and 27 units power tonne cane.
The sugar industry is an energy We could achieve up to 31 percent steam on
intensive industry where there is lot of scope cane with 26.5 units power. (including
for reduction and conservation of energy in refinery). The lowest figure achieved is steam
the form of steam, power, fuel, water and 29.4 percent on cane. Power 25.52 units per
Man power. The steps taken to have the best tonne of cane.
practise in specific energy consumption in
Here we need uniform and consistent
sugar, co-gen and distillery of M/s.
operation of each unit.
Dhanalakshmi Srinivasan Sugars Pvt. Ltd.,
Perambalur discussed here. • Automation with DCS system helps us to
study the real time performance of each
35
Dhanalakshmi Srinivasan Sugars Pvt. Ltd., Perambalur
Factory entrance
Fluidised Bed Drier Pans & MVC area
Sugar Bins & Packing Area

unit, in the mills as well as in boiling • Hot condensate is used for Air heating of
house. the Hopper (FBD) for sugar Drying.
• Basic need – proper training of bottom • VFD for most of the motors and planetary
level workers and all operating persons. gear boxes for all the places in the sugar
• Proper maintenance of all machinery and plant helps to reduce the power consumption.
equipments to achieve the designated
performance. Future Plan
We have scope for further reduction of
• Uniform and higher rate of crushing to
steam consumption. By fixing targets for each
the installed capacity or even more than
area, the employees are giving continuous
the installed capacity up to 110-115%.
training and awareness in the areas of rejections
• FFE needs regular cleaning (descalling of of products, reducing the recycling, food safety,
tubes) to achieve the required performance. human safety and Environmental safety.
• Syrup Brix 68-72 is maintained.

Conclusion
• All pans works in continuous mode with In energy conservation and energy
forth vapour of the evaporators. efficiency continual improvement is possible at
• R.J. heating with pan vapour & 5th all times. Since Sugar Industry is an agro
Vapour based industry fixing of specific energy
consumption target is to be discussed in detail
• D.J. with 4th, 3rd and 2nd vapour since the Raw material (sugarcane)
• C.J. heating with 1st vapour availability varies from region to region based
on availability of water and competitive crops
• All juice heaters DCH and no need for like maize, cotton, Banana and tapioca.
cleaning which reduces use of huge man
power. With all these odds, it is the
responsibility of (us) technocrats in the
• With SRT and FFE, the retention time of Industry to work constantly to improve the
juice and syrup is very short which keeps efficiency of all the machines and equipments
the inversion loss of sugar very minimum. (to reduce the energy consumption) for the
• Heat recovery from condensate (flash sustainability of sugar and allied Industry.
system) improves the performance of
Falling Film Evaporators. Acknowledgement
We are thankful to our management for
• Automation – Eliminate human error,
encouraging to study deeply on this and
consistency in performance and help real
support by the entire team of our Factory for
time data collection.
collecting datas required.
• Flow meters for all liquids (including
massecuite) in the sugar plant is provided. Reference
• Exhaust steam is used only in the first 1. DPR and related equipment drawings.
effect of the evaporator.
37
Sugar Industry – Technological Advancements in Steam Saving
Chandrasekar B., Ravikumar A.
Sugar Industry – Technological Advancements

in Steam Saving
Vice president (Operations), General Manager (Engineering)
Ponni sugars (Erode) Limited., bcs@ponnisugars.com
Introduction environmental footprint, and maintain their

The sugar industry is a significant competitiveness in the global market. This
contributor to the global economy, playing a paper aims to provide valuable insights and
vital role in providing sweeteners for various guidance to sugar industry stakeholders
food and beverage products. However, it is seeking to embark on the journey towards
also one of the most energy-intensive energy conservation and sustainability.
industries, consuming substantial amounts of
(A) Falling Film Evaporator
energy in the form of electricity, steam, and
fuels for its operations. With increasing In the sugar industry, falling film
concerns about environmental sustainability evaporators play a pivotal role in the
and rising energy costs, there is a pressing concentration of sugar solutions. These
need for the sugar industry to adopt measures evaporators operate by allowing a thin film of
to conserve energy and reduce its liquid to flow down a vertical tube while
environmental footprint. steam is used to heat the liquid, causing
evaporation and concentrating the solution.
Energy conservation in the sugar industry
Despite their widespread use, traditional
is crucial not only for reducing operating costs
falling film evaporators are often associated
but also for minimizing greenhouse gas
with significant energy consumption due to
emissions and mitigating the industry’s impact
inefficient design and operation.
on climate change. By implementing
energy-efficient technologies and practices, By optimizing the design, operation, and
sugar mills can enhance their competitiveness maintenance of falling film evaporators, sugar
while simultaneously contributing to global mills can significantly reduce their energy
efforts to combat climate change. consumption, improve process efficiency, and
enhance overall sustainability.
This technical paper aims to explore
various strategies and technologies for energy Enhanced Heat Transfer Efficiency: One
conservation in the sugar industry. It will of the primary opportunities for energy
delve into the specific energy-intensive savings lies in improving heat transfer
processes involved in sugar production, such efficiency within falling film evaporators. This
as cane crushing, juice extraction, can be achieved through the use of advanced
evaporation, crystallization, and drying, and heat transfer surfaces, such as enhanced
identify opportunities for improving energy tubes or plates, which facilitate more efficient
efficiency at each stage. heat transfer between the heating medium
(steam) and the sugar solution. Additionally,
In conclusion, energy conservation is
optimizing the flow dynamics within the
paramount for the long-term viability and
evaporator tubes can minimize heat transfer
sustainability of the sugar industry. By
resistance and reduce energy losses.
adopting innovative technologies, optimizing
processes, and fostering a culture of energy Temperature and Pressure Control:
efficiency, sugar mills can minimize their Precise control of operating parameters,
energy consumption, reduce their including steam pressure, temperature, and
38
flow rates, is essential for maximizing energy monitoring and adjustment of these
efficiency in falling film evaporators. parameters, maximizing energy savings.
Implementing advanced control systems and
In summary, falling film evaporators
automation technologies can enable real-time offer the sugar industry a proven pathway to
monitoring and adjustment of process achieve substantial energy savings. By
parameters to ensure optimal performance leveraging their efficient heat transfer
while minimizing energy consumption. mechanisms, optimizing process parameters,
Heat Integration and Optimization: integrating heat across production systems,
Integrating falling film evaporators with other and implementing rigorous maintenance
process units within the sugar mill can practices, sugar mills can enhance their
further enhance energy efficiency. Heat competitiveness while reducing their
integration strategies, such as utilizing excess environmental footprint.
heat from other processes or recycling heat
(B) MEE configaration
from evaporator condensate, can reduce the
overall energy demand of the sugar production Efficient configuration of multiple effect
evaporator (MEE) systems is instrumental in
process.
improving energy conservation in the sugar
Regular Maintenance and Cleaning: industry. Here’s an exploration of the factors
Proper maintenance and cleaning of falling and strategies involved:
film evaporators are critical for ensuring
Principle of Multiple Effect Evaporation:
optimal performance and preventing fouling or
Multiple effect evaporators operate on the
scaling, which can impair heat transfer
principle of using the vapor generated in one
efficiency and increase energy consumption.
effect to heat the subsequent effect, thereby
Routine inspection, cleaning, and servicing of
reducing the overall energy input required for
evaporator components can help mitigate
evaporation. This cascading effect allows for
fouling issues and maintain peak
significant energy savings compared to
performance.
single-effect evaporators.
Low Residence Time: Falling film
Optimal Number of Effects: Determining
evaporators operate with relatively low
the optimal number of effects in an MEE
residence times, meaning the liquid spends
system is crucial for maximizing energy
less time within the evaporator system. This efficiency. Adding more effects increases the
short processing time reduces energy concentration gradient between the heating
requirements, as less energy is needed to medium and the feed, thereby enhancing
maintain the desired temperature and energy savings. However, there’s a
concentration levels. diminishing return in energy savings with
each additional effect, as the complexity and
Optimized Process Parameters: Sugar
cost of the system also increase. Therefore,
mills can optimize various operating
careful analysis and optimization are
parameters of falling film evaporators to
necessary to strike the right balance between
further enhance energy efficiency. This
energy savings and capital investment.
includes controlling steam pressure,
temperature, and flow rates to ensure optimal Steam Economy and Heat Integration:
performance while minimizing energy Efficient steam utilization is essential for
consumption. Advanced control systems and maximizing the energy-saving potential of
automation technologies enable real-time MEE systems. Heat integration techniques,
39
such as using exhaust steam from other full potential of energy conservation in the
processes or utilizing low-pressure steam in sugar industry.
the first effect, can improve steam economy
(C) Syrup Brix
and overall energy efficiency. Additionally,
The syrup brix, or the concentration of
employing advanced control systems to
dissolved solids in the sugar syrup, can have
optimize steam pressure, temperature, and
a significant influence on energy savings in
flow rates throughout the MEE system can
the sugar industry. Here’s how:
further enhance energy conservation.
Steam Consumption: Evaporators in the
Temperature and Concentration
sugar industry typically use steam as the
Gradients: Maintaining optimal temperature
heating medium. Higher syrup brix allows for
and concentration gradients across the MEE
more efficient use of steam since less steam
system is critical for maximizing energy
is required to evaporate the water. This
efficiency. Careful design considerations, such
reduces the overall steam consumption and
as proper sizing of heat exchanger surfaces
associated energy costs. Lower syrup brix, on
and optimizing feed flow rates, help ensure the other hand, leads to higher steam
efficient heat transfer and minimize energy consumption and increased energy usage.
losses.
Overall Process Efficiency: The syrup brix
Condensate Recovery and Recirculation: affects not only the evaporation process but
Recovering and recirculating condensate from also downstream processes such as
the MEE system can significantly reduce the crystallization and drying. Higher syrup brix
demand for fresh water and steam. solutions typically require less energy for
Condensate contains valuable heat energy these processes, leading to overall energy
that can be reused within the evaporator savings across the sugar production chain.
system, reducing the need for additional
In conclusion, the syrup brix plays a
heating and improving overall energy
crucial role in determining energy savings in
conservation.
the sugar industry. Higher syrup brix
Process Optimization and Control: solutions result in more efficient evaporation,
Continuous monitoring and optimization of reduced steam consumption, and improved
operating parameters, such as feed flow rates, overall process efficiency, leading to
heating medium temperatures, and vacuum significant energy savings. Proper control and
levels, are essential for maximizing energy optimization of syrup brix levels are essential
conservation in MEE systems. Implementing for maximizing energy efficiency and
minimizing production costs in the sugar
advanced process control algorithms and
industry.
automation technologies can help maintain
optimal operating conditions and minimize (D) Automation with DCS
energy wastage. A Distributed Control System (DCS)
By implementing an efficiently offers numerous benefits in sugar factory
operations, including significant energy
configured MEE system and incorporating
savings. Here’s an explanation of these
these strategies, sugar mills can achieve
benefits:
significant energy savings while maintaining
high levels of productivity and sustainability. Centralized Control and Monitoring: DCS
Proper design, operation, and maintenance of allows for centralized control and monitoring
MEE systems are essential for realizing the of various processes and equipment within the
40
sugar factory. Operators can oversee multiple visualizing energy consumption data alongside
aspects of production, including milling, process data, operators gain insights into the
extraction, evaporation, crystallization, and relationship between energy usage and
drying, from a single interface. This production output. This visibility enables
centralized control enhances operational them to implement strategies for load shifting,
efficiency, reduces manual intervention, and peak shaving, and demand management to
minimizes errors, leading to energy savings by reduce energy costs and improve overall
optimizing process parameters. energy efficiency.
Real-time Data Acquisition and Analysis: Remote Monitoring and Control: Many
DCS systems enable real-time data acquisition DCS systems offer remote monitoring and
from sensors and instruments throughout the control capabilities, allowing operators to
sugar factory. This data provides valuable access and manage plant operations from
insights into process performance, equipment anywhere with an internet connection. This
health, and energy consumption. By analyzing flexibility enables swift response to process
this data in real-time, operators can identify deviations, equipment failures, or energy
inefficiencies, optimize energy-intensive inefficiencies, minimizing downtime and
processes, and implement corrective actions optimizing energy usage even during
promptly, resulting in energy savings. off-hours.
Advanced Process Control Algorithms: Continuous Improvement and

DCS systems often incorporate advanced Optimization: DCS systems support
process control algorithms to optimize process continuous improvement and optimization
parameters automatically. These algorithms initiatives through historical data analysis
continuously analyze process variables and and performance monitoring. Operators can
adjust setpoints to maintain optimal operating analyze historical trends, identify patterns,
conditions. For example, in the juice and implement strategies for continuous
extraction process, DCS can control factors process improvement and energy optimization.
such as temperature, pressure, and flow rates By leveraging DCS for ongoing optimization
to maximize sugar extraction efficiency while efforts, sugar factories can achieve sustained
minimizing energy consumption. energy savings over time.
Energy Management and Optimization: In summary, DCS offers numerous

DCS systems facilitate energy management benefits in sugar factory operations, including
and optimization initiatives within the sugar centralized control, real-time data analysis,
factory. Operators can monitor energy advanced process control, energy
consumption in real-time, identify areas of management, remote monitoring, and
high energy usage, and implement continuous improvement. By harnessing these
energy-saving measures accordingly. For capabilities, sugar factories can optimize
instance, DCS can control the operation of energy-intensive processes, minimize energy
pumps, fans, and compressors to ensure they waste, and achieve significant energy savings,
operate at optimal efficiency levels, thereby contributing to both cost reduction and
reducing energy waste. environmental sustainability.
Integration with Energy Monitoring (E) Boiling scheme

