Bagasse is the residue obtained from crushing cane in the mills. Bagasse is used as a raw material by the paper industry and it is also very commonly used as fuel in boilers in the sugar factory for co-generation of power. Bagasse & wood fibre are made into building boards by a process analogous to paper making. Moisture contents is the main determinant of calorific value i.e. the lower the moisture content, the higher the calorific value. Most mills produce Bagasse of 49% moisture content, and most boilers are designed to burn Bagasse at around 50% moisture. In general, bagasse has a heating value of 2200 Kcal/kg on a wet, as-fired basis at 50% Moisture. For every 100 tons of Sugarcane crushed, a Sugar factory produces about 30 tons of wet Bagasse. Bagasse is often used as a primary fuel source in cogen boiler for steam & power generation.
Sugarcane press mud is the residue of the filtration of sugarcane juice. The clarification process separates the juice into a clear juice that rises to the top and goes to manufacturing, while the mud gets collected at the bottom. The mud is then filtered to separate the suspended matter, which includes insoluble salts and fine bagasse. Press mud is commonly known as filter cake and is used as manure by the farmers. Depending on the quality of sugar cane and the extraneous matter that comes with sugarcane, press mud is about 3.5% to 4.5% of total cane crushed. When press mud is mixed with the spent wash generated by the distilleries, the resultant product is enriched organic manure, which has the capability to improve yields in farms
Composition of Sugar Mills Press Mud
It is high in protein content (21%) and essential amino acids such as methionine, Lysine, tryptophan which are required for the growth of animals compared to cereals. Hence, it is widely used as cattle feed.
It is a kind of high protein fodder/feed made from corn /Maize through fermentation, distillation, evaporation and drying. The fodder contains not only rich protein but also amino acids, vitamins and mineral matters favorable to the growth of animals. Moreover, this product is used as a feed for poultry, livestock, aquaculture, cattle and other species as well.
Composition of DDGS (Distillers Dried Grain with Solubles)
The composition of raw press mud includes carbon, nitrogen, phosphorous, potash, calcium, magnesium, copper, zinc, manganese, iron, silicon and wax. The composition varies significantly on the soil conditions, cane varieties, period of supply of cane and geographical variations. The NPK content in the press mud is about 2.5%, 1.5% and 3% respectively.
Simultaneously, spent wash is an effluent which is a waste of distilleries producing alcohol/ethanol, mostly attached to sugar mills. The spent wash also has beneficial nutrients like nitrogen, phosphorous, potassium etc
At present, the sugar mills use spent wash with press mud to produce bio compost as manure. This is an approved method of disposal of distillery effluents. As per real time experience, the productivity of not only sugarcane but other crops also is much better with use of this manure. It is therefore in the interest of farmers and the agriculture sector to use press mud and spent wash to produce this manure.
Characteristics of Bio Manure.
|1||pH of 1% solution||7.0 – 7.2|
|2||Moisture content||30-35 %|
|3||Organic Carbon||20-25 %|
The brand name of our bio compost is “Bhagya Boomi”. Our bio-composting facility can produce about 6000 MT (Approx) of organic manure per annum.
Molasses, an important byproduct of the sugar industry, is used extensively for the manufacture of ethyl alcohol and alcohol based downstream chemicals in addition to the manufacturing of potable alcohol. Sugarcane molasses is a viscous, dark and sugar-rich byproduct of sugar extraction from sugarcane. Sugarcane molasses is also used for alcohol / fuel ethanol production and the distillery process yields vinasses that can also be used in animal feeding.
Approximately 4-5% molasses can be produced from one tonne of fresh sugar cane. Molasses composition varies highly and depends on cane varieties, climate and processes. It contains nearly 45% un-crystallized, fermentable Sugar & Sucrose.
Bagasse is one of the important biomass sources, which is used as a fuel in the cogen boiler. As a result, considerable quantities of fly ash are being generated during bagasse combustion. Fly Ash is the residual output from the boiler furnace after bagasse has completely burnt out. This fly ash is rich in potassium and is used by local farmers in their agricultural fields for cultivation
Dissolved sugar from ground up molasses is diluted by mixing water with it. Sulfuric acid is added with diluted sugar to prevent bacterial contamination. Yeast is added with this before feeding to fermentor. Glucose and fructose are obtained by hydrolysis of sucrose. The conversion of sucrose present in molasses is getting fermented in the fermenter, while Glucose and Fructose is converted into ethanol and carbon di-oxide.
Raw scrubbed CO2 gas is pumped through the pipeline at low pressure of 300 mm water column to the CO2 plant. The CO2 gas is taken to the buffer vessel. The CO2 gas is compressed to a Pressure between 15 to 18 Kg/cm2 with the help of CO2 compressor. The raw CO2 gas will be passed through the Activated Carbon filters, which purifies the CO2 gas from odor, hydrocarbons and other impurities etc.This gas is further oxidized for removing of odor using bubbler tanks.
The purified CO2 gas passes through the drier unit, where moisture is removed from the CO2 gas. The dry and purified CO2 gas from drier is passed to the stripper cum Liquefier Unit (NH3/ CO2Heat Exchanger). In the liquefier cum stripper unit the CO2 gas is cooled to the temperature between -15 to -26 deg C with the help of Liquid ammonia and the CO2 gas becomes liquid of 99.99% in the Liquefier cum stripper unit.
This liquid CO2 will be transferred to the CO2 Storage Tanks with the help of gravity. The final product of Liquid CO2 (-24o C to -29o C) will be stored in the insulated storage tanks.
This Pure Liquid CO2 will be sent to the customers as per their requirements by insulated Mobile Tankers.