Bagasse Pulp Manufacturing (Cap: 50 Tons/Day)

BAGASSE PULP MANUFACTURING (CAP: 50 TONS/DAY)

[EIRI/EDPR/4716] J.C.: 2936INR, 2936US$

INTRODUCTION

The sugarcane bagasse is the main residue product of the Indian agricultural industry. Sugarcane bagasse pulp is considered a fine raw material for manufacturing paper and sustainable tableware products. The bagasse is a fibrous waste left after the juice is squeezed out from the sugarcane by pressing it.

Generally, sugarcane bagasse is yellowish-gray to lemon-colored consisting of lignin and cellulose fibers. Sugarcane bagasse is a mixture of hard fibers and soft parenchyma i.e. bagasse pith. Bagasse is rich in cellulose content. The chemical composition of sugarcane bagasse is majorly 50% cellulose, about 25% hemicellulose, and about 25% lignin.

Bagasse is the by-product of the sugar industry and is also one kind of papermaking fiber material. As the foundation of paper and pulp industry, fiber materials include wood fiber and straw fiber. Except for the sugarcane bagasse, there are some other materials like wheat straw, reed, bamboo, and kenaf, etc. 

Among all kinds of fiber materials, bagasse is low-cost and inexhaustible to make paper pulp. The bleached bagasse pulp can be mixed to certain quantity of macro fiber and used to manufacture various high-grade cultural paper and living paper, such as bodystock paper, copy paper, two-side offset paper, sanitary tissue, napkin and etc. With the proper manufacturing process, the bagasse pulp also can be applied to make coated art base paper or newspaper.

Sugarcane is annual rhizomatous plant; the average length of fiber is usually 1047-3.04mm. After squeezing, the length of bagasse fiber is similar to the hardwood fiber, is 1.0-2.34mm. Bagasse pith is a parenchyma cell, it reduces the opacity and strength of paper, and increase the chemicals consumption and difficulty of manufacture. So the depithing is important for bagasse pulping.

Sugarcane bagasse belongs to the straw fiber, is easy to cook or bleach and requires fewer chemicals consumption. Because silicon content of bagasse is lower than other straw fibers, which decide the bagasse pulp process or equipment is more mature and easy.

COST ESTIMATION

Plant Capacity            50 MT/Day

Land & Building (16,000 sq.mt.)    Rs. 10.80 Cr

Plant & Machinery                    Rs. 15.00 Cr

Working Capital for 1 Month    Rs. 5.03 Cr

Total Capital Investment          Rs. 32.99 Cr

Rate of Return                          23%

Break Even Point                      59%

CONTENTS

INTRODUCTION

BAGASSE

USES AND APPLICATIONS OF PULP

BESIDES, THE END USE OF PAPER AND PAPER PRODUCTS ARE,

SUGARCANE BAGASSE PULP ADVANTAGES

PROPERTIES AND COMPOSITION OF BAGASSE

A TYPICAL CHEMICAL ANALYSIS OF WASHED AND DRIED BAGASSE MIGHT SHOW:

TECHNICAL DETAILS OF BAGASSE PULP

BAGASSE PULP PROCESSING

MATERIAL PREPARATION

BAGASSE PULP COOKING

BAGASSE PULP WASHING

BAGASSE PULP SCREENING

BAGASSE PULP BLEACHING

ADVANTAGES OF BAGASSE PULP PRODUCTION

PULP BLEACHING PROCESS

PRINCIPLES FOR PULP BLEACHING PROCESSING

BASIC PRINCIPLE OF PULP BLEACHING

OXIDIZING BLEACHING

REDUCTIVE BLEACHING

RELATIVE EQUIPMENT

THE SPECIFIC PROCESS FLOW CHART IS AS FOLLOWS:

PULP WASHING PROCESS

TECHNICAL PRINCIPLE

TECHNICAL REQUIREMENT FOR PULP WASHING

PULP COOKING PROCESS

BATCH COOKING

SUPER BATCHING COOKING

PROCESSING OF SUPER BATCHING COOKING:

ADVANTAGES OF SUPER BATCHING COOKING:

DISPLACEMENT COOKING

PROCESSING OF DISPLACEMENT COOKING:

1. RDH COOKING SYSTEM

2. DDS COOKING SYSTEM

SPECIFICATIONS:

CONTINUOUS COOKING

HORIZONTAL TUBE CONTINUOUS DIGESTER

VERTICAL CONTINUOUS DIGESTER

ADVANTAGES OF CONTINUOUS COOKING

CHEMI-MECHANICAL PULPING

PROCESS OF APMP PULPING

PRINCIPLE FOR APMP PULPING

THE FUNCTION OF NAOH:

THE FUNCTION OF H2O2

MAIN EQUIPMENT OF APMP PRODUCTION LINE

SCREW CONVEYOR:

TEARING MACHINE:

HEAT RECOVERY EQUIPMENT:

CONDENSING EQUIPMENT:

ADVANTAGES OF APMP PRODUCTION LINE

COMMON PULPING PROCESS

IMPORTANT BENEFITS WHEN BAGASSE IS USED FOR MAKING PAPER:

COOKING

WASHING

SCREENING

BLEACHING

BAGASSE PULP PROCESSING

MATERIAL PREPARATION

BAGASSE PULP COOKING

BAGASSE PULP WASHING

BAGASSE PULP SCREENING

BAGASSE PULP BLEACHING

PRODUCTION STEPS AND SUSTAINABILITY OF BAGASSE OF BAGASSE PRODUCTS

PRODUCTION STEPS OF BAGASSE PRODUCTS:

SUSTAINABILITY

PRODUCING BAGASSE PULP

PROCESSING DETAILS FOR BAGASSE PULP

DEPITHING

DEPITHING OPERATION

TYPICAL ARRANGEMENT OF A BANK OF DEPITHERS

CHEMICAL PULPING AND BLEACHING OF BAGASSE

DIGESTION

BLACK LIQUOR

BLEACHING

MECHANICAL AND CHEMI-MECHANICAL PULPING

SEQUENCES OF BAGASSE PULP PROCESSING

MATERIAL PREPARATION

BAGASSE PULP WASHING

BAGASSE PULP SCREENING

BAGASSE PULP BLEACHING

MARKET POSITION OF BAGASSE PULP

BAGASSE PULP HAS ADVANTAGES

INTENSE MARKET COMPETITION

THE DOWNSTREAM MARKET IS VAST

REGION OVERVIEW:

TAMIL NADU NEWSPRINT AND PAPERS LTD

GUANGXI YANGPU NANHUA SUGAR INDUSTRY

FOOD GRADE

INDUSTRIAL GRADE

APPLICATION OVERVIEW:

FOOD PACKAGING

PAPER

KEY COMPANIES IN THE GLOBAL BAGASSE PULP MARKET COVERED IN CHAPTER 3:

PROCESS FLOW DIAGRAM FOR BAGASSE PULP

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION:

2. FIXED ASSETS:

3. WORKING CAPITAL:

4. BREAK-EVEN POINT:

5. OTHER FIXED EXPENSES:

6. MARGIN MONEY:

8. TOTAL LOAD:

9. LAND AREA/MAN POWER RATIO:

PROJECT IMPLEMENTATION SCHEDULES

INTRODUCTION

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

TIME SCHEDULE

IMPLEMENTATION SCHEDULE

INDIAN SUPPLIERS OF PLANT AND MACHINERY

OVERSEAS SUPPLIERS OF PLANT AND MACHINERY

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF RAW MATERIALS

UTILITIES

POWER

WORKING

TOTAL MANPOWER AND PAYROLL

UTILITIES

WATER

WATER QUALITY PARAMETERS FOR PROCESSED WATER:

STEAM

POWER

EFFLUENT TREATMENT AND DISPOSAL

TOLERANCE LIMITS FOR INDUSTRIAL EFFLUENT DISCHARGE

WASTE TREATMENT

PRIMARY TREATMENT

ANAEROBIC TREATMENT

ANAEROBIC TREATMENT HAS THE ADVANTAGES OF

SECONDARY TREATMENT

TERTIARY TREATMENT

SOLIDS CONCENTRATION

TYPICAL WASTE SOLIDS CHARACTERISTICS

EQUIPMENT REQUIREMENT

EQUIPMENT REQUIREMENTS

DOCUMENTS REQUIRED FOR LICENSES

LIST OF DOCUMENTS:

MACHINERY PHOTOGRAPHS

SWOL ANALYSIS

STRENGTHS

OPPORTUNITIES

WEAKNESS

LIMITATIONS

ORGANIZATION CHART

LIST OF TURNKEY CONSULTANT

FLOW DIAGRAM OF MATERIAL BALANCE

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)