Systems: DCS can be integrated with energy Boiling schemes in vacuum pans play a
monitoring systems to track energy usage crucial role in the energy efficiency of sugar
across different processes and equipment. By refining processes. Vacuum pans are used in
41
the final stages of sugar production to energy efficiency due to smoother operation
concentrate sugar syrup into crystallized and more consistent conditions.
sugar. Different boiling schemes refer to
In conclusion, the choice and
variations in operating conditions, such as
optimization of boiling schemes in vacuum
temperature, pressure, and time, during the
pans can have a significant impact on energy
boiling process. These schemes can
efficiency in sugar manufacturing processes.
significantly impact energy consumption and
By carefully controlling operating parameters,
efficiency. Here are a few effects of different
utilizing heat recovery systems, and
boiling schemes on energy efficiency:
optimizing process design, manufacturers can
Temperature and Pressure Control: reduce energy consumption and operational
Efficient control of temperature and pressure costs while maintaining product quality.
within the vacuum pan is essential. Lowering
the pressure inside the pan reduces the (F) Vapour bleeding system
boiling point of the syrup, allowing it to boil Vapor bleeding arrangements in a sugar
at lower temperatures, thus saving energy. industry refer to the extraction of vapor from
Additionally, precise control of temperature various stages of the sugar manufacturing
gradients across the pan can improve process for different purposes. This vapor can
efficiency by reducing heat losses. be utilized for various heating and
evaporation purposes within the sugar plant,
Evaporation Rate Optimization: thereby contributing to energy savings in
Controlling the rate of evaporation is crucial. several ways:
Too rapid evaporation can lead to increased
Multiple Effect Evaporation: Vapor
energy consumption due to higher heat
bleeding is often used in multiple effect
transfer requirements, while too slow
evaporators where vapor from one effect is
evaporation prolongs the process and may
utilized to heat the next effect. This cascading
increase overall energy usage. Finding the
of vapor helps in maximizing the utilization
optimal evaporation rate for the specific
of heat and reduces the overall energy
characteristics of the sugar syrup can improve
consumption for evaporation.
energy efficiency.
Preheating of Feed Liquor: Vapor
Automation and Control Systems:
extracted from one stage can be used to
Advanced automation and control systems can
preheat the feed liquor before it enters the
optimize the boiling process in real-time,
evaporation system. Preheating reduces the
adjusting parameters such as temperature,
amount of heat required in subsequent stages,
pressure, and feed rates to maximize
thus conserving energy.
efficiency while maintaining product quality.
Heating of Process Streams: Vapor can be
Insulation and Heat Exchanger used to directly heat various process streams
Efficiency: Proper insulation of the vacuum within the sugar refinery, such as juice,
pan and optimization of heat exchangers syrup, or water. By utilizing vapor for heating
reduce heat losses to the surroundings, purposes, the demand for external energy
improving overall energy efficiency. sources like steam boilers can be reduced,
leading to energy savings.
Batch vs. Continuous Boiling: The choice
between batch and continuous boiling Condensate Recovery: Condensate from
processes can also impact energy efficiency. vapor bleeding arrangements can be collected
Continuous processes typically offer better and returned to the boiler as feedwater. This
42
reduces the need for fresh water intake and production enables companies to assess the
the energy required to heat it, thus efficiency of each process. Deviations from
contributing to overall energy savings. optimal operating conditions can indicate
Optimized Process Design: Proper design inefficiencies or potential energy losses,
and optimization of vapor bleeding prompting adjustments to improve overall
arrangements, including the selection of process efficiency.
extraction points and the routing of vapor Equipment Performance Tracking:
streams, can maximize energy efficiency by Regular monitoring of equipment
ensuring that vapor is utilized effectively performance, such as boilers, turbines, and
throughout the refinery. pumps, helps detect any abnormalities or
Integration with Cogeneration Systems: inefficiencies that may lead to increased
Vapor bleeding arrangements can be energy consumption. Identifying and
integrated with cogeneration systems where addressing equipment malfunctions, wear and
surplus steam is used for power generation. tear, or suboptimal operation can contribute
This further enhances energy savings by to significant energy savings.
utilizing waste heat for productive purposes.
Resource Utilization Optimization:
In conclusion, vapor bleeding Measurement and monitoring of raw material
arrangements play a crucial role in energy usage, water consumption, and waste
savings within the sugar industry by enabling generation allow companies to identify
the efficient utilization of heat and steam opportunities for resource optimization. By
generated during the refining process. By minimizing waste and maximizing resource
optimizing vapor extraction points and efficiency, energy consumption can be reduced
utilizing vapor for various heating and indirectly through reduced processing
evaporation purposes, sugar refineries can requirements and associated energy usage.
significantly reduce their energy consumption
and operational costs. Real-time Control Systems: Implementing
real-time control systems that continuously
(G) Monitoring and measurement monitor and adjust process parameters based
Measurement and monitoring of various on predefined targets or algorithms can
parameters in a sugar industry can play a optimize energy usage dynamically. For
crucial role in identifying areas for energy example, automated control of heating and
savings and optimizing processes. Here’s how: cooling systems based on real-time
temperature measurements can prevent
Energy Consumption Monitoring: By
continuously measuring energy consumption energy wastage by maintaining optimal
throughout different stages of sugar production, operating conditions.
such as extraction, purification, evaporation, Energy Audits and Benchmarking:
and crystallization, companies can identify Conducting regular energy audits and
which processes are the most energy-intensive.
benchmarking against industry standards or
This allows for targeted efforts to reduce energy
best practices help identify areas of
usage in those areas through optimization or
improvement and set energy-saving targets.
technological improvements.
Measurement and monitoring data serve as
Process Efficiency Analysis: Monitoring the basis for these assessments, providing
parameters like temperature, pressure, flow insights into where energy-saving initiatives
rates, and humidity in various stages of sugar can be most effective.
43
Employee Awareness and Training: • Quintiple system of evaporator with

Providing employees with access to real-time rotational cleaning arrangement
data and training them to interpret and act
• Addition of one no. of Falling film evaporator
upon it can foster a culture of energy efficiency
resulting in first two effects as FFE.
within the organization. Empowering employees
to identify energy-saving opportunities based on • IIIrd effect vapour bleeding (partial) to Pans.
monitoring data can lead to continuous
• Installing mechanical circulators for all
improvement initiatives at all levels of the
batch pans.
company.
• Maintaining syrup and melt brix above 68
Overall, measurement and monitoring of
degrees.
parameters in a sugar industry not only help
in identifying energy-saving opportunities but • Implementation of DCS in Mill House &
also facilitate continuous improvement efforts Boiling House with appropriate logic prompts.
aimed at enhancing operational efficiency and
reducing environmental impact. • Maintaining consistent crushing rate
Ponni’s proposed plan on steam saving:

Ponni’s journey on steam reduction
• Installation of Falling film evaporators for
• Condensate flash heat recovery system the remaining III, IV & V effects.
• Addition of one no. of vertical continuous • Clear juice heating by wide gap PHE
pan using IInd effect vapour.
44
• Raw juice heating by condensate. to time. We extend our heartfelt thanks to all
the team members for their continuous
• Complete III effect vapour bleeding to Pans.
guidance and support rendered in the
• Installation of more vertical continuous execution of projects and successfully running
pans. with full understanding.
• Introducing MVR based boiling in some of we acknowledge the leadership and

the pans. guidance provided by our Management, whose
vision and encouragement have empowered us
Conclusion
to publish this technical paper.
we express our gratitude to the
Management for their unwavering support As we conclude this paper, we look
and encouragement throughout the course of forward to continuing our journey of
this endeavour. Their vision and dedication exploration and discovery, fuelled by the
have been instrumental in facilitating the collective passion and commitment of our
successful completion of theprojects from time team.
45
Ethanol from the Sugarcane as a Alternative Blended Fuel for Petrol Engine to Improve Energy Economy
Murugesan A., Prakash R., Ramesh C., Kumaravel A., Vasudevan D., Mohan K.
Ethanol from the Sugarcane as a Alternative Blended Fuel

for Petrol Engine to Improve Energy Economy
Dr. Murugesan A., Prakash R., Ramesh C., Kumaravel A., Vasudevan D., Mohan K.
Department of Mechanical Engineering, K.S.Rangasamy College of Technology, Tiruchengode – 637 215.
hodmech@ksrct.acin
1. Introduction (i) Production of the ethyl alcohols,

Ethyl alcohol (C2 H5 -OH) as a promising (ii) Properties,
alternative fuels for Spark Ignition Petrol
Engines for the following reasons; (iii) Government Initiations
2. Production of ethanol (ethyl alcohol)

(i) It is convenient to handle as a petrol at
room temperature Ethanol is the next higher member of
the alcohol family to methanol. It is produced
(ii) It can be produced from raw materials mainly by the fermentation of plant-derived
like sugar cane, corn etc. These raw materials. Its principal current uses are for
materials are either renewable or the production of alcoholic beverages and to a
plentifully available as fossil fuels. lesser extent in the chemical (including
(iii) Many of the properties of the ethonal is pharmaceutical) industries.
similar to those of petrol. Ethanol can be produced from three
different sources:
(iv) Except for aldehyde, their exhaust emissions
are lower than those of petroleum fuels. (i) Sugar containing materials
In the following sections, these aspects (ii) Starch containing materials

of using alcohols as fuels are discussed: (iii) Cellulosic materials
Fig. The schematic diagram of sugarcane ethanol production
46
In the fermentation section, by the action gasoline. Hence,. an S.I. engine need not lose
of enzymes that are added, the sucrose form any power when operating on alcohols. In fact,
of sugar is first converted to glucose. as will be shown later, because of the higher
volumetric efficiency there is about 10%
C12H22O11 + H2O (enzyme action) →
increase in the peak power output. The
2 C6H12O6 ignition limits are wider for alcohols. Hence
less throttling is required with them at
(1)
part-loads in for S.I. engines, leading to
C6H12O6 (enzyme action) → higher efficiency.
2 C2H5 − OH + 2CO2 The self-ignition temperature of the
alcohols is higher, which is reflected in their
(2) higher Octane Numbers, both Research and
In the next step, another group of Motor, compared to gasoline. Hence higher
enzymes ferment the glucose to ethyl compression ratios can be used in S.I. engines
(alcohol). with ethanol as fuel, leading to better
efficiency. Hence hot spots in the engine like
After the fermentation is over, the spark plug and the exhaust valve will
distillation is carried out to separate the have to be well cooled when using them as
ethanol. The residue of the distillation can be fuels.
used as a cattle feed. The CO2 generated can
be sold as a valuable by product, either as Table 1
compressed gas or as dry ice. Properties of Alcohols and Petroleum Fuels
3. Properties of ethyl alcohols
Property Ethyl alcohol Petrol
Ethyl alcohols have a hydroxyl radical
(OH) in their structure and hence are some Sp. Gravity at 0.79 0.72-0.75
15°C (aprox.)
times called Oxygenated fuels.. Table 1 lists
the important properties of these alcohols in Latent heat of 900 400
comparison with those of typical samples of vaporization, kJ/kg
gasoline and diesel oil. The density of the Stoichiometric A/F 9.00 14.6
ethyl alcohol is in the same range as gasoline. ratio
The stoichiometric air requirement for the Mixture heating 2970 2930
alcohols is lower (Table 1) since they already value kJ/kg of air
contain oxygen in their structure. This means (for stoic mixture)
that a larger amount of the alcohols can be Ignition Limits, 3.5 − 17.0 8.0 − 19.0
burnt in a given amount of air than gasoline. (A/F) (λ = 0.38 − 1.89) (λ = 0.53 − 1.26)
The lower calorific value of the ethyl Self ignition 557 335
temperature °C
alcohols is much lower than for gasoline.
Hence a greater amount of fuel has to be Octane Number
carried by a vehicle for the same range when Research > 100 80-90
changing over from gasoline to ethyl alcohol.
Motor 89 70-85
The combination of lower air Cetane number 8 15
requirement for combustion and lower calorific
Low calorific vale 26,880 44,100
value leads to a stoichiometric mixture
kJ/kg
heating value slightly higher than for
47
4. Central Government Initiations
Figure 2 Photographic view of launched pilot E20 fuel at Bengaluru
As part of its carbon reduction blended with 20% ethanol at the India Energy
commitments, India has launched the Ethanol Week in Bengaluru on Feb 6, 2023 towards
Blended Petrol programme to mix this biofuel the cleaner burning version of petrol as shown
with petrol to reduce the consumption of fossil in figure 2. Ethyl alcohol is a biofuel that is
fuel. India launched pilot E20 or petrol naturally made by fermenting sugar.
5. State Government Initiations

The Tamil Nadu government released March 2023 as shown in figure 3. For
the TN Ethanol Blending Policy 2023 on 18th promoting of Tamil Nadu as a green economy
Figure 3 Photographic view of launched TN Ethanol Blending Policy 2023
48
and investment hub for alternate cost-effective greenhouse gas emissions during the
green fuel, improve the farmer income, revive manufacture and combustion of ethanol aids
the sugar industry and to attract investments in the fight against climate change.
worth Rs 5000 crore in molasses/grain based
Greater octane rating
ethanol production capacity.
The octane rating of ethanol is higher
The policy seeks to support indigenous than that of gasoline. Better engine efficiency,
production of fuel grade ethanol under the performance, and combustion characteristics
EBP Programme. Due to crude oil fluctuations may result from this. Compression ratios and
prices, it is prudent for pioneer states like thermal efficiency can be increased in engines
Tamil Nadu to augment biofuel production tuned for greater ethanol blends.
within the state using indigenous sources,
which could partly insulate the import price Resistance to engine knock
shocks, address the pollution concerns and Since ethanol has a higher-octane rating
enhance agricultural output and its utilization than gasoline, it lowers the possibility of
and also it will satisfy the three Sustainable engine knock, enabling more aggressive
Development Goals (SDGs) like Affordable engine tuning and leading to a potential
and Clean energy (Goal 7), Climate Action increase in power output in engines meant to
(Goal 13) & Life on Land (Goal 15). run on E20.
6. Advantages of E20 fuel Possible financial savings

Producing ethanol in large volumes is
Renewable
less expensive than producing gasoline.
One of the key ingredients of E20 is
Considering regional market dynamics and
ethanol, which is made from renewable
governmental regulations, E20 may result in
resources like corn, sugarcane, or biomass.
lower costs for customers.
Hence, E20 is a greener and more sustainable
fuel than regular gasoline. It’s crucial to remember that while E20
has numerous benefits, there are drawbacks
Energy security and domestic production as well.
Many countries generate their own
7. Disadvantages of E20 Fuel
ethanol, which lessens their reliance on oil
imports. By generating employment in the Compatibility with existing engines:
agriculture and biofuel industries, this Not every engine on a vehicle on the
improves energy security and boosts regional road today is made to run on E20. To
economies. guarantee compatibility, manufacturers must
alter engines and fuel systems. Upgrades or
Assistance for agricultural sectors
retrofits may be necessary for older vehicles.
Ethanol manufacturing frequently
depends on crops like corn and sugarcane. Infrastructure cost
The development of biofuel from these crops Significant expenditures in additional
gives farmers new sources of income, infrastructure, such as storage tanks, pumps,
enhancing the long-term financial viability of and pipes, are necessary for the widespread
farming communities. implementation of E20.
Lower emission of greenhouse gases More corrosive

