Vasantdada Sugar Institute, Manjari (Bk.), Pune 412 307, India.

1. USE OF ALTERNATE SUGAR PROCESSING INTERMEDIATES AND SUPPLEMENTARY CROPS FOR AUGMENTING ETHANOL SUPPLY R. V. Godage1, D. A. Patil2 and S. V. Patil3 Vasantdada Sugar Institute, Manjari (Bk.), Pune 412 307, India. Author for correspondence:sanjay01356@hotmail.com

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

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

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

5. India-Gasoline & Ethanol demand

6. Estimated Indian Ethanol demand

7. ALTERNATE SUGAR PROCESSING INTERMEDIATESCase StudyCrushing capacity = 4000 TCD Distillery capacity = 60 KLPD Sugar price = Rs. 11.50/kg Ethanol price = Rs. 21.50/Liter Bagasse price = Rs. 250.0/MT Pol % Cane = 13.23 All data on per day basis

8. Conventional route (Per day basis)

9. Particulars Two m/c boiling Sugar recovery 9.82 % Sugar production 3928.0 qtls. BH % cane 5.56 % BH production 222.04 MT/day Ethanol 74.943 KLPD Ethanol revenue Rs. 16.113 Lac Sugar revenue Rs. 45.172 Lac Total revenue Rs. 61.285 Lac Total revenue per MT of cane Rs. 1532.12/MT Two massecuite/B-Heavy molasses route (Per day basis)

10. Particulars PJ for Sugar + SJ for Ethanol Sugar recovery 8.76 % Sugar production 3504.0 qtls. FM % cane 2.46 % FM production 98.538 MT/day Ethanol from FM 22.977 KLPD SJ % cane 40.94 SJ Production 1637.60 MT/day Ethanol from SJ 78.404 KLPD Total Ethanol 101.381 KLPD Ethanol revenue Rs. 21.797 Lac Sugar revenue Rs. 40.296 Lac Total revenue Rs. 62.093 Lac Total revenue per MT of cane Rs. 1552.32/MT Total secondary juice route (Per day basis)

11. Particulars PJ for Sugar + Partial SJ for ethanol (as per distillery capacity) Sugar recovery 9.41 % Sugar production 3764.0 qtls. FM % cane 2.72 % FM production 108.95 MT/day Ethanol from FM 26.595 KLPD SJ % cane 31.38 SJ Production 1255 MT/day Ethanol from SJ 60.085 KLPD Total Ethanol 86.680 KLPD Ethanol revenue Rs. 18.636 Lac Sugar revenue Rs. 43.286 Lac Total revenue Rs. 61.922 Lac Total revenue per MT of cane Rs. 1548.05/MT Partial secondary juice route(Per day basis)

12. Particulars Total juice for ethanol Sugar recovery - Sugar production - FM % cane - FM production - Ethanol from FM - MJ % cane 98.28 MJ Production 3931.20 MT/day Ethanol from MJ 297.496 KLPD Total Ethanol 297.496 KLPD Ethanol revenue Rs. 63.962 Lac Sugar revenue - Total revenue Rs. 63.962 Lac Total revenue per MT of cane Rs. 1599.05/MT Total mixed juice route(Per day basis)

13. Particulars Partial MJ for ethanol (as per distillery capacity) Sugar recovery 9.24 % Sugar production 3696.0 qtls. FM % cane 2.86 % FM production 114.28 MT/day Ethanol from FM 27.433 KLPD MJ % cane 20.75 MJ Production 830.0 MT/day Ethanol from MJ 60.540 KLPD Total Ethanol 87.973 KLPD Ethanol revenue Rs. 18.914 Lac Sugar revenue Rs. 42.504 Lac Total revenue Rs. 61.418 Lac Total revenue per MT of cane Rs. 1535.45/MT Partial mixed juice route(Per day basis)

14. Particulars Sugar Production (Qtls/day) Ethanol Production (KLPD) Conventional 4600 36.996 B-Heavy 3928 74.943 Secondary Juice 3504 101.381 Partial Secondary Juice 3764 86.680 Whole Cane Juice - 297.496 Partial Whole Cane Juice 3696 87.973 Comparative Sugar and Ethanol Production

15. Particulars (Litres/MT) FM or BH SJ or MJ Per MT of Sugar cane Conventional 254.1 - 9.25 B-Heavy 336.97 - 18.74 Secondary Juice 233.17 47.88 25.34 Partial Secondary Juice 233.17 47.88 21.64 Whole Cane Juice - 75.67 74.37 Partial Whole Cane Juice 240.05 75.67 21.99 Comparative Ethanol Yields

16. Particulars Sugar Revenue Ethanol Revenue Total Revenue Conventional 52.900 7.954 60.854 B-Heavy 45.172 16.113 61.285 Secondary Juice 40.296 21.797 62.093 Partial Secondary Juice 43.286 18.636 61.922 Whole Cane Juice --- 63.962 63.962 Partial Whole Cane Juice 42.504 18.914 61.418 Comparative Revenue Generation(Rs. Lac)

17. Particulars Sugar Conversion cost Ethanol conversion cost Total cost Harvesting & Transport Cost Conventional 225.0 550.0 52.49 827.49 B-Heavy 225.0 542.0 65.58 832.58 Secondary Juice 225.0 542.7 88.71 856.41 Partial Secondary Juice 225.0 547.0 75.85 847.85 Whole Cane Juice 225.0 267.0 260.31 752.31 Partial Whole Cane Juice 225.0 548.0 76.98 849.98 Expenditure, (Rs./MT)

18. Total expenditure Expected cane price Total revenue Particulars Conventional 1521.35 827.49 694.06 B-Heavy 1532.12 832.58 699.54 Secondary Juice 1552.32 856.41 695.91 Partial Secondary Juice 1548.05 847.85 700.02 Whole Cane Juice 1599.05 752.31 846.74 Partial Whole Cane Juice 1535.45 849.98 685.47 Expected cane price, (Rs./MT)

19. Particulars Sugar Production (Qtls) Ethanol Production (KL) Conventional 8,28,000 6,659.28 B-Heavy 7,07,040 13,489.74 Secondary Juice 6,30,720 18,248.58 Partial Secondary Juice 6,77,520 15,602.40 Whole Cane Juice - 53,549.28 Partial Whole Cane Juice 6,65,280 15,835.14 Maximum Production (180 days)

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

21. SUGAR BEET CROP YIELD

22. Average Composition of Sugar Beet

23. CHARACTERISTICS OF SUGAR BEET JUICE

24. Sugar beet roots Process flow diagram of Ethanol manufacturing from sugar beet juice – Beet weighment Water Beet washer Wash water to field Beet slicer Exhaust steam Beet Diffuser Diffused Juice Diffused pulp Screening Pulp press Suspended matter Juice evaporation & syrup cooling Pulp for cattle feed Low brix juice to diffuser Syrup weighment Water &Yeast Fermentation CO2 Bio-methanation or Bio-composting Steam Primary distillation (R.S.) Sp. wash Ethanol Dehydration

25. Case Study

26. Case Study 500 TBD to connect with existing 45 KLPD Distillery Unit

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

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

33. COST OF CULTIVATION FOR S. SORGHUM

34. SWEET SORGHUM PLOT AT VSI

35. ANALYSIS OF RAW AND CLARIFIED JUICE

36. S. SORGHUM – STALK AND JUICE ANALYSIS

37. Economics of Ethanol Production From Sweet Sorghum

38. Economics of Alcohol Production From Sweet Sorghum

39. Economics of Alcohol Production From Sweet Sorghum

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

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

42. Thank You