Detailed Project Report on sugarcane plantation and sugar mill with by product and ethanol for electricity

SUGARCANE PLANTATION AND SUGAR MILL WITH BY PRODUCT AND ETHANOL FOR ELECTRICITY [CODE NO 3725]

In general sugarcane grows well in well drained, medium loam soil which is neither too acidic nor too alkaline, though cane is grown in the pH range 4.5 to 8.5. In sandy loam soil, incorporation of organic matter is necessary as also additional irrigation. If the soil is clayey, more care is necessary in cultivation. The soil should preferably be deep. Sugarcane can grow in low lands, provided water logging does not persist for a long period and the variety grown is tolerant to the situation.

It is best to grow sugarcane on a 3-year rotation - plant crop, first ratoon, second ratoon and cereal, leguminous/green manure crop. It is important that the organic matter and the nitrogen content of the soil is maintained properly. The practice of green manuring, as followed in Australia, is important. If possible the green manure crop should be grown separately and ploughed in at the appropriate time. If this is not feasible, the green manure crop should be taken as an inter crop by sowing along with the planting of sugarcane or a little earlier.


COST ESTIMATION

Plant Capacity            SUGARCANE PLANTATION & SUGAR MILL WITH BY PRODUCT AND ETHANOL FOR    
                                ELECTRICITY                        
Land & Building (130000 Hactare)     US$. 66.53 Cr  
Plant & Machinery                    US$. 12.94 Cr
Working Capital for 2 Months    US$. 39.51 Lacs
Total Capital Investment          US$. 80.90 Cr
Rate of Return                         19%
Break Even Point                     56%