The carbon footprint of ethanol is Compared to gasoline, ethanol has
smaller than that of gasoline. Reducing different chemical characteristics, and it is
49
corrosive to several materials that are vehicles which are compatible with ethanol
frequently used in fuel systems. Component blends.
deterioration or damage could result from
compatibility problems. 8. Conclusion
BS6-II norms were introduced in April
Absorption of water
2023 in India and to be compliant, auto
Because of its hygroscopic qualities,
manufacturers had to modify their engines to
ethanol can draw moisture from the
make them compatible with E20 fuel. With
surrounding air. Phase separation brought on
E20 fuel, the automotive industry can look
by this water absorption may result in
forward to a cleaner and more sustainable
corrosion if the manufacturer doesn’t account
future in the ever-changing world of
for it.
alternative fuels. India has a goal to cover the
Agricultural effects on the environment entire country with E20 fuel by 2025. Use of
Intensive farming methods used to ethanol as blended fuel in petrol engine
produce ethanol may be a factor in increasing the efficiency, compatibility with
environmental problems such as soil erosion, various engines, environmental impact and
pesticide use, and deforestation. Utilising improve the energy economy. They can be
sustainable farming methods is essential to produced from abundant fossil fuels or from
reducing these effects. renewable fuels. As liquid fuels they can be
handled as easily as petroleum fuels.
To sum up, E20 is at the forefront of
renewable and sustainable fuels. The push
from the government too has made it
necessary for manufacturers to develop
50
Potential for Green Hydrogen Generation

in the Sugar Industry
RA Chandgude1, AP. Dhage2, SM Rao3
1
Technical Adviser and Head, PG Patil - Technical Adviser (Electrical),
2
Sugar Engineer,
3
Sugar Engineer, Sugar Engineering Department, Vasantdada Sugar Institute, Pune, Maharashtra (India)
ra.chandgude@vsisugar.org.in
Abstract reformation (SMR). However, sugar mills offer

alternative methods for producing hydrogen, such as
The western states of India boast over 7,000
pyrolysis of bagasse, water electrolysis using excess
kilometers of coastline that provide a consistent flow
electricity from co-generation, and bio-photolysis of
of wind energy. The region’s tropical climate also
bagasse, press mud, and molasses using both
makes it an excellent environment for sugarcane
biological and thermochemical components.
and other crops, and the high sun irradiance allows
for solar energy production. Additionally, the area Introduction
has many year-round rivers that can generate
electricity. Sugarcane mills and co-generation Across the globe, sugarcane is an
facilities offer several pathways for energy important crop in subtropical and tropical
production, and existing infrastructure supports regions for the production of sugar.
global efforts to develop cleaner and more Approximately 28.30 million hectares of
sustainable energy. sugarcane are cultivated in 124 countries, with
a production of about 1.80 billion metric tons.
Sugar mills are now producing green energy by
converting food into ethanol. The process involves
India is the foremost consumer and the
using juice/syrup, B & C molasses, and surplus
second-largest producer of sugar worldwide. In
power from bagasse which is a by-product of
the production season of 2021-22, India
sugarcane. This method of renewable energy is
considered sustainable and helps reduce carbon accounted for approximately 18.80% of the
footprints. Furthermore, biogas is produced from world’s sugar production and 16.20% of its
waste generated during the clarification of consumption. The nation boasts a substantial
sugarcane juice as well as from wasted wash waste 757 sugar mills with a total installed capacity
during the manufacturing of ethanol. of 431.50 lakh metric tons. Of these mills, 522
were operational with a capacity utilization
In January 2023, the Indian government announced
the National Green Hydrogen Mission, which aims rate of 91.50%. The sugar mills play a vital
to produce a minimum of 5 million metric tonnes role in the Indian economy by supporting the
of green hydrogen by 2030. This goal is aligned livelihoods of approximately 50 million
with the objective of generating about 125 GW of sugarcane cultivators and generating five lakh
related renewable energy capacity. The Ministry of direct and indirect employment opportunities.
New and Renewable Energy defines green hydrogen
as having a well-to-gate emissions level of no more Bagasse, which is a by-product of
than 2 kg CO2 equivalent per kilogram H2 as a sugarcane, is considered as the primary
12-month average. This includes water treatment, source of fuel for power generation in the
electrolysis, gas purification, drying, and sugar industry. During the sugarcane season,
compression of hydrogen. cane trash is used as an additional fuel for
power generation, and in the off-season as
Green hydrogen has several opportunities for
production due to the integrated nature of sugar well. The sugar cane roots also have
mills, by-product co-generation, and ethanol significant fibers, which can be used for power
production. Currently, India produces hydrogen by generation. Bagasse is mainly used as a fuel
combusting fossil fuels through steam methane to meet the captive steam and power demands
51
Potential for Green Hydrogen Generation in the Sugar Industry
RA Chandgude, AP. Dhage, SM Rao
of sugarcane juice extraction and processing. The Following are the possibilities of
major bio-energy source in the sugar industry is hydrogen and renewable energy sources in the
bagasse, which is utilized for heat and sugar mills,
bio-electricity generation. Molasses, which is I. Bagasse Gasification
another by-product, is used for conversion to Bagasse is a residue of the sugarcane
bio-ethanol. Press mud and spent wash are both milling process, which is primarily utilized as
used for the production of biogas and fuel for power and steam generation.
bio-composites, as well as tableware particle However, it can also undergo a
board pulp. thermochemical process called gasification to
Over the past twenty years, many sugar turn the solid biomass into a mixture of CO,
H2, and other gases, known as syngas. The
mills have installed co-generation units to
produce steam and electricity for the produced syngas can then be subjected to the
extraction and processing of sugarcane juice. water-gas shift reaction to enhance the
production of hydrogen. To create syngas, the
Once the electricity needs of the sugar mill
steam methane reforming and partial
have been met, any excess power is exported
oxidation of methane processes are used,
to state and national grids. Co-generation,
which include two steps for the production of
also known as combined heat and power
hydrogen (H2): The first step is the
(CHP), is a process that simultaneously
production of syngas (CO, CO2, and H2), and
produces both electricity and thermal energy.
the Second Step is the production of
Indian sugar mills are shifting their focus hydrogen from syngas.
from the food sector to the energy sector. They • Advantages: Utilizes an already-available
are currently producing 7.5 GW of bio-electricity bagasse. It can be integrated with the
and have the potential to produce up to 15 GW. existing infrastructure of sugar mills.
Additionally, they are generating 4.50 billion • Challenges: The purity of hydrogen
liters of bio-ethanol and have the potential to might need further processing.
produce up to 6.82 billion liters. These mills
II. Molasses Fermentation
have the potential to generate compressed
Molasses is a by-product of the
bio-gas, manufacture chemicals, organic
production of cane or beet sugar. It is
manure, and potash fertilizer. They can also
separated from sugar crystals through the
capture CO2 as a by-product. process of centrifuging. Molasses has several
uses, including for the production of potable
(A) Hydrogen Generation in the Sugar alcohol, fuel ethanol, and rectified spirit. It
Industry can also be used as animal feed. Additionally,
molasses can be fermented using specific
Hydrogen is considered as the most
bacteria, such as Clostridium species, in the
eco-friendly and sustainable fuel available in absence of light to produce hydrogen.
the universe. It is expected to play a significant
• Advantages: Biological processes
role in enhancing environmental sustainability
generally have lower energy inputs
endeavors and improving air quality. However, compared to thermochemical processes.
there exist various obstacles that prevent the
• Challenges: The yield of hydrogen can be
widespread adoption of green hydrogen. Water
lower compared to other methods.
electrolysis and the reformation of hydrocarbons Requires specific conditions like pH,
such as methane are commonly used methods temperature, and microbial culture
for producing hydrogen. maintenance.
52
III. Water Electrolysis using Excess process can be combined with dark
Electricity fermentation to enhance the overall hydrogen
The co-generation units use sugarcane yield from molasses
residue, called bagasse, to produce steam and • Advantages: Can be integrated with dark
electricity at the same time. These units fermentation for increased yield.
generate around 70-110 kWh of surplus
electricity per tonne of cane, after fulfilling • Challenges: Requires specific conditions
the energy demand of sugar plant (sugarcane and infrastructure for light exposure and
juice extraction, and processing). However, bacterial culture.
most states have recently reduced their tariffs
(B) Potential of Hydrogen generation
from Rs. 6.50 - 6.70/kWh to Rs. 3.9 -
4.75/kWh, which has created problems for I. Feedstock Availability
sugar mills with surplus electricity and techno Primary source: Bagasse, the fibrous
economics. To solve this problem, surplus matter that remains after sugarcane stalks
electricity from co-generation units and are crushed to extract the juice. It’s a rich
proposed sugar units can be used to perform source of cellulose. Additionally, a by-product
water electrolysis, which will split water into of sugar production can also be used in
hydrogen and oxygen. certain hydrogen Production processes.
• Advantages: It produces high-purity II. Technology Selection
hydrogen. Can be integrated into existing
• Gasification:
electrical infrastructure.
Gasification involves heating of bagasse
• Challenges: Efficiency is dependent on
at high temperatures in the presence of
the availability of excess electricity.
controlled amounts of air or oxygen to produce
Electrolysis equipment can be costly.
synthesis gas (or syngas). This syngas, a
IV. Steam Methane Reforming (SMR) mixture of hydrogen, carbon monoxide, and
using Biogas other gases, can then be processed further to
Biogas is produced as a result of treating enrich the hydrogen content.
press mud and distillery spent wash, which
• Steam Methane Reforming (SMR)
are generated during the clarification of
with Biogas:
sugarcane juice and the anaerobic digestion of
waste streams from sugarcane mills. This Biogas generated from molasses can be
biogas is rich in methane and can undergo reformed with steam to produce hydrogen.
steam methane reforming, which is a process This method requires a source of methane,
that produces hydrogen from methane. which can be derived from the anaerobic
digestion of molasses.
• Advantages: It utilizes waste biogas,
which might otherwise be flared or vented. III. Purification
• Challenges: It requires a consistent • Pressure Swing Adsorption (PSA):

supply of biogas with a high methane A widely used method to purify
content. SMR is an energy-intensive process. hydrogen. It works by adsorbing impurities at
V. Photo-fermentation high pressure and releasing them at low
pressure.
Some specific photosynthetic bacteria can
produce hydrogen when exposed to light. This
53
• Membrane Separation: If successfully implemented, this

transformation can turn a traditional sugar mill
Uses selective membranes that allow into a bio refinery that produces not only sugar
only hydrogen to pass through, separating it but also clean energy in the form of hydrogen.
from other gases.
(C) Considerations
IV. Integration with Existing (i) Economic Viability
Infrastructure The feasibility of any of these methods
To implement hydrogen generation, the in a real-world scenario would heavily depend
design must consider integration with the on economic considerations, including the cost
existing sugar mill operations. This could of infrastructure modifications, operating
involve using waste heat from boilers, costs, and the market price of hydrogen.
optimizing steam distribution, and using
(ii) Environmental Impact
existing storage and transport facilities.
Sustainable hydrogen production should
V. Safety Considerations consider environmental impacts, including
emissions, water usage, and waste production.
Hydrogen is highly flammable. Proper
storage, handling, and safety protocols must (iii) Infrastructure
be in place. Design considerations include leak Adapting current infrastructure to new
detection systems, explosion-proof equipment, technologies can be challenging and costly.
and proper ventilation. However, the integrated nature of sugarcane
mills and co-generation units can offer synergies
VI. Economic Considerations that might offset some of these challenges.
• Investment Cost: Initial costs for setting (D) Tentative revenue generation from
up hydrogen production equipment, hydrogen production in the sugar
modifications to existing infrastructure, industry
and training personnel.
Option - I: Bagasse gasification
• Operating Cost: Costs associated with Typically, for every tonne of sugarcane
feed-stock preparation, energy consumption, crushed, about 270-300 kg of bagasse is
maintenance, and manpower. produced. The average bagasse saving after
sugar processing is about 6-8% on cane. So,
• Revenue Streams: Apart from selling normally after sugar processing
hydrogen, potential revenue streams could 60-80 kg/tonne of cane bagasse is saved.
include selling carbon credits if the
Note
operation reduces greenhouse gas emissions.
Costs mentioned above are tentative and
VII. Environmental Impact exclude transportation costs and government
incentives if any.
Shifting towards hydrogen can
significantly reduce the carbon footprint of the Water is required only for reactions to
sugar industry. By using by-products like increase hydrogen yield.
bagasse and molasses for hydrogen production, Electricity required for gasification and
the industry can become more environmentally process equipment. Also, gasification,
friendly. However, designing the basis for purification systems, and potential CCS are
hydrogen generation is a complex process that required. Gasification of bagasse/ biomass can
requires consideration of technical, economic, yield 106.4g of hydrogen from 1000 g of dry
and environmental factors. biomass.
54
Economic Calculation
Potential If the hydrogen price is, say Rs. 320-340 /kg of = 3.192 kg × Rs.320 / kg hydrogen
revenue hydrogen = Rs. 1021.44 / tonne of cane.
Costs Fixed Cost: Capex, O & M, purification, and storage = 3.192 kg × Rs. 248/kg
costs assumed Rs. 248 / kg of hydrogen (information = Rs. 791.62/ tonne of cane
from gasification plants)
Variable Cost: Bagasse = 60 kg bagasse × Rs. 2.258/kg
= Rs. 135.48/tonne of cane
Additional = Potential revenue – Variable (bagasse) & fixed Rs. 10211.44 (Potential revenue) -
Revenue (O&M etc) costs Rs. 791.62 (O&M, etc.) -
from saved Rs.135.48/tonne of cane
bagasse = Rs. 94.34 / tonne of cane
Note
Costs mentioned above are tentative and exclude transportation costs and government incentives if
any.
Water is required only for reactions to increase hydrogen yield.
Electricity required for gasification and process equipment. Also, gasification, purification systems,
and potential CCS are required.
Gasification of bagasse / biomass can yield 106.4 g of hydrgen from 1000 g of dry biomass.
Option II: Water electrolysis by surplus The potential of Hydrogen generation

electricity through surplus co-generation electricity
Typically, for every tonne of sugarcane The surplus electricity is utilized for
crushed, about 60 kWh for Back Pressure and water electrolysis, which consumes around 9
75 kWh for condensing route electricity is liters of water and the tentative electricity
produced, which is exported to the grid. requirement for water electrolysis is about
45-50 kWh/kg of hydrogen.
Economic Calculation
1. Back pressure Route

Surplus power 60 kW/tonee
Potential of Hydrogen Generation = =
Electricity for water electrolysis 45
= 1.33 kg/tonne of cane
Potential If the hydrogen price is, say Rs. 320-340 / kg = 1.33 kg × Rs.320 / kg hydrogen
revenue of hydrogen = Rs. 426.6 / tonne of cane.
Costs Electrolyser infrastructure cost = 1.33 kg × Rs. 65 / kg
= Rs. 86.45/ tonne of cane
Surplus electricity = 60 kW/tonne × Rs. 4.75 / kWh
= Rs. 285 / tonne of cane
Additional = Potential revenue – Variable (bagasse) & Rs. 426.6 (Potential revenue) - Rs. 86.45
Revenue fixed (O&M, etc.) costs (Electrolyser infrastructure cost, etc.) - Rs.285
/ tonne of cane = Rs. 55.22 / tonne of cane
The costs mentioned above are tentative and exclude water costs, transportation costs and Government
incentives if any.
55
2. Condensing Route
Surplus power 75 kW/tonee
Potential of Hydrogen Generation = =
Electricity for water electrolysis 45
= 1.67 kg/tonne of cane
Potential revenue If the hydrogen price is, say Rs. 320-340 / = 1.67 kg × Rs. 320 / kg hydrogen
kg of hydrogen = Rs. 533.33 / tonne of cane.
Costs Electrolyser infrastructure cost = 1.67 kg × Rs. 65/kg
Surplus electricity = 75 kW/tonne × Rs.4.75/kWh
= Rs. 356.25/tonne of cane
Additional Revenue = Potential revenue – Variable (bagasse) & Rs. 533.33 (Potential revenue) -
fixed (O&M etc) costs Rs. 108.55 (Electrolyser infrastructure
cost) -
Rs. 356.25/tonne of cane
The costs mentioned above are tentative and exclude water costs, transportation costs and Government
incentives if any.
Conclusions Acknowledgement
• There are multiple avenues for hydrogen The authors are thankful to Director
production in sugarcane mills and their General Honorable Sambhaji Kadupatil and
co-generation entities, the best approach Adviser Honorable Shivajirao Deshmukh for
would likely be a combination of methods encouraging the study on potential for green
tailored to the specific conditions and hydrogen generation in the sugar industry.
resources of each mill.
References
• From this simple calculation, hydrogen
1. Aitor Arregi, Jon Alvarez, etl Vol.43 2015,
production from bagasse seems potentially Hydrogen Production from Biomass Pyrolysis
profitable with a short break-even time. and In-line catalytic Steam Reforming,
However, this is a very simplistic view. In Chemical Engineering Transactions, pages
the real world, considerations like 547-552,
fluctuating market prices, equipment 2. International Journal of Hydrogen Energy
maintenance, variations in sugarcane yield, Volume 48, Issue 40, 8th May 2023 by
and technology efficiencies will play a role. ELSEVIER,
3. National Green Hydrogen mission by MNRE-
• For an actual project, a detailed feasibility Strategic interventions for Green hydrogen
study involving all technical, economic, transition.
environmental, and logistical aspects 4. Various Newspaper information and Website
would be necessary. information.
56
A Concept Towards Energy Conservation – Heating

of Cane Juice by Flue Gas
Simanchala Panda, Murgesh Hattikal, Vatnal R.V.
Nirani Sugars Limited, Mudhol.
sipanda@rediffmail.com
Abstracts process house. and export the surplus electric

