Raw Material Requirement

Raw materials required for Sugar and Co-Gen Plant

Sugarcane is the main raw material. Sugar cane is obtained from the farmers within 40 km
radius. The raw materials required are given in Table 1.

Table 1: Details of raw materials for Sugar plant

After
Sl Existing: Source Mode of
Raw Materials expansion:
No 5,000 TCD transport
10,000 TCD
1 Sugar Cane, TPM 1,50,000 3,00,000 Villages in 40 km radius
2 Lime, TPM 180-200 300-350
3 Flocculent, TPM 200-210 400-410
4 Washing Soda , TPM 5-10 15-20
5 Caustic Soda, TPM 5-10 15-20
6 Color Precipitant, TPM 5-10 15-20
7 Refinery Flocculent, TPM 5-10 15-20
By trucks
8 Phosphoric Acid, TPM 5-10 15-20
through
9 Defoaming Agent, TPM 5-10 15-20 Local
Road
10 Antiscalent, TPM 5-10 15-20
11 Mill Sanitation (Bacteriocide), TPM 5-10 15-20
12 Sulfamic Acid, TPM 5-10 15-20
13 Rodine, TPM 5-10 15-20
14 Formic Acid, l/month 5-10 15-20
13 Lubricants (Wheel bearing grease, 2-3 4-5
Lubricating oils etc.,), KL/month

The details of raw materials for existing and proposed expansion co-gen plant are given in
Table 2 and Table 3 below.

Table 1: Bagasse requirement for Steam generation at Co-Gen Plant

Existing: After Expansion:
PARTICULARS
5000 TCD 10,000 TCD
Steam generated per Ton of Bagasse 2 Ton 2 Ton
Total Boiler capacity (in TPH) 165 255
Total Bagasse required to generate steam
1980 1980
based on total boiler Capacity (in Ton/Day)
 Table 2: Bagasse Generated at Sugar Plant and its requirement for Co-Gen Plant
Existing: After Expansion:
PARTICULARS
5,000 TCD 10,000 TCD
At Sugar Plant:
Bagasse @ 32% (in Ton/Day) 1,600 3,200
No. of days of Sugar crushing at Sugar Plant 240 240
Total Bagasse Available (in Tons per Annum) 3,84,000 7,68,000

Bagasse requirement for Co-Generation Plant: 35 MW Capacity 35 MW Capacity

No. of days of Operation of Co-Generation Plant 330 330
Bagasse required for Boiler of 165 TPH (in Tons/Day) 1,980* 1,980**
Total Bagasse required for Boiler (in Tons per Annum) 6,53,400* 6,53,400**
* Currently, the steam requirement for Sugar plant process is less than 165 TPH. Thus, Boiler
is operated at lower capacity to generate steam. Therefore, the bagasse generated 1,600
Ton/Day is adequate.
** After expansion of sugar crushing capacity, the steam requirement will be more and
theBoiler will be run at full capacity to generate power and steam. There will be excess
bagasse of 1,14,600 TPA and will be used in the distillery incineration boiler of 52 TPH.

Raw materials required for Distillery Plant

Details of the raw materials required for process, their source of procurement and mode of
transportation is given in Table 4.Fuel requirement by distillery unit &its mode of transportation
is provided in Table 5.

Table 3: Raw material requirement for Distillery unit

Estimated
Sl. Existing Mode of
Raw Materials Quantity after Source
No. quantities transport
expansion
From own
Molasses C Heavy (in KLD) 250 1743 Pipe line /Tanker
sugar plant
From own
Molasses B Heavy (in KLD) 218 1569 Pipe line /Tanker
sugar plant
1 From own
Cane juice syrup (in KLD) Nil 1452 Pipeline
sugar plant
Grains includes wheat /
broken rice / maize / barley / Nil 1100 Local Lorries /Trucks
sorghum (in TPD)
2 Sulphuric Acid, l/d 30-35 190-200 Local HDPE Containers
3 Urea, kg/d 35-40 250-300 Local Plastic containers
4 Antifoam agent, kg/d 30-35 190-200 Local HDPE containers
5 DAP, kg/d 10-15 45-55 Local Plastic containers
6 Dry Yeast, kg/d 10-20 75-85 Local Plastic containers
7 Caustic Flakes kg/d 35-40 250-300 Local Plastic containers
8 Magnesium Sulphate kg/d 10-15 45-55 Local Plastic containers
9 Nitric Acid l/d 15-20 95-110 Local Plastic containers
 Table 4: Fuel requirement of distillery unit & mode of transportation
Sl. Existing After Expansion
Fuel Source Transportation
No. MT/day MT/day
For Incineration Boiler – 52 TPH
Direct feeding to boiler
Conc. Spent From distillery
1 450-480 450-480 through pipeline and
Wash process
nozzles.
Bagasse
Feeding through belt
(supplementary- From own
2 170-190 170-190 conveyer from sugar unit
alternative fuel sugar plant
/truck
to coal)