INTRODUCTION    
CHARACTERISTICS OF SUGAR CANE:    
AREA AND PRODUCTION OF SUGAR CANE:    
CLIMATE & SEASON:    
ETHANOL    
ETHYL ALCOHOL    
GASOHOL    
AZEOTROPIC DISTILLATION    
PROPERTIES OF SUGAR    
RAW SUGAR:-    
CUBE SUGAR:-    
ICING SUGAR:-    
LIQUID SUGAR:-    
UTILISATION OF BY-PRODUCTS:-    
ALCOHOL AND ITS USES:-    
BAGASSE AS RAW MATERIAL FOR PAPER AND BOARDS:    
USES & APPLICATION    
MANUFACTURING STEPS    
RAW MATERIALS & OTHER SPECIFICATIONS    
THE RAW MATERIALS ARE DESCRIBED HERE:-    
SUGARCANE:-    
LIME STONE:-    
COKE:-    
SULPHUR:-    
SUPERPHOSPHATE:-    
SODIUM HYDROSULPHITE:-    
FLOCUULENTS:-    
FILTER CLOTH:-    
GUNNY BAGS:-    
QUALITY CONTROL AND SPECIFICATIONS    
INDIAN STANDARD REQUIREMENTS FOR DIFFERENT KINDS OF SUGAR    
GLOBAL MARKET POSITION OF SUGAR    
GLOBAL SUGAR PRODUCTION UP SLIGHTLY IN 2019/20:    
GAINS IN BRAZIL AND EUROPEAN UNION OFFSET DECLINES IN INDIA    
SELECTED MY 2018/19 REVISIONS FROM NOVEMBER 2018 FORECAST:    
WORLD CENTRIFUGAL SUGAR: PRODUCTION AND CONSUMPTION
  1,000 METRIC TONS, RAW VALUE    
WORLD CENTRIFUGAL SUGAR: IMPORTS AND EXPORTS 1,000 METRIC
  TONS, RAW VALUE    
WORLD CENTRIFUGAL SUGAR: ENDING STOCKS 1,000 METRIC TONS,
   RAW VALUE    
GLOBAL MARKET SITUATIONS AND FUTURE OF SUGAR    
PROJECTION HIGHLIGHTS    
MARKET TRENDS AND PROSPECTS    
PRICES    
FIGURE. EVOLUTION OF WORLD SUGAR PRICES
PRODUCTION    
FIGURE.  WORLD SUGAR CROPS    
FIGURE. SUGAR PRODUCTION CLASSIFIED BY CROP    
CONSUMPTION    
FIGURE. PER CAPITA SUGAR DEMAND IN MAJOR COUNTRIES & REGIONS    
TRADE    
FIGURE. SUGAR EXPORTS FOR MAJOR COUNTRIES AND REGIONS    
FIGURE. SUGAR IMPORTS FOR MAJOR COUNTRIES AND REGIONS    
MAIN ISSUES AND UNCERTAINTIES    
SUGAR CANE PLANTATION    
PREPARATORY CULTIVATION:    
SEED RATE, TIME OF PLANTING AND SPACING:    
HOEING AND WEED CONTROL:    
IRRIGATION:    
PROCESS FLOW SHEET    
MANUFACTURING PROCESS FOLLOWED IN SUGAR INDUSTRY    
MACHINERY SUPPLIERS FOR SUGAR INDUSTRY IN INDIA    
SEQUENCES IN SUGAR MANUFACTURE    
MILLING:    
CLARIFICATION:    
EVAPORATION:    
CRYSTALLIZATION:    
SEPARATION:    
REFINEMENT:    
DRYING:    
PACKING:    
PROCESS OF MANUFACTURE    
JUICE EXTRACTION    
CLARIFICATION:-    
EVAPORATION:-    
CRYSTALLIZATION:-    
CENTRIFUGATION:-    
DRYING:-    
DRYING OF SUGAR :-    
DRYING OF SUGARS AND THEIR IMPORTANCE ON KEEPING QUALITY :-    
DETAILED PROCESS DESCRIPTION IS SUGAR MANUFACTURE    
PROCESS DESCRIPTION    
CANE SUGAR PRODUCTION -
FIGURE SIMPLIFIED PROCESS FLOW DIAGRAM FOR CANE SUGAR PRODUCTION.    
REFINED SUGAR PRODUCTION -    
FIGURE SIMPLIFIED PROCESS FLOW DIAGRAM FOR REFINED SUGAR
   PRODUCTION.    
CHANCES OF LOSSES IN DIFFERENT SECTION    
BY-PRODUCTS OF SUGAR INDUSTRY    
BAGASSE:-    
MOLASSES:-    
FILTER CAKE:-    
SUGARCANE WAX:-    
BYE PRODUCTS OF THE SUGAR INDUSTRY    
BAGASSE :-    
CHEMICALS :-    
MOLASSES :-    
ALCOHOL BY PRODUCTS AND DERIVATIVES :    
FILTER MUD :    
MANUFACTURING PROCESS OF ETHANOL FROM MOLASSES    
CHEMICAL REACTIONS:    
FIGURE. MANUFACTURE OF ETHANOL FROM MOLASSES    
FUNCTIONAL ROLE OF VARIOUS UNITS    
(A) MOLASSES STORAGE TANK:    
(B) STERLIZATION TANK:    
(C) YEAST CULTIVATION TANK:    
(D) YEAST STORAGE TANK:    
(E) FERMENTATION TANK:    
(F) DILUTER:    
(G) SCRUBBER:    
(H) BEER STILL:    
(I) ALDEHYDE STILL:    
(J) DECANTER:    
(K) RECTIFYING COLUMN:    
(L) STORAGE TANK:    
(M) MIX TANK:    
(N) TERNARY AZEOTROPIC DISTILLATION:    
SUGAR CANE ETHANOL PRODUCTION    
FIGURE: SCHEMATIC OF PROCESS OF SUGARCANE TO PRODUCE
   ETHANOL AND SUGAR.    
PROCESS IN DETAILS FOR ETHANOL PRODUCTION    
BY PRODUCT OF SUGAR CANE (PER TON OF SUGARCANE)
SUPPLIERS OF PLANT AND MACHINERY (GLOBAL)    
SUPPLIERS OF PLANT AND MACHINERY    
SUPPLIERS OF RAW MATERIALS    
QUICK LIME    
SODA ASH    
CASTOR OIL    
HYDROCHLORIC ACID    
SULPHURIC ACID    
SODIUM HYDROSULPHITE    
SUPER PHOSPHATE    


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)