Energy resource sunder the earth are utilized by energy export to grid for additional revenue
developed society to meet their day-to-day demands. gain. So that the sugar industries are come
The availability of these resources is drastically forward for energy conservation by
reduced & after some century these resources will implementing latest technology and by
be grandma’s story to our coming generation. Hence installation of steam conservative devices. A
energy saving has become the demand of a national large quantity of heat emitted to atmosphere
sustainable development and it is also equal
by flue gas from boiler. If the flue gas will
responsible for each industry by utilizing bio-energy
use for cane juice heating, it will not only
(renewable energy)& waste heat resourcesduring
processfor better productivity & minimize the
benefit for sugar industry but also very
pollution load. The cane sugar industries helpful to living being by reduction of
throughout the world releases high heat value of emission load.
flue gas to atmosphere. If the sugar industry will Chemical and physical constituents of
utilize a portion of waste heat from flue gas on wet bagasse: The chemical composition &
process, it will not only save the bagasse but also
physical properties of bagasse aredepending
reduce the emission load.
on sugar cane variety, soil condition,
Keywords: Flue gas, waste heat, cane juice irrigation method & maturity of cane.The
heating, steam conservation & bagasse saving chemical composition of bagasse by different
Introduction authours are given in table no:1
In India the sugar industries are
According the Magasiner N, Gamble GE
contributing a main role in nations gross
and Charles Mbohw the estimated elements
domestic products (GDP) as well as its role in
of wet bagasse is, 22.5% Carbon, 23% Oxygen,
achieving food security and it’s by products
3% Hydrogen, 50% moisture, 1.5% Ash,
are will be used as raw materials for various
2.50-2.88 % dissolved solids & fiber %
products. Bagasse is a major byproduct of
47.00-47.50 on bagasse.
sugar cane after juice extracted at mill
section. it is considered as fibrous and pithy Calorific value formula of wet bagasse:
material, hence used as fuel to meet the To calculate gross calorific value & Net
thermal and electric energy requirement of calorific value of wet bagasse the percentage
Table no: 1 (Composition of bagasse)
Chemicals Deerr Tromp Kelly M.R* Davies Gregory

Carbon-C 46.5 44.00 48.20 47.50 47.90 49.00 48.10
Hydrogen - H 6.50 6.00 6.00 6.10 6.70 7.40 6.10
Oxygen-O 46.0 48.00 43.10 44.40 45.40 41.80 43.30
Ash C 1.00 2.00 2.70 2.00 - 1.80 2.50
*
= mean of results of Prinsen Geerligs, v.d. Kreke and Spencer.
Source: Hand book of cane sugar engineering by Hugot 1986
57
A Concept Towards Energy Conservation – Heating of Cane Juiceby Flue Gas
composition of wet bagasse is given in Table No:2
Table 2: The percentage composition of wet bagasse
Calorific value
Sr.No Constituent
(Kcal/Kg)
1 Fiber - f 4600
2 Sugar -s 3955 = 4000
3 Impurities -i 4100
4 Water -w 00
Source: Hand book of cane sugar engineering by Hugot 1986

As per Hugot the formula for GCV & NCV in Kcal/Kg of wet bagasse is given below
G.C.V = 4600 (f/100) + 3955 (s/100) + 4100 (i/100)
N.C.V = 4600 (f/100) + 3955 (s/100) + 4100 (i/100) − 350 (100-w)/100 – 600 w/100
By Von Pritzelwitz formula is given below
GCV = [19632-(30.98%brix) - (196.32 × % moisture) - (196.32 × %ash)] KJ/Kg
NCV = [18335-(30.98 × %brix) - (207.6 × %moisture) - (183.35 × %ash)] KJ/kg
Air required for Bagasse Combustion: To confirm the complete and efficient combustion in a
furnace, an appropriate quantity of oxygen must be brought into contact with the bagasse. The
quantity of air should be calculated based on chemical reaction method (Stoichiometric quantities).
For complete combustion of bagasse, the carbon present in bagasse converts into carbon dioxide,
hydrogen into water, and Sulphur into Sulphur dioxide.
(i) C + O2 −−−−−> CO2
12 kg + 32 kg −−−−−> 48 kg
1 kg + (32/12) kg −−−−−> 1 + (32/12) kg
1 kg + 2.67 kg −−−−−> 3.67 kg
(ii) H2 + O −−−−−> HO2
2 kg + 16 kg −−−−−> 18 kg
1 kg + 8 kg −−−−−> 09 kg
0.125 kg + 01 kg −−−−−> 1.125 kg
(iii) S + O2 −−−−−> SO2
32 kg + 32 kg −−−−−> 64 kg
01 kg + 01 kg −−−−−> 02 kg
• Composition of dry air:
% By weight % By volume
Oxygen 23.15 20.84
Nitrogen and inert gases 76.85 79.16
58
(A) Air for dry bagasse combustion
Table No:3 Calculation of Air for dry bagasse
Mass of air required

Oxygen required Oxygen required
Sr.No Composition %(kg/kg) for combustion (kg/kg
(kg/kg comp.) (kg/kg bagasse)
bagasse)
1 Carbon 0.4695 2.67 0.4695 ∗ 2.67 = 1.262
2 Hydrogen 0.0606 8.0 0.0606 ∗ 8 = 0.4848
3 Oxygen 0.4244 − − 0.4244
100
1.323 ∗ = 5.75
4 Nitrogen 0.0013 − − 23
5 Sulphur 0.0006 1 0.0006
6 Ash 0.0476 − −
Total 1.323
The minimum air required theoretically moisture, practically requires excess air
for dry complete combustion is 5.75 kg/kg of for complete combustion not less than
bagasse and the quantity of water formed is: 48% of the theoretical air.
0.0606 + 0.4848 = 0.5454 kg water. Hence the actual air required (after
addition of excess air) for wet bagasse
(B) Air for wet bagasse combustion:To obtain complete combustion is 4.23 kg/kg of
complete combustion for wet bagasse, bagasseas compared to theoretical air required
without unburned bagasse and all carbon 2.858 kg.
burns to CO2, it is necessary to supply
a certain excess of air. Charles explained
that wet bagasse which content 50%
Table No:4 Calculation of Air for wet bagasse combustion
Mass of air required

Oxygen required Oxygen required
Sr.No Composition %(kg/kg) for combustion (kg/kg
(kg/kg comp.) (kg/kg bagasse)
bagasse)
0.4695
1 Carbon = 0.2348 2.67 0.6269
2
0.0606
2 Hydrogen = 0.0303 8.0 0.2424
2
0.4244
3 Oxygen = 0.2122 − − 0.2122
2 100
0.6574 ∗ = 2.858
4 Moisture 0.50 − − 23
0.0006
5 Sulphur = 0.0003 1 0.0003
2
0.0476
6 Ash = 0.0238 - -
2
Total 0.6574
59
Heat recovery from flue gases That means 01 kg bagasse having

Heat in flue gases released to moisture content 50.00% will produce 4.22 kg
atmosphere is recovering to some extent by flue gas.
installing heat recover devices such as air
Specific heat of flue gas
preheater & economizer. This is not only
reducing the temperature of flue gases but Formula for Specific heat of flue gas
also saves the cost of cooling the gases before = 0.27 + 0.00006 T (T in °C)
leaving them into the atmosphere and
improve the efficiency of boiler. Whereas the Specific heat of flue gas at 150°C is 0.24
temperature of flue gas released to Kcal/kg/°C
atmosphere is in the range 140 to 150°C. To
Sensible heat of flue gases
consider the dew point condensation there is
a scope to recovered the heat from flue gas The sensible heat lost with flue gases
for heating of cane juice. given by E. Hugot as:
Enthalpy of flue Gases from Dry and Wet Q = [(1-w)(1.4 m - 0.13) + 0.5] T
Bagasse Q = sensible heat lost in flue gases, in
Formula to calculate the enthalpy of flue Kcal/kg of bagasse
gas going to stack.
T = temperature of the flue gases, in
h = Cp T °C
Where h is Specific enthalpy (Kcal/kg) w = moisture per unit bagasse

Cp is Specific heat Capacity (Kcal/kg/°C) m = ratio of weight of air used for
T is Temperature in °C combustion to weight theoretically necessary
Calculation for Weight of flue gas Heat transfer coefficient of flue gas
producing from wet bagasse Heat transfer coefficient K
2
Quantity of flue gas from 1 kg wet in Kcal/m /hr/°C =
bagasse = Pg = 5.76 ∗ (1 − w) ∗ m + 1 kg
[(α * Pg * Cf) / (S(r-1))] * Ln
Where Pg is qty of flue gas in kg [(To-t)/(T-to)]
w is moisture inunit bagasse Erosion of metal due to SO2 gas & dew
m is air required per unit bagasse point of flue gas
The existence of moisture in flue gas due
Table No:4 Composition of wet bagasse flue gas
to moisture in fuel and air, sulphur dioxide
Mass of and sulphur trioxide, reacts with moisture
Sr. flue gas
Composition %(kg/kg) Products and forms sulphuric acid.the basic reactions
No (kg/kg
bagasse) takes place are
1 Carbon 0.2348 CO2 0.825 S + O2 −−−−−> SO2
2 Hydrogen 0.0303 H2O 0.27
3 Oxygen 0.2122 O2 0.23

SO2 + O2 ↔ SO2
4 Nitrogen 0.0013 N2 2.4 H2O + SO2 ↔ H2SO3H2O + SO3 → H2SO4

6 Sulphur 0.0003 SO2 0.0004
Based on the ppm of SO3 and
7 moisture 0.5 H2O 0.5
water-vapor concentration, the dew point
8 Ash 0.0238 A
temperature of flue gas may vary around
Total 4.2254
90° to 140°C.
60
Present practice of steam consumption at only saving the fuel but also reduce emission
process house load to atmosphere.
Normally steam consumption in process Barriers to use flue gas for juice heating:
house is divided in two parts such as juice There is great fear to use flue gas for waste
heating and massecuite boiling. that vapor heat recover due to following points
demand is meeting by vapor generated during
• Corrosion of equipment due to presence of
concentration of clear cane juice at
SO2 gas in flue gas, which is converted to
multi-effect evaporators.
H2SO4
Steam % cane for juice heating varies
• Corrosion and erosion of metal surface
from 12.00 to 16.00 % depends on
due to presence of carbon particulate in
configuration of vapor bleeding from MEE.
flue gas.
Similarly Steam % cane for massecuite
• Fear of dew point condensation of flue gas.
boiling is varies from 22.00 to 25.00 %
depends on feed material Brix, massecuite • Distance from flue gas stack to process
dropping Brix, types of massecuite boiling and house.
vapor bleeding arrangement from MEE.
• Selection of material for heat exchanger
Thoughts for juice heating by flue gas At present flue gas used for boiler feed
In Indian sugar mills the average steam water by economizer, air heating by
% on cane at present is 36.00and if we pre-heater & Bio potash produced from
consider the fuel steam ratio is 2.2, then the distillery spent wash.
bagasse % on cane is (362.2) 16.36 used as Design concept to come out from barriers
fuel for boiler. We know thatOne kg bagasse
1. Scrubbing of flue gas to eliminate the
after burning it is producing 4.22kg flue gas.
effect of SO2 gas
Percentage of flue gas on cane will be (16.36
× 4.22) 69.03 % . To consider the dew point 2. Eliminate the carbon particulate by passing
of flue gas, we can utilize the waste heat from the flue gas through hot condensate water
the flue gas for juice heating. It will be not on counter current direction.
Fig. Schematic diagram of flue gas for juice heating
61
3. Maintain the dew point of flue gas. production cost. Because of convention
operation practice followed due to
4. Proper piping for easily handling flue gas
non-available of steam saving devices. If this
for juice heating
concept accepted by sugar industry, it shall
5. Bag filter after scrubbing of flue gas to give multiple benefits mentioned above, which
maintain zero carbon particulate. will accelerate financial growth of sugar
industries.
The temperature of flue gas after
scrubber is to be maintained 120°C. The Acknowledgement:
specific heat of flue gas will increase due to The Authors are highly grateful to the
moisture content will increase. So that the Executive Director of MRN group to give
quantity of flue gas will be reduced some permission for publication of the Technical
extent and that temperature is suitable for article in one day seminar of SISSTA on 16th
juice heating. March 2024.
Benefit to sugar factory
Reference:
• Steam % cane shall be reduced ultimately 1. E. HUGOT “HANDBOOK OF CANE SUGAR
bagasse saving. ENGINEERING: edition 1986
• Vapor bleeding from MEE shall be simple 2. Abdalla Mohamed Abdalla, Tagelsir Hasan
Hassan and Mohamed Eltayeb Mansour
• Operation of evaporator is also simple. “Performance of Wet and Dry Bagasse
Combustion in Assalaya Sugar Factory –
• Energy saving and reduce production cost Sudan” ,Innov Ener Res 2018, 7:179
• Low investment and turn waste into 3. Nirmal Sajan, Ruben Philip, Vinayak Suresh,
wealth Vishnu M, Vinay Mathew John “FLUE GAS
LOW TEMPERATURE HEAT RECOVERY
• Reduce emission load SYSTEM FOR AIR-CONDITIONING”
International Journal of Research in
Conclusion: The sugar industries of India Engineering and Technology eISSN: 2319-1163
struggling financial crisis due to higher | pISSN: 2321-7308.
62
Power Loss Recovery from Slip Ring Motor Starter

Patil. PG, Rao. SM
Technical Adviser (Electrical), Sugar Engineer (Electrical) Sugar Engineering Department,
Vasantdada Sugar Institute, Pune, Maharashtra (India)
Abstract Introduction
Slip Ring Induction motors(SRIM) have been The slip power recovery system (SPRS)
popular for decades in the Sugar, Steel, and provides speed and torque control like the
Cement Industry for starting and driving large resistors but can also recover the power taken
Inertia applications. In Maharashtra Sugar off the rotor and feed it back into the power
Industry around 250 installations had already system to avoid energy waste. Using LRS OR
installed SRIM for fibrizer, Leveler and Chopper ASR to control the Slip Ring Motor meant
applications. The SRIM has been used particularly that the Slip Power is wasted as heat in the
to cater the non- uniform load pattern. The tentative
Resistor Bank.
rating for the application like fibrizer by using
SRIM is avg. 1000 to 2500 KW in each industry. Hence the idea behind the SPRS solution
is to recover this Slip power from the rotor
The SRIM motor is driven by an old conventional and feed it back to the power system to avoid
LRS (liquid resistance starter) or ASR (automatic
energy dissipation in the resistors. All the
resistance with slip regulator). However, the
rotor energy previously lost as heat in the
drawback of these starters is the continuous power
rheostat is now saved, and for high power
loss in the form of heat in rotor resistance
depending upon the % slip, & this power loss is
motors, the energy savings can be significant.
termed as slip power. By LRS the power loss is
Background
around 5-7.5% i.e 100-150 KW per hour and by
using ASR we limit the power losses up to The construction of a Slip-ring Motor is
approx.3-5% the wasted energy is 60-100 KW per different from a standard Squirrel Cage
hour. Induction Motor (SQIM). In SRIM, the
three-phase stator is just like a normal SQIM
This power loss is national loss which is not useful
and is connected directly to the power system.
for doing any work done. We can recover this power
However, in SRIM the rotor also has a
loss by using the Slip Power Recovery (SPR) system.
three-phase winding which is accessible. The
The SPR consists of AC drive (interconnected rotor terminals are connected to separate slip
converters and inverter) along with synchronizing rings mounted on the rotor shaft. These slip
system. rings provide a means for electrical connection
The AC drive is connected to the three-phase rotor between the stationary part of the motor
winding of SRIM. The feedback power will be given (stator) and the rotating rotor winding. Brushes
to the 415-volt power system through SPRS. The ride on these slip rings and the rotor winding
slip power from the fibrizer SRIM can be recovered is connected to external resistors (LRS or ASR).
and fed back to the AC source as to utilize it outside
The motor speed / torque can be adjusted
the motor. By systematically addressing these areas,
by changing the rotor resistance. The addition
you can increase the overall efficiency of a drive
of resistance to the rotor circuit of a wound
system, leading to reduced energy consumption and
improved performance. Hence the SPRS system with
rotor induction motor (WRIM) does result in
slip ring motor and slip ring starter will be a the dissipation of power as heat in the
techno-economical solution for recover the slip resistors. This is one of the drawbacks of
power and to minimize the national losses in using external resistance for controlling motor
Industry. characteristics. However, it is often a
63
Patil. PG, Rao. SM
necessary trade-off to achieve specific will be continuous power loss as heat loss in
performance requirements. rotor resistance depending upon the % slip, &
Regarding the effect on motor this power loss is termed as slip power.
torque-speed characteristics, the addition of In a Slip Ring induction motor the slip
resistance to the rotor circuit shifts the rings allow easy recovery of the slip power
maximum torque point and alters the shape which can be electronically controlled to
of the torque-speed curve. By increasing rotor control the speed / torque of the motor. The
resistance, the motor’s starting torque can be oldest and simplest technique to invoke this
increased, allowing it to develop high torque slip power saving in slip ring induction motor
even at low speeds. This is particularly by mechanically vary the rotor resistance
advantageous for applications with high (which is practically not possible for frequent
starting loads, such as those requiring heavy change in load pattern), electrically by cutting
acceleration or lifting. the resistance using the contactors. The same
is also achieved up to certain extent by
The ability to adjust the rotor resistance
automatically varying the rotor resistance by
also enables fine-tuning of the motor’s using “Automatic Rotor Starter with Slip
speed-torque characteristics to match the Regulator (ASR)”.
requirements of the load. This versatility
makes WRIMs suitable for a wide range of Furthermore, the wasted energy partly
industrial applications where precise control in ASR or from conventional buffer
over motor performance is essential. resistances, can be recovered by using the Slip
Power Recovery system. Instead of wasting
Some applications specifically in sugar the slip power in the rotor circuit resistance,
industry demands Slip Ring Motors due to a better approach is to convert it to AC line
non-uniform load pattern to deliver the power and return it back to the AC line. All
required torque in running operation. This is the rotor energy previously lost as heat in the
achieved by adding resistance in rotor circuit resistance is now saved, and for large motors,
results in change in slip so the Torque. There this amounts to significant cost savings.
64
Scheme power flow between a load and a power source

In usual practice, a SPR drive consists by continuously monitoring and adjusting its
of two interconnected converters and inverter output based on feedback from the system. In
the context of putting power back into the
or AC to AC converter drive. The slip ring
power system, this typically refers to the
converter is connected to the three terminals
operation of a powerconverter in a grid-tied
of the rotor winding. The feedback power
renewable energy system or energy storage
converter is connected to the 415 volt power
system.
system. A feedback power converter is a type
of power electronic device that regulates the
Principle of slip recovery
Pm2 = S. Pm1 Pm = (1-S) Pm1
65
Patil. PG, Rao. SM
Hence, PM2 = S/(1-S). Pm For one day will be, 90 KWH × 24 × 6.5
= 14,040/- (considering unit rate Rs. 6.5 per
S = (Ns-N)/Ns
unit)
Pm - Shaft Power
For one month 14,040 × 30 = 4,21,200/-
Pm1 - Motor Input Power
For one crushing season of 5 months =
Pm2 – Motor Rotor Power Rs. 21, 06,000/-
Methodology SPRS system initial cost about 25 Lakhs
The research is planned as follows. along with additional maintenance cost.
(a) Visits to be given to various plants which Hence, to recover the slip power loss in
are having fibrizers with higher rating LRS starter the SPRS system along with LRS
slip ring motors and liquid resistance starter can be used.
starters / auto slip regulator starters.
However, the anticipated power loss in
(b) Accordingly, visits were given to ASR may be less. Hence, replacement of
following plants, existing LRS system by ASR system may be
• 1500 KW slip ring motor with ASR. more advisable instead of installing SPRS
system along with LRS.
• 2000 KW slip ring motor with LRS.
In case of new installations of fibrizer a
(c) Various readings were taken at site on squirrel cage motor and 690 V AC VFD will
fibrizer starters. Those are as follows. be more advisable.
Expected results
Acknowledgement
Following typical example will give the
The authors are thankful to Shri.
slip power recovery and ROI: For a 2000 KW
Sambhaji Kadupatil, Director General and
Fibriser Motor –
Shri. Shivajirao Deshmukh, Advisor and Shri.
1. Wasted rotor power loss with R. A. Chandgude, Technical Advisor and Head
conventional buffer resistance will be 5 Sugar Engineering department, Vasantdada
to 7.5%. = 100-150 KW. Sugar Institute, Pune for providing all the
required support in the conduct of research
2. However, by using ASR the same has
trials.
been lowered to 1-2%.
References
3. By using SPRS, Average power can be
recovered from LRS will be 5% approx. 1. POWER ELECTRONICS, BY Dr. P.S.
BIMBHRA, Ph.D., M.E. (Hons.), F.I.E. (India),
4. Let us consider minimum 100 KW is M.I.S.T.E., M.I.E.E. (U.K.), Professor & Head
power recovery, and considering 90 % of Electrical and Electronics Engineering
SPRS efficiency – Recovered power will Department, Thapar Institute of Engineering
and Technology.
be approximately 90 KW.
2. Published paper in ABB, Slip Power recovery
5. Therefore, Saved energy in Rs. By system(SPRS) for slip ring motors on
replacing LRS with SPRS Dec-2022.
66
Best Energy Saving Practice and Benchmarking

in Ethanol Industry - A Case Study
Dr. Ravi Shrinivasan,
Amaravathi Co-Op Sugar Mills Ltd, Krishnapuram - 642111, Tamilnadu, India
raviacsm@gmail.com
Abstracts are regarded as solar, wind, hydrothermal,

India is the third largest ethanol producing country geothermal, and biofuels. Liquid biofuels are
in the world. The primary feedstock for ethanol promising alternatives for gasoline and diesel.
production is sugarcane-based juice, syrup, B-Heavy Among different types of biofuels, bioethanol
Molasses and C-Heavy molasses. Grain based can be blended with gasoline due to its high
feedstock like maize, sorghum, broken rice etc are octane and low cetane numbers, which thus
used. Sugarcane and grain cultivation is the highly
results in better oxidation of hydrocarbons.
intensive crop and needs physical and mechanical
Thus, bioethanol is a renewable and
energy. Energy utilization starts with photosynthesis
in feedstock development to ethanol production. eco-friendly substitutive fuel to gasoline.
Positive energy output is the basic factor deciding Industrial bioethanol is produced from
the energy balance. In India, Ethanol blending biomass, either in the form of free sugars,
policy initiated in the year 2005 and currently E20 starch, or lignocellulose. Biomass in the form
Ethanol blending programme is undergoing at of free sugars, such as sugarcane, is globally
present 12% ethanol blending with petrol is
used to produce ethanol at large scales due to
achieved. more than 1000 of new ethanol units are
the lowest total production cost and fossil
under construction which is approved by
Government of India and established 1364 KL as energy consumption. The production process
installed capacity and achieved 700 KL of ethanol of bioethanol from sugarcane includes five
is blended produced from sugarcane based and main units: feed handling, fermentation,
grain-based feedstock. This article discusses in separation, dehydration, and stillage
detail for the best practice and energy balance evaporation. Separation, dehydration, and
adopted in ethanol industry.
stillage evaporation processes of bioethanol
Keywords: feedstock - intensive crop production consume more than 88% of the
photosynthesis - energy balance - Ethanol blending total required energy and takes 5.6% of the
Policy - Global warming - Greenhouse gas total cost for the first- and second-generation
emission ethanol. Several studies presented energy and
cost reduction for the bioethanol production
Introduction
process.
With increasing greenhouse gases (GHG)
emission, oil price fluctuations, and increasing The present research sets out to propose
demand for energy, particularly in the a conceptual design of a novel bioethanol
transportation sector, scientists and production process focusing on reducing
manufacturers have been thinking of using energy consumption and costs. To this end,
alternative renewable energy sources. nine scenarios in separation, dehydration, and
Approximately 85% of the world’s energy evaporation units are proposed and contrasted
demand is provided by non-renewable and with one another. For bioethanol separation,
fossil fuels, leading to serious environmental a three-column Othmer distillation system,
problems such as ozone depletion and climate which is the most commercial distillation unit
change. These problems necessitate using for ethanol separation worldwide, is chosen
renewable fuels as a sustainable energy along with different column operating
resource for long-term use.Renewable fuels pressures [23]. Due to the difference in
67
Best Energy Saving Practice and Benchmarking in Ethanol Industry - A Case Study
Ravi Shrinivasan
operating pressures, heat loads of condensers it.Ethanol is not the only product created
and reboilers are integrated efficiently. during production. By-products also have
Furthermore, thermal coupling and energy content. Corn is typically 66% starch
dividing-wall are applied in a multi-column and the remaining 33% is not fermented. This
system for better thermal and economic unfermented component is called distillers
efficiency. grain, which is high in fats and proteins, and
makes a good animal feed supplement. In case
This study presents economically viable
of sugar cane is used, the yield is higher, and
strategies for further energy reductions in a
conversion to ethanol is more energy efficient
commercial case-study for ethanol production.
than corn.
The most energy demanding units with high
operating costs of bioethanol production plant Variable energy considerations
are separation, dehydration, and stillage
To evaluate the net energy of ethanol
evaporation units. In this study, nine
four variables must be considered:
scenarios in the mentioned units were
investigated for enhanced thermal and 1. The amount of energy contained in the
economic efficiency. final ethanol product
Ethanol fuel energy balance 2. The amount of energy directly consumed

In order to create ethanol, all biomass to make the ethanol (such as the diesel
needs to go through some of these steps: it used in tractors)
needs to be grown, collected, dried, fermented, 3. The quality of the resulting ethanol
and burned. All of these steps require compared to the quality of refined gasoline
resources and an infrastructure. The ratio of
the energy released by burning the resulting 4. The energy indirectly consumed (in order
ethanol fuel to the energy used in the process, to make the ethanol processing plant, etc.).
is known as the ethanol fuel energy In this regard, geography is the decisive
balance (sometimes called “Net energy gain”) factor. In tropical regions with abundant
and studied as part of the wider field of water and land resources, such as Brazil and
energy economics.1 unit of energy input Colombia, the viability of production of
equals 1.3 energy units of corn ethanol ethanol from sugarcane is no longer in
energy. The energy balance for sugarcane question; in fact, the burning of sugar-cane
ethanol produced in Brazil is much more residues (bagasse) generates far more energy
favorable, 1 to 8. Over the years, however, than needed to operate the ethanol plants,
many reports have been produced with and many of them are now selling electric
contradicting energy balance estimates. energy to the utilities. However, while there
In 1995 the USDA released a report may be a positive net energy return at the
stating that the net energy balance of corn moment, recent research suggests that the
ethanol in the United States was an average sugarcane plantations are not sustainable in
of 1.24. It was previously considered to have the long run, as they are depleting the soil of
a negative net energy balance. However, due nutrients and carbon matter[citation needed]
to increases in corn crop yield and more On the other hand, productivity of sugar cane
efficient farming practices corn ethanol had per land area in Brazil has consistently grown
gained energy efficiency. Ethanol has a over the decades; sugar cane has been shown
substantial net positive direct energy balance: to be less depleting to the soil than cattle and
1.5 to 1.6 more units of energy are derived yearly cultures;[18] and there are many
from ethanol than are used to produce regions in the country where sugar cane has
68
been cultivated for centuries.[19] Those facts and adequate sun and water, and
suggest that related soil depletion processes optimizing a sufficient mix and rotation of
are very slow and therefore ethanol from plant species on cultivated, fallow, and
sugar cane may be far more sustainable in preserved land for human, animal, and
the long run than common fossil fuel energy consumption.
alternatives. Besides, since the energy surplus
Using ethanol returns carbon to the
is high in the case of sugar-cane ethanol,
atmosphere whereas burning gasoline adds
conceivably part of that energy can be used
carbon to the atmosphere. Thus, the effects of
to synthesize fertilizers and replenish soil
gasoline burning increase over time.
depletion over a long time, therefore making
the process indefinitely sustainable. Energy Management Best Practices
The picture is different for other regions, Any organization can more effectively
such as most of the United States, where the manage its energy use and costs by adopting
climate is too cool for sugar cane. In the U.S., a continual improvement approach to energy
agricultural ethanol is generally obtained from management, commonly known as an energy
grain, chiefly corn. But it can also be obtained management program or Strategic Energy
from cellulose, a more energy balanced Management (SEM). An energy management
bioethanol. program provides a systematic and proactive
approach to assessing and reducing the
Clean production bioethanol
energy uses and costs of your organization. An
Clean production bioethanol [20] is a energy management program is not a single
biofuel obtained by maximizing project but an ongoing process. It can be a
non-greenhouse gas emitting (renewable) stand-alone effort devoted exclusively to
resources: energy management or adapted to an existing
management program such as existing quality
• energy directly consumed to make the
assurance or environmental management
ethanol is renewable energy. The farm
programs at a facility. The most successful
equipment and ethanol plant use an
energy management programs are developed
ethanol engine, biodiesel, air engine or
and maintained by a team of individuals from
electricity cogenerated during ethanol
various functions such as maintenance,
production, or even wind power and solar
engineering, production, financing and
energy.
management. Energy efficiency is a good
• energy indirectly consumed is, as much as investment. Typically, energy cost savings of
possible, renewable. Examples would be as much as 15% can be achieved in three
reducing either the amount or fossil years by implementing a systematic
carbon content of applied pest control energy-management program. At first glance,
chemicals and fertilizers, or accomplishing creating and implementing an
deliveries of farm inputs or of finished energy-management program may seem to be
bioethanol fuel to market that minimize an overwhelming task, but it doesn’t have to
the use of fossil fuels. Optimally located be. This chapter outlines simple steps
biomass and ethanol production must following a Plan, Do, Check, act continuous
balance many factors: minimizing improvement cycle for putting the basic
distances to and from markets, effectively elements of energy management in place
collecting and employing biomass wastes, within your organization. Steps to getting
maximizing crop yields based on enduring started the next several pages outline the
soil quality, available natural pest control steps toward developing and implementing a
69
Ravi Shrinivasan
continuous systematic energy management The inlet temperature of the wash

program. entering the stripper is very important which
consumes higher energy if it is cooled or at
Step 1 - Plan Obtain support from plant
management and Best - Multi-variable ambient temperature instead of pre- heated.
regression modelling Pre-heating through Beer heater by alcohol
vapour and Plate heat exchange through
Step 2 - Do Regular energy team meetings
spentwash waste heat will add the inlet
Step 3 - Check Monitoring progress against temperature of the stripper column will
baseline reduce the energy demands for the boiling of
Step 4 - Act Acting on results wash. For 100 KLPD ethanol plant,
Step 5 - Repeat the four steps above on a pre-heating device will reduce the steam in
regular basis. considerable level is required to be optimized.
Similarly, alcohol vapour from multi-pressure
Technical best practices will reduce the stem consumption in
evaporator for increasing the brix of the
Best Practice Method - 1: Combined heat
spentwash. Regular cleaning and
and power system uses steam generation
maintenance of heat exchangers will reduce
equipment to create electricity to meet
the energy needs in the plant and indirectly
plant needs.
reduces the energy bill. The crucial role of
In this case, for power generation from cooling tower is the best energy saving and
steam generated in the boiler requires huge heat exchange from alcohol vapor cooled in
investment for the installation of Power the cooler and condensersto achieve required
generator with controller. Additional running production level. Reduced cooling tower
cost will increase by return the power cost efficiency will affect the performance of energy
will be reduced. Actually, CHP operation will
saving.
not be able to match thermal and electrical
demands of the ethanol plants. Water Best Practice Method - 3: Increase
consumption will increase and coordination is combustion air temperature
required to the power grid officials.
In boiler section, fuel burnt with oxygen
Co-generation power units will consume more
in the combustion system. The combustion air
energy produced from waste water treatment
supplied to the furnace is a considerable area
output as biogas. But sufficient gas production
is difficult to supply 100% electricity is very important. When increasing the inlet
generation without additional fuel source. temperature of the combustion air in the
Where as sustainability of ethanol production boiler will reduce the fuel requirement by
only achieved if the co-generation installed in 0.2% for steam generation. The waste heat
the unit. will be used in the system in terms of feed
water pre-heating and air pre-heating.
Best Practice Method - 2: Optimization of Implementation of this will not require
Heat Exchangers additional investment for improving the
In ethanol plant, heat exchangers like combustion pre-heating. Where as the
Reboilers, plate heat exchangers, condensers, economizer to be provided in the system for
coolers are the main heat exchangers plays pre-heating o feed water will automatically
crucial role in consuming or delivering energy reduce the fuel requirement in terms it
in connection with the plant operation relates require additional investment for adding
with ethanol production. economizer.
70
Best Practice Method - 4: Eliminate Best Practice Method - 4: Yeast

rectifier overhead vapor flow to reflux Propagation
condenser In best fermentation condition, cell
By design most of the rectifier column volume in the mash is very important for
overhead should be condensed in first effect converting fermentable sugar in ethanol.
evaporator. In practice most delta - t plants, Yeast growth in the propagation vessel is
condense significant amounts of rectifier directly concerned with the cell volume from
overheads in the reflux condenser where heat one vessel to another vessel for time
of vaporization is wasted in the cooling tower. management and healthiness of the yeast cell.
Productive use of rectifier overhead includes Temperature of the yeast cell is the critical
syrup solids in forced circulation evaporator, parameter in contamination control and
heating wash, evaporator condensate or healthiness of the living cell. Cell population
back-set. There could be productivity increase will be reduced if the temperature of the yeast
if the process receiving heat is the plant propagation increases. Proper aeration is also
bottleneck. A plant condensing 50 gpm in another parameter that directly supports the
reflux condenser will save 70000 MBtu growth of yeast cell from mash. Compressed
annually and cooling tower energy bill will be air quality and air pressure that reduces
reduced at higher level. power requirement for aerating propagation
tanks. For aerating the yeast slurry with
Best Practice Method - 5: Improved Yeast 80:20 concentration aerated at 1 cfm /cf for
performance 1328 hours in year save 900000 kwh. This
In ethanol production, yeast is the prime will reduce the energy bill.Higher
player in ethanol synthesis during the concentration of alcohol percentage in
fermentation of given feedstock. Using yeast fermented wash consumes less energy in
with high tolerant in temperature and high stillage during distillation due to higher yeast
osmotic pressure will decrease the fermentation concentration. Direct injection yeast for
time, increase feed concentration ultimately fermentation as dry yeast application will
increased alcohol concentration in mash/wash. reduce the energy bill directly saved from
According to kinetic theory, additional heat will yeast propagation vessel for aerating the
reduce fermentation time by approximately 25% medium. Propagation vessels are replaced by
in corn ethanol production. Temperature closing system eliminating 25000 to 900000
maintenance in fermentation and time should kwh/year for aeration and reduced cooling
be keenly observed for improving ethanol yield tower usage for cooling the propagation
from mash. High ethanol tolerance type of yeast vessels also reduce the energy bill. O&M cost
used in the fermentation will automatically for the yeast propagation vessels are
reduce the energy requirement in the stillage eliminated from the total cost. Similarly,
separation in distillation plant. Monitoring the CAPEX will be reduced for avoiding yeast
yeast propagation process in fermentation is propagation vessels for direct yeast
very important for improving the yeast application in ethanol plant.
performance in alcohol fermentation. Increased The following additional best practice of
alcohol concentration in the mash entering the controlling system to be followed in ethanol
stillage column will automatically reduce the plant for better energy management.
steam requirement for distilling the alcohol
1. Utilize heat of compression for air dryer
vapor. In addition, the water requirement in the
mash preparation is also important in energy 2. Vacuum purge, desiccant compressed
saving and its conservation. air dryer
71
Ravi Shrinivasan
Predictive modelling control and bench controlled by automated system but in

marking of ethanol plant many plants, it is controlled manually by
plant operators. Excessive reflux rate
(A) Predictive modelling control does not increase proof but result in
1. Predictive modelling control: higher steam usage inside stripper
Utilization of modelling programme for column. Plant designs include automatic
plant operator for the entire ethanol system which utilize a
plant operation. A special software temperature/pressure curve to control
controls all the process in the plant and proof. Many systems are taken out of
has directions to optimize efficiency of service due to inaccurate sensors or poor
the plant through automatic adjustments control tuning. Periodic sensor
based upon current operating system. calibration along with control loop tuning
Each process will be managed upon should allow consistent automatic
optimizing the plant productivity while operation. If better control system
reducing energy costs. The predictive operates in reflux rate control the energy
modelling is generally solid in module saving in steam generation in boiler and
addressing a certain portion of process. reduced steam usage in plant.
The system will keep coordinated thereby
4. Ethanol fermenter loop control
reducing the operating cost associated
system: In fermentation section, all the
with this process. The software reduces
fermented wash requires circulation for
the cost of energy used per kilo litre of
molecular contact with yeast cells for
ethanol. Installation of control software
proper utilization of sugar and it
is more expensive than general software.
converted to ethyl alcohol. The
The greatest energy saving will come
recirculation pumps are in worst
from a full predictive control with
condition which could not properly pump
multi-variable input that is optimized for
the required volume for recirculation.
an individual plant.
Addition of VFDs in recirculation pumps
2. Temperature Guage calibration: and control logic can minimize the
Regular maintenance of temperature and pumping energy needed while keeping
its calibration ensures correct fermentation temperature within the
measurements for control system. It is optimum range. Energy saving upto
more economical in grain ethanol plant 35-40% is about 300 - 600 KW that can
where liquification tank where 100F be reduced in energy bill.
lower than the actual temperature
5. Thin stillage solids separation:
requires maximum quantum of thermal
Removal of suspended solids from the
energy to maintain the additional
fermented wash utilized for distillation is
temperature in the slurry flow. The
very essential for avoiding scaling in the
requirement of temperature gauge
column. Thin stillage solids separation
requires periodic calibration that saves
can be accomplished with a dissolved air
million of rupees as thermal energy
flotation clarifier or dedicated centrifuge
costs.
system. The centrifuges can be adjusted
3. Automatic control of reflux rate: to provide greater solids content of wet
Reflux rate is varied to achieve desired cake at the expense of increased levels
ethanol content “Proof” in rectifier of suspended solids in thin stillage.
column. Proof can be precociously Reducing suspended solids of back set
72
allows addition of slightly more The bench marking of ethanol plants is

fermentable material per batch. This based on a plant producing ethanol and dried
kind of solid separation by centrifuge distillers dried soluble (DDGS) and venting
system reduces the water consumption in CO2 to the atmosphere.
washing the sludge and reduced scaling Process Benchmarking
in the stripper column consumes lesser Benchmarking information is used to
level of steam with more production establish best practices based upon the energy
reduces the cost of production. used in the total plant. Using existing
modelling and theoretical calculations, the
(B) Benchmarking of Ethanol Plant following table is provided to estimate the
Benchmarking will allow previously energy usage of different standard processes
constructed plants to compare their energy within a plant.The majority evaporator steam
use and serve us an Energy Key Performance use is allocated to the distillation process
because steam is recovered from the rectifier
Indicator (KPI) goal. The opportunity for
at a rate of 70% of input steam. This process
improvement through adaptation of the best
assumes a thermal oxidizer/heat recovery
management practices can bring older energy
steam generator (TO/HRSG) combination.
use in line with newer designs. The most Natural gas use from the TO is not shown
advanced best practices may also provide the because HRSG uses waste heat reclaimed
best opportunity for older plants to from the TO exhaust. Electrical energy for
outperform the newly designed plants. utilities is allocated over the total process.
Table - 1 Section wise energy requirement for Grain Alcohol Unit
Process section Major Equipment handled Electricity Steam Water
Grain handling Hammer mills, Conveyors and dust colelctors 580 - -
Liquification Jet cooker, Pumps and agitators 220 1.0 535
Fermentation Agitators Pumps 850 0.5
Distilaltion Columns, reboiler 120 7.5 -
Dehydration Molecular sieve, Evaporator 90 1.5 -
Seperation Centrifuge, Evaporators 1050 - -
Drying Rotary drum dryers 980 7.0 -
CO2 Bottling Unit Dry ice Manufacturing / Bottling of liquid 700 0.57 10
CO2
Steam Boiler/Turbine Boiler /Turbine 650 4.0 86
utilities Product storage /Pumping /Air 250 - 150

compressor/cooling towers/Plant lighting
/Laboratory
73
Ravi Shrinivasan
Table - 2 Benchmarking of Feedstock
Feedstock/Per KL of Feedstock requirement for 100

S.No Feedstock Yield/Per Ton
Ethanol KLPD ethanol Plant
1. Sugarcane Syrup 296 3.38 kg/lit 338 Tons/day
2. Sugarcane juice 296 3.38 kg/lit 338 Tons/day
3. B-Heavy Molasses 313 3.9 kg/lit 390 Tons/day
4. C-Heavy Molasses 250 4.0 kg/lit 400 Tons/day
5. Maize 380 2.63 kg/lit 263 Tons/day
6. Damaged Grains 380 2.63 263
7. Broken Rice 380 2.63 263
8. Wheat 435 2.29 229
Feedstock Benchmarking The ethanol yield per Kiloliter is the

most critical KPI for a plant. The cost of the
Feedstock benchmarking, or yield, is the
corn feedstock in grain alcohol unit is the
number of products produced per ton of corn.
major expenditure for an ethanol plant and
Generally, the following statements can be
Sugarcane syrup / juice / B-Heavy / C-Heavy
made about ethanol production from a corn
molasses cost per kilo litre, the sale of ethanol
kernel feedstock. (Table 2)
is the primary saleable product. A plant able
• Ethanol yield can rise or fall slightly with to increase the ethanol yield per Kilo litre
will create more income at nearly the same
little variation in energy use.
input expense.
• Distillers grain co-product yield is a trade
Conclusion
off with the amount of the material
converted to soluble products and ethanol. A case study on energy balancing and
benchmarking in ethanol plant discussed in
details and assumed the following features
• The water in corn is a function of the
1. Best Practices in Combined heat and
moisture content when utilized.
Power systems, Optimization of heat
The largest factor to the energy and exchangers, increased compressed air
water usage benchmark numbers is the temperature, Elimination of rectifier
efficiency with which the plant utilizes the overhead vapor flow to reflux condenser,
feedstock, or product yield. Below are the Improved yeast performance, yeast
propagation will automatically improve
yields utilized for the base plant in this
the plant performance and resulted into
guidebook. Contact your Focus on Energy
alcohol production.
representative if your plant’s yields vary and
you would like an estimate of savings 2. Reduced electrical power consumption
potential based upon product diversity at your reduces the cost of production by proper
plant. optimization of Process plant.
74
3. Reduced steam consumption will reduce References

the fuel requirement in boiler and in 1. Ethanol Technical best Practices (October
turn reduce the cost of Production/per 2020) Energy best Practice Guide, Wisconsin,
litre of ethanol 2. Biofuel Annual (2021)- United States
Department of Agriculture (USDA), NewDelhi
4. Calibration of Temperature and Pressure
3. Hosein Shapouri James A. Duffield Michael
gauges is very important in deciding the
Wang - (2002)The Energy balance of Corn
steam requirement and cooling effect
Ethanol : An Updae, USDA, 300 7th Street,
through cooling tower. S.W., Room 361 Washington, DC 20024.
5. Moisture content in the hydrated ethanol 4. ETHANOL IN Tamil Nadu, Andhra Pradesh,
decides the performance of the molecular Telangana, Gujarat, Chhattisgarh, & Goa TO
IMPROVE REVENUE: REDUCE SURPLUS
sieve dehydration unit performance.
SUGAR & INCREASE ETHANOL
6. Benchmarking in ethanol plant in 5. Project feasibility Report, Praj Industries Ltd,
Feedstock benchmarking/Yield of ethanol, Pune.
Process benchmarking will definitely 6. David Lorenz , David Morris (1995) Corn
increase the Plant performance and Ethanol - A energy balance (1992)Institute for
reduces the difficulties in process plant Local Self-Reliance 1313 5th Street SE, Suite
306 Minneapolis, MN 55414
operation.
7. Adam J. Liska, Haishun S. Yang, Virgil R.
7. Optimization Process plant is very Bremer, Terry J. Klopfenstein, Daniel T.
essential that will directly help the pant Walters, Galen E. Erickson, and Kenneth G.
operation and yield improvement, Cassman (2009)Improvements in Life Cycle
electricity consumption and steam and Energy Efficiency and Greenhouse Gas
Emissions of Corn-Ethanol ,Journal of
water consumption.
Industrial Ecology
Acknowledgement www.blackwellpublishing.com.
8. State Energy Action Plant, Government of
I express sincere thanks to our
Karnataka () Confederation of Indian Industry
Commissioner of Sugar and Administrator of Bureau of Energy Efficiency Ministry of Power,
our sugar mill for support in conceiving this Govt. of India 4th Floor, Sewa Bhawan, R. K.
article. Puram, New Delhi.
75
Well Planned Heat Energy Utilization During Higher Imbibitions Rate with Sulphur Free Sugar Production
Gopalakrishnan N., Bhaskar P., Narayan Mahana, Kiran S.
Well Planned Heat Energy Utilization During Higher

Imbibitions Rate with Sulphur Free Sugar Production
1
Gopalakrishnan N., 2Bhaskar P., 3Narayan Mahana, 4Kiran S.
1
Sugar Technologist-Chennai, 2Manager (Process), SNJ Sugars and Products Limited,
3
Sugar Technologist, Vasantdada Sugar Institute, Pune India, 4Chief Chemist, Piyush Sugar, Maharashrtra.
e-mail: bhas.pgn@gmail.com
Abstract refined sugar is higher as compare to other

The financial disaster of major Indian sugar mills countries, hence it is difficult to build a
is highly influenced by climatic cycle in sugar cane marketing space in international market. To
cultivation, low productivity efficiency due to improve productivity sugar industries shall be
conventional machinery, un- awareness regarding focused on improvement in quality as well as
losses and wastage of heat energy. Sugar industry optimum capacity utilization with minimum
shall be financial gain by bagasse saving, If sugar
energy consumption. For that the technical
industry will utilize maximum the heat energy from
awareness shall be developed from working
hot water condensate & pan vapor to condenser. it
will not only be saving fuel but also get premium platform to administration block. A heat
from sugar. energy auditing is very much essential to
proper utilization of heat energy from
Keywords: Heat energy, condensate water, fuel
different resources. For this a detail study
saving, sulphur free sugar
regarding heat lost through hot condensate
Introduction water, pan vapor to condenser. After that an
action plan shall be implemented by
The sugar cane itself contains seventy
installation of equipment with minimum
percentage waters, which is extracted during
investment. It will not only promote the
evaporation & crystallization for production of
productivity but also accelerate the financial
sugar. This hot water generates during juice
growth of sugar industry.
heating, thickening & crystallization in
process it contains huge quantity of heat Concept regarding heat energy
energy. This heat energy can be utilized for management & sulphur free sugar
juice heating at different stages, so that the production:
vapor from evaporators is being diverted for To avoid sugar loss in bagasse,
massecuite boiling. Whereas the hot
management took steps to increase the
condensate water sends to cooling tower for
imbibition rate at mill section. In fact, the pol
cooling purpose to meet the guidelines of
% bagasse is come down up to 1.60. whereas
pollution board. The industry is not only loss
the mixed juice % on cane increases with
heat energy but also consume electrical
lower brix percent. For smooth operation of
energy for cooling of hot condensate water.
massecuite boiling section syrup brix shall be
Secondly steam % cane will go higher side
minimum 60 deg. Ultimately the steam %
high. Hence sugar industry shall be installed
cane increased with higher side condensate
equipment to recover the heat energy from
water. but the Management of hot condensate
hot condensate water for sulphured & raw
water & vapor load at pan condenser is
juice heating. It will save near about 1.5 to 2
always overlooked by factory management.
% steam on cane & also hot water-cooling
Author has made an exercise regarding
tower efficiency will be improved.
utilization of heat energy from different
Action plan for energy conservation: In resources during sugar process and placed the
India the production cost of suphitation / same for betterment of sugar industry.
76
General Information
Sr. No Parameters Unit Qty
1 Cane crushing Ton/day 7200
2 Crushing rate Ton/Hour 300
3 Mixed juice % cane % 110
4 Quantity of M.J Ton 330.00
5 Sp.Density of juice 1.06
6 Volume of juice M3 311.321
7 Bagasses % cane % 28.00
8 Bagasses quantity Ton 84.00
9 Imbibition water % cane % 40
10 Imbibition water quantity Ton 120
11 Filtrate juice % cane % 12
12 Filtrate juice quantity Ton 36
13 Sulphited juice % on cane % 122
14 Sulphited juice Qty. Ton 366
15 Sulphited juice Qty. before heating M3 345.283
16 muddy juice% on cane % 12
17 muddy juice qty Ton 36
18 Clear juice qty before heating Ton 330
19 Clear juice% cane 110
20 Brix % MJ 14
21 Brix % SJ 14
22 Brix % CJ 14
23 Sp.Heat of juice 0.944
24 Syrup brix 64
25 A m/c % ON CANE % 28
26 B1 m/c % ON CANE % 12
27 B2 m/c % ON CANE 0
28 C m/c % ON CANE % 7
29 R m/c % cane % 25.2
30 Cane to boiling house MT 4200
31 Water evaporated Ton 222.6563
77
Sr. No Parameters Unit Qty
32 cane diverted to distillery Ton 3000
33 % cane diverted to boiling house % 58.33333
34 C J for syrup dilution MT 45
35 Net CJ to evaporator 285

st
36 Steam to 1 body calendria Ton 90.50633
37 Vapor going to condenser Ton 1.088604
38 Steam%cane % 30.16878
39 radiation loss % 1.00
40 Gross Steam % cane % 31.16878
41 Qty. Of steam MT 93.50633
42 5th body heating surface Sq.Mt 1000
43 4th body heating surface Sq.Mt 1000

rd
44 3 body heating surface Sq.Mt 2000
45 2nd body heating surface Sq.Mt 4500
46 1st body heating surface Sq.Mt 4200
Pressure and temperature of evaporator bodies
Sr.No Steam/vapor Calandria pressure Kg/cm2 ab Body pressure Kg/cm2 ab Temp °C
1 Ex.steam to S.K 2.13 2.1330 123
2 1st vapor 2.13 1.7224 115

nd
3 2 vapor 1.72 1.3305 107.5
4 3rd vapor 1.33 0.9572 97.5

th
5 4 vapor 0.96 0.6026 85.5
6 5th vapor 0.60 0.2667 66
Juice heating
Sr.No Juice heating Stage Heater By from To

st th
1 Raw Juice 1 V.L.J.H 5 vapor 32 47
nd
2 Raw Juice 2 tubular condensate 47 73
3 Sul. Juice 1st tubular Condensate 70 82
nd rd
4 Sul. Juice 2 tubular 3 vapor 82 91
rd nd
5 Sul. Juice 3 DCH 2 vapor 91 103
st nd
6 Clear.Juice 1 PHE 2 vapor 97 104
nd st
7 Clear.Juice 2 PHE 1 vapor 104 111
78
Massecuite boiling scheme
Sr.No M/C Cane T/Hr Vacuum pan Heating media M/C %
1 A M/C 175 Batch pan 2nd vapor 14.00
A M/C 175 Batch pan 3rd vapor 14.00
2 B 1M/C 175 Conti.Pan 3rd vapor 12.00
3 B 2M/C 175 Batch pan 3rd vapor 0.00
4 C M/C 175 Conti.Pan 3rd vapor 7
5 R M/C 175 Batch pan 2nd vapor 25.2
Vapor bleeding Arrangement • Use clear juice for B & C sugar melting.
Modification of vapor bleeding Conclusion

arrangement
The sugar factory shall be attained financial
st
• Use pan vapor for Raw juice 1 stage growth by lowering steam consumption and by
heating. producing sulphur free sugar. Minimize the
consumption of electrical energy at boiling
• Use hot condensate water for raw juice 2nd house and at condensate water cooling system.
stage and sulphited juice 1st stage heating. The payback period of investment is only one
crushing season.
• Vapor from 3rd effect evaporator shall be
used for massecuite boiling.
79
Acknowledgement Reference
Authors are expressed thanks to the 1. Hand book of Sugar Engineering by E-Hugot
management of SNJ Sugars, VSI, for giving 2. Hand book of Sugar engineering by Honig –
Volume 1
permission to submit this technical paper for
publication in the Seminar Proceedings.
Further, extending thanks to President of
SISSTA to permit this paper for one day Joint
Seminar at Ponni Sugars.
80
Enhancing the Energy Environment Economic and

sustainability (EEES) for Effective Utilization Sugarcane
Bagasse and Leaves - A Study
Dr. Vasudevan D., Murugesan A., Prakash R., Venkatesan S., Mohan K., Raja K.
Department of Mechanical Engineering, K.S.Rangasamy College of Technology, Tiruchengode – 637 215.
vasudevand@ksrct.ac.in
Abstract products.Garbage, or waste, is certainly an

In this present study, focussed on enhancing the unused and worthless substance, but we are
energy environment economic and sustainability unaware that, with the right processing,
(EEES) for effective utilization of sugarcane bagasse waste may also be something constructive and
and leaves waste. This biomass used to produce valuable.
electrical energy, it will product environment and
economic development of the country. Biomass In an effort to reduce the pollution
energy is the kind of energy obtained from living caused by their wastes, a number of Indian
organisms, such as plants and animals. The 30 % industries have begun to install waste
of the raw material from sugar cane is in the form treatment systems. Some of them even employ
of sugarcane waste. This waste is very good the trash from their operations to create new,
potential to be produce as a green energy. Study,
valuable products, which must first undergo
mainly focussed on effect the potential of sugarcane
certain processing. One of these methods
waste at the Pooni sugar mill. Initially, record the
sugarcane waste produced by the factory, in daily involves processing the residual waste or from
basis. Furthermore, these recorded data are the production of sugar into concrete blocks,
analysed using the software homer energy to compost, and other materials.
obtained the sources of electrical energy (Green
energy) generated during a day, then calculated for Currently, waste utilization is crucial,
a year. As well, the analysis also carried out on the particularly in solving the issues of industrial
demand of electricity in the factory. This study also organic waste, rubbish buildup in large cities,
done to evaluate how much the role of electrical and waste from plantations and agriculture.
energy from biomass such as sugarcane bagasse Organic material produced through
and leaves as a provider of electrical energy. The photosynthetic operations, either as wastes or
outcomes of the analysis showed that sugarcane
products, is known as biomass. Plants, trees,
waste as much as 1.035 tons/day on average was
grass, sweet potatoes, animal dung, forest
able to meet all the electrical energy requirements
for the operation of the ponni sugar factory. waste, and livestock manure were a few
examples of biomass. Biomass is utilized not
Keywords: Biomass, sugarcane waste, electrical just for food, animal feed, vegetable oil,
energy, renewable energy
building materials, and other primary uses,
but also as a fuel source. Biomass, which has
I. Introduction
little economic value or is left over after the
Energy enhancement, environmental main product is extracted, is frequently
conservation and economic sustainability utilized as fuel.
issues are likely to remain three of the major
long-term challenges human facing globally. India has a wealth of possibilities for
The industry located close to population is using biomass as a source of energy. Both
easy to functioning. An industry is unable to plant and animal wastes have the potential
operate in the nation without there is a to be developed. Significant amounts of waste
mechanism in place that reduces the negative are produced by food crops and plantations;
impact that come with manufacturing its this waste can be converted into biofuel or
81
Enhancing the Energy Environment Economic and sustainability (EEES) for Effective Utilization Sugarcane
other uses. Three benefits are realized right Since CO2 was captured and stored in
away when garbage is used as biofuel.The fossil fuels millions of years ago, the
first step is to increase overall energy environment damaged when it was released
efficiency because waste has a significant back to its current level. These facts make a
amount of energy that is wasted if not study on the use of waste from sugar factories
used.Secondly, financial savings, as it’s as biomass quite interesting. Bagasse, a waste
frequently more expensive to dispose of waste product from sugar factories, has a lot of
potential for usage as a biomass raw material.
than to use it.Third, reduce the demand for
The Ponni sugar plant, which is situated in
landfills because it will become more
Erode, Tamil Nadu, India, was the site of a
expensive and more difficult to provide them,
case study for this study .Finding out whether
particularly in metropolitan areas.
sugarcane waste was available at the Ponni
Among the methods for converting sugar factory was the aim of this study. The
biomass into energy is gasification, although objective is to ascertain whether sugarcane
its advancement in the country has been waste has the capacity to produce electrical
extremely restricted. Additionally, little energy. Analyzing sugarcane waste’s biomass
research is being done on gasification energy as a sustainable source of electrical
technology, that is technically or financially energy for the community is the ultimate goal.
possible to produce is included in this II. Methodology
category. It is also comparatively basic and
straightforward to use.Thus, this gasification 2.1 Location selection
technique is suitable for development in India; The Ponni Sugar Factory in Erode,
however, before this technology can be widely Tamil Nadu was selected as the research site.
used, basic research must be This site was picked because it has a biomass
conducted.Technology for converting biomass energy source that is renewable and can be
into energy is called biomass gasification. An used to generate electricity. The figure1 (a)
apparatus known as a gasifier is where the location of the Ponni Sugar Factory in Erode,
gasification process is carried out. Tamil Nadu and 1 (b) Sequence of procedures
to obtain sugarcane crops into various by
This device uses a reactor (combustion products.
chamber) with a restricted air supply to break
2.2 Preliminary study
down biomass fuel. To put it another way, the
process of incomplete combustion of solid Observations, data collection and
biomass raw materials, which involves a little prepration of the documents for effective
utilization of waste into green energy in the
reaction between oxygen and solid fuel in the
Ponni Sugar Factory in Erode, Tamil Nadu.
form of biomass, is known as biomass
gasification.Combustion reduces water vapor 2.3 Problem identification and
and carbon dioxide to combustible gases, such formulation
as carbon monoxide (CO), hydrogen (H2), and The procedure includes identifying and
methane (CH4). Because the quantity of CO2 formulating the issues that the Ponni Sugar
released during its usage as a fuel can only Factory in Erode, Tamil Nadu is facing. Direct
be reabsorbed by replanting these kinds of observation and management interviews at
crops, biomass energy is considered the Ponni Sugar facility were used to identify
sustainable because it does not contribute to the problems. The challenge presented in
new environmental pollution. composing this final project is how to
82
Figure 1(a). Location of this study in google maps
Figure 1(b). Sequence of procedures to obtain sugarcane cropsinto various by products

The research steps are described as follows.
83
maximize the location’s current biomass The bagasse data, which is 30% of the
resources in order to produce electricity with daily production for a year, is displayed in
significant power. Figure 3. There is no production process and
no empty biomass feedstock because there is
(a) Data collection
no milling season from the month of
The following datas are collected from the
November to April. In June, bagasse up to
Ponni sugar mill based on the average sugarcane
1,300.120 tons/day can be observed.
waste released per day in terms of tons.
Additionally, July has the lowest stock,
(b) Data processing producing about 1,250.160 tons of bagasse
This data can be processed with the help every day.
of HOMER software. It will be useful for
Available Biomass
simulation and help to further improvement Month
in reducing Man cost, Machine cost and (tonnes/day)
Material cost (3 Ms) January -
February -
III. Results and Discussion
March -
3.0 Biomass Potential Analysis Using
April -
Homer Software
May 900.440
The average annual biomass feedstock
amount at Ponni Sugar Factory is displayed June 1,300.120
in Figure 2. The primary raw material used July 1,250.160
in industrial processes is called a feedstock. August 1,200.100
Sugarcane waste serves as the feedstock. The
September 900.130
availability of feed stock higher in the month
October 828.210
of June were as lowest in the month of July.
An average of 30% of daily production for a November -
year’s worth of feedstock is derived from the December -
biomass potential at the Ponni Sugar factory. Annual average: 531.596
There is no production process and no empty
biomass feedstock because there is no milling Figure 3. The bagasse and sugarcane leaves data of
season from the month of November to April. 30% of the daily production for one year
Figure 2. The average amount of biomass feedstock in a year in Ponni Sugar Factory
84
Figure 4. The component selection in the Homer energy software
The bagasse data for a year is displayed bagasse per day are observed in June.
in Figure 4, representing thirty percent of the Additionally, the lowest stock is in July, when
daily production. From November to April, 628,110 tons of bagasse are produced daily.
there is no milling season, which means that
Figure 5 displays the major load
there is no production process and no biomass
simulation image at Homer Energy from
feedstock to be used. Up to 1,300.120 tons of
November to April. During that period, the
Figure 5. The primary load simulation image from November to April at Homer Energy
85
Ponni factory is not producing, therefore the Figures 5 and 6 show that this company
amount of power utilized is rather minimal. did not conduct sugarcane milling or create
Hourly data gathering from April through anything between November and April.
November. Therefore, it is assumed that the Therefore, it is assumed that the average
average industrial load is 148 kW from industrial load is 148 kW from November to
November to April. April. Meanwhile, the corporation has a
The main load simulation results from milling and production process for sugarcane
May to October, while Ponni sugar was in that runs from May to October. Therefore, it
production and the power load was high, are is assumed that the average industrial load is
displayed in Figure 6. In order for Homer to 3256 kW from May to October.A graph of the
adapt to monthly variations in the electric annual electrical load profile broken down by
generator’s profile. Nonetheless, the load hour and month is presented in Figure 7.
profile in the tropics can be thought of as
According to Homer Energy, the daily
constant for every month in this study. This
profile of industry electricity is somewhat
profile results from the lack of notable climate
consistent overall, however it does fluctuate.
variations throughout the course of the year.
Similarly, the profile varies every month of
The Homer Energy software just needs the year, but the total stays constant.
total active power data for the power
simulation. According to the settings The first generator simulation, which
employed, the electric load simulation in this uses bagasse as a biomass resource, simulates
generating system is expected to have 15% the provision of electrical power and a
random variability and 20% time to step. machine that can transform mechanical
energy into electrical energy. the steam
generated by the turbine using bagasse fuel
Figure 6. The primary load simulation results from May to October
86
Figure 7. A graph of the electricity load profile per hour per month in one year
in the boiler. 30% of bagasse was utilized. company’s production load of 19,015,288 kWh
This fuel is dependent on how the electric is used. with an annual electricity purchase
power plant’s generator is built. In this study, of 644,727 kWh from PLN. The biomass
AC is utilized to run a generator. generator has capacities: 1600 kW
Figure 8 illustrates how data processing Homer Energy software does not require
with Homer software yields the power load sampling every minute, but every hour.
generated by a biomass generator with an This load data is taken from interviews with
annual output of 6,935 MW when the Ponni sugar factory employees.
Figure 8. Simulation results of the power generated by the generator
87
V. Conclusion a result, the sugar business in Ponni is able

The following information is derived from to supply its own electricity.The biomass
the simulations and analysis that were generator produces 6,935 MW of electricity in
a year. Sugarcane biomass has the ability to
performed with the Homer software. The use
meet energy needs through electricity
of generators connected to the PLN grid is the
generation. The remaining biomass in the
best and most optimal option for the design
Ponni sugar factory is used by the community
of a biomass generator at the Ponni sugar.The
to make bio briquettes and bricks.
Ponni sugar factory produces 6,935 MW from
one generator for the period of 24-month. As
88
Upgrading ESP with Innovative Fixed Vane Scrubber

Technology to Meet Particulate Emission below 50 mg/Nm3
Rajesh Verma1, Prakhar2
1
CEO, EnviropolEngineers Pvt. Ltd., A-50, Sector-65, Noida, India, ceo@enviropolengineers.in
2
Manager, Enviropol Engineers Pvt. Ltd., A-50, Sector-65, Noida, India.pv@enviropolengineers.in
Abstract by maintaining stable flue gas parameters. By

For ages, the partially cleaned hot flue gases from incorporating the FVS after the ESP, the mill
the ESP outlet and white Ash Ballsemitted into the can achieve emissions levels below 50
atmosphere from Chimney have posed an mg/Nm3.
environmental challenge. To address this issue and
Ponni Sugar mill, located along the
ensure compliance with CPCB regulations in the
banks of the Cauvery River, currently
most cost-effective manner for Bagasse-fired Boilers,
an innovative Scrubber Technology known as the operates a 95 TPH High-Pressure Boiler (112
Fixed Vane Scrubber (FVS) has been adopted. By ksc/545 Deg C), utilizing high-moisture
integrating the FVS with the existing ESP, we can bagasse as its primary fuel source. In
significantly reduce particulate emissions in the flue response to the challenge of reducing
3
gas exiting the stack to just 50 mg/Nm . particulate emissions, particularly the
In 2019, the first installation of this combined presence of ash balls in the flue gas from the
scheme (ESP + FVS) was implemented successfully ESP outlet, Ponni Sugars sought an
at Ponni Sugars Erode, specifically on their 95 TPH economical solution to address ongoing ESP
High-Pressure Boiler operating at 112 bar/540 maintenance issues. ENVIROPOL met this
degrees Celsius. This installation has consistently challenge by introducing an advanced
3
achieved emissions of 50 mg/Nm . Notably, the
scrubber solution, thereby promoting a cleaner
issue of ash balls falling from the discharged flue
environment through the implementation of
gas stack in nearby areas has been effectively
resolved, addressing concerns raised by local an innovative scheme that places the FVS
villagers and farmers. Scrubber after the ESP.
The demonstrated success of the FVS technology in

this context underscores its potential applicability
downstream of existing ESP systems, offering a
viable solution to meet stringent emission standards
in the global Sugar Industry.
Keywords: FVS-Fixed Vane Scrubber, ESP-

Electrostatic Precipitator,APCD- Air Pollution
Control Device, EEPL-Enviropol Engineers Pvt Ltd.
Introduction
The Innovative Fixed Vane Scrubber
offers a groundbreaking alternative to the
traditional “ESP Field Extension concept”
employed in Sugar mill boilers. This
innovation provides several advantages,
including a significant reduction in
maintenance demands for ESP, fewer
instances of increased ESP emissions due to
the rapping system, and enhanced efficiency
89
Upgrading ESP with Innovative Fixed Vane Scrubber Technology to Meet Particulate Emission below 50 mg/Nm3
Rajesh Verma, Prakhar
Fixed vane scrubber Advantages

Working principle 1. Can handle a wide range of particle sizes
The dust laden flue gas enters the
2. No requirement of Nozzles
bottom of Fixed Vane Scrubber tangentially
and flows upward forming vortex. This vortex 3. Low water requirement
/ cyclonic action of the saturated gas stream 4. No moving parts
as it spins upwards forces the heavier
particles to fall out of suspension. Scrubbing 5. Simple operation, only occasional
liquid is introduced to the scrubber as a spray cleaning required
directed down over circular “Scrubbing Vane” 6. Can accept higher dust concentration in
arrangement. As the liquid drains through the scrubbing water
vanes, it creates curtain of Scrubbing liquid.
The flue gas collides with the curtain and 7. Wide range of applications
dust particles get trapped in the water Case study - Ponni sugars, Erode, Tamil
curtain. The slurry thus produced is washed nadu
down to the outlet.
Case Study presented here elucidate the
experience and learnings at Ponni Sugars
highlighting the successful reduction of
particulate emission in stack gas below 50
mg/Nm3 with Fixed Vane Scrubber installed
in the downstream of existing 3 Field ESP of
the HP Cogen Boiler.
The Case Study is divided in four Phases

as described below :
Phase-I: Study & Decision Making

Having rich experience on successful
operation of 350+ Wet Scrubbers across globe,
Team Ponni in association with Enviropol
Engineers Pvt. Ltd. (EEPL) were exploring
various ways to reduce the particulate
emissions. While exploring, Ponni had
following Options:
The cleaned flue gas is then allowed to
pass through high efficiency mist eliminator • ESP- field extension
vane (demister) for separation of entrained • Installation of Biomass dryer
liquid droplets from flue gas. The change in • Placement of EGB in the down stream
momentum allows the finer liquid droplets to • Putting up a deflector on top of the chimney
coagulate and form coarser droplets and
gravitational and centrifugal forces are • Placement of efficient Wet Scrubber
responsible for the separation of liquid Constraints with the Options

droplets from the gas stream • ESP Field Extension was ruled out
primarily due to space constraint and
The filtered flue gas then allowed for fluctuating emissions during soot blowing
discharge to atmosphere through stack.
90
• Installation of Biomass Dryer in the The boiler layout was conceived as

downstream of ESP was dropped due to shown below (Refer-Fig.3) considering FVS
high Capex even though it was a Revenue model in the downstream of ESP. The overall
Generating solution length of the boiler got reduced, as compared
to conventional model with ESP extension.
• EGB, being a new technology in 2019 for
Indian market, the same was not
considered.
After extensive discussion, study and

visits made to see the functioning of FVS, Wet
Scrubber option was concluded, in view of
following added advantages:
(a) No Nozzles present, (b) Chokeless

Scrubber, (c) Low Water Requirement
Boiler description
The steaming conditions of Cogen HP
Boiler and other related parameters are
elicited in Table -1.
Table-1.Steaming conditions of Cogen HP

Boiler - Ponni Sugars Erode Limited
Parameter Design Value Units
Fuel Bagasse &

Fig. 3 : HP Boiler layout-Ponni Sugars
Imported Coal
The hot and partially cleaned flue gas
Steam Evaporation 95 TPH
from the ESP was passed through the high
[MCR]
efficiency Fixed Vane Scrubber. During the
Steam outlet Pressure 112 Ksc process of Scrubbing, the dust particle got
Steam outlet 545 °C entrapped in the water curtain created inside
Temperature the scrubber followed by the Efficient Vane
Feed Water Temperature 126 °C type Demister to capture the water mist to
from Boiler bring down the emission below 50 mg/Nm3 in
Deaerator to Economizer accordance with the prevailing environmental
Draught system Balanced - FD & norms.
ID Fans
FVS at Ponni Sugar was designed to
Back-end Equipment Economizer & APH
handle 100% flue gas leaving at 140°C after
SH Steam Temperature Interstage ESP from 95 TPH Boiler to achieve 50
Control Attemperation mg/Nm3 as outlet emissions.
between Primary
& Secondary
Superheaters Phase-II: Manufacturing & Installation
Flue gas temperature at 140 °C The complete system was designed &
APH out manufactured by Enviropol in India.
Existing Air pollution ESP
The system,as shown in Fig 4, was
control device
erected at site in four months followed by
91
Upgrading ESP with Innovative Fixed Vane Scrubber Technology to Meet Particulate Emission below 50 mg/Nm3
Rajesh Verma, Prakhar
(KI +PUVCNNCVKQP QH (85 KP 2QPPK 5WICTU
92
electrical and instrumentation work within Way forward

next one month time. This was the first In order to mitigate adverse impact of
installation of Scrubber after ESP across globe corrosive gas (low pH < 4) and harmful finer
& the plant was situated near Cauvery river, particulates & aerosols etc. on the wetted
Ponni insisted for mechanized slurry handling parts of the equipment installed, it is planned
syetm to have no water spillage. to spray/doze as fine mist of the select
alkaline reagent to the moist biofuels fed to
Phase-III: Boiler Operation with FVS the Wet Scrubber to achieve the desired
The system was successfully operated till results of cleaner and corrosion free
end of the crushing season. During the period, equipment and environment.
several tests were conducted under varying Replication
operating conditions to build up the data bank
The Integrated ESP -FVS scheme can be
for future installations. On an average, test
replicated in all Biomass fuel [with /without
results have shown reduction in outlet
fossil as co-fuel] fired boilers asadd -on at the
particulate emission < 50 mg/Nm3. This is
downstream of the Boiler under review.
clearly demonstrated from the clean stack
with FVS in place showcasing results before
&after . [Fig.5.]
Fig. 5. Clean Stack and no more tiny balls in the vicinity
93
Enviropol is doing the same for EID PONNI Sugars for providing this opportunity
Parry on their 2 × 40 TPH Boiler where in to instal FVS after ESP intheir HP Cogen
we are installing FVS after their 3 Field ESP plant.
to meet stringent emission norms References
1. Rajesh Verma -- Webinar Programme [June
Acknowledgement 2023].
Team ENVIROPOL are grateful to the
Management and the Energetic team of
94

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SISSTA, SEDL & PONNI SUGAR - Joint Seminar at Tiruchengode, 2024

Lowest Steam Consumption at a Sugar Plant of

Abstract Keywords: Evaporation, crystallisation, steam

• Instead of 2nd effect, all vacuum pans

This sugar plant has successfully

Phase-3: Crushing plant capacity

• 2 nos. of tubular falling film evaporators Pleased by the performance and

also erected to stabilize/optimize the addition and modification of available and

Parameters Phase-1 Phase-2 Phase-3 Phase-4

References 4. Increased rankine cycle and evaporators

Reduction of Steam Demand in Sugar Processing of Jai

Abstract by-products are potential sources of energy.

Table 1: Parameters for existing 2500 TCD

Sr. Existing scenario Proposed scheme

Fig. 2: Proposed vapour bleeding arrangement for expanded plant capacity

Highlight of factory parameters is given • Flash heat recovery system (CIGAR®)

• Existing 1st & 5th mill replaced by 33’ ×

turbine generation. The evaporator

Table 3: Comparison of the parameters of phase 1 and phase 2

Phase-1 (Before After Modification

1 Cane Crushing Capacity 3600 TCD 5000 TCD

2 Total Cane Crushed 6200804.24 tons 619878.159 tons

3 No. of Days 202 days 134 days

4 Power Generated 12398775.00 kWh 14623936.00 kWh

5 Power consumption per TCH Sugar 18.62 TCH 22.60 TCH

7 Bagasse Generated 175015.51 tons 177427.982 tons

8 Bagasse used for Sugar 98813.80 tons

10 Bagasse Saved % on cane 8.65 13.25

11 Reduction in Steam Consumption 18 % 5.96%

Table 4: Summary of performance parameters of phase 1 and phase 2

Sr. No Parameters PHASE-1 (3600 TCD) PHASE-2 (5000 TCD)

Conclusion technology for reduction in energy demand in

Maximizing Energy Efficiency through Cogeneration

Abstract Sugars maximizes energy utilization while

Identified root cause: Fuel compression Objective 4: Implementation of Fan-less

Objective 5: Improved Energy Efficiency

(9 ATA extraction steam utilized for TG

at steam pressure and temp is 105 kg/cm2

⎛ Total quantity ⎞ ⎛ No of days ⎞

= 5976 tons of steam (which is 5976000 kg of steam)

Therefore, the energy saved is (energy of

⎛ Total quantity ⎞ ⎛ No of days ⎞ = 1950.565 tons

Therefore, the energy saved is (energy of = 370.51 tons per year

In terms of fuel saving Benefits achieved

Operational Efficiency: Optimized steam zone temperature, and furnace temperature.

Energy Efficient Air Compressor: Conclusion

Energy Conservation Best Practices in the Sugar Industry

Abstract Plant installed with 3500 TCD sugar

This factory is designed for 33 percent

Fluidised Bed Drier Pans & MVC area

Sugar Bins & Packing Area

• Syrup Brix 68-72 is maintained.

Sugar Industry – Technological Advancements

Introduction environmental footprint, and maintain their

Advanced Process Control Algorithms: Continuous Improvement and

Energy Management and Optimization: In summary, DCS offers numerous

Integration with Energy Monitoring (E) Boiling scheme

Employee Awareness and Training: • Quintiple system of evaporator with

Ponni’s proposed plan on steam saving:

• Introducing MVR based boiling in some of we acknowledge the leadership and

Ethanol from the Sugarcane as a Alternative Blended Fuel

1. Introduction (i) Production of the ethyl alcohols,

2. Production of ethanol (ethyl alcohol)