Goodrich SUGAR & CHEMICAL COMPLEX LIMITED OFFERS
SECOND GENERATION TECHNOLOGIES FOR
'SUGARCANE COMPLEX'
AS ALTERNATE TO CONVENTIONAL SUGAR,
ETHANOL & CO-GENERATION PLANTS
 
A.   Conventional Sugar Plants-
 
Basis- 160 days of working in a year

 

OPTIONS

2,500 TCD

5,000 TCD

10,000 TCD

Technology
status

1
Sugar recovery
10 - 11%
40,000 - 44,000 tons (Value Rs. 60-66 crores)
80,000 - 88,000 tons
(Value Rs. 120-132 crores)
1,60,000 -1,76,000 tons (Value Rs. 240-264 crores)
Technology is available in India
2
Molasses 4.5% - 5% (50% sugar contents)used for Bio-ethanol
18,000 - 20,000 tons of molasses - converted into 50-55 lakh litres of Bio-ethanol a year (Value Rs. 10-11 crores)
36,000 - 40,000 tons of molasses - converted into 100-110 lakh litres of Bio-ethanol a year (Value Rs. 20-22 crores)
72,000 - 80,000 tons of molasses - converted into 200-220 lakh litres of Bio-ethanol a year (Value Rs. 40-44 crores)
Technology is available in India
3
Bagasse 30 - 32% used in Co-generation of power & Process steam
12 - 15 MW of power generation (Exportable surplus 8-10 MW - Value Rs. 8-10 crores)
25 - 30 MW of power generation (Exportable surplus 18-22 MW - Value Rs. 18-22 crores)
50 - 60 MW of power generation (Exportable surplus 40-45 MW - Value Rs. 40-45 crores)
Technology is available in India
4
Press mud 3.5-4% with 60-70% moisture,used as Bio-manure
14,000 - 16,000 tons of press mud (No value)
28,000 - 32,000 tons of press mud (No value)
56,000 - 64,000 tons of press mud (No value)
-
5
Sugarcane trash 27% of cane-not recovered from the Field
1,08,000 tons (Estimated Bio-mass) (No value)
2,16,000 tons (Estimated Bio-mass) (No value)
4,32,000 tons (Estimated Bio-mass) (No value)
-
6
Sugarcane top leaves 11% of cane-not recovered from the Field
44,000 tons (Estimated top-leaves) (No value)
88,000 tons (Estimated top-leaves) (No value)
1,76,000 tons (Estimated top-leaves) (No value)
-
 
Overall investment
Rs. 100 - 125 crores
Rs. 200 - 225 crores
Rs. 350 - 400 crores
 
 
Turnover per year
Rs. 80 - 90 crores
Rs. 160 - 180 crores
Rs. 320 - 360 crores
 
 
Pay-back period
8 years
7 years
6 years
 

 
B.   Second generation "Cane Complex" technologies-
 
Basis- 160 days of working in a year

 

OPTIONS

2,500 TCD

5,000 TCD

10,000 TCD

Technology
status

1

Recovery of 7.5% Sugar from Primary juice

30,000 tons
(Value Rs.45 crores)
60,000 tons
(Value Rs. 90 crores)
1,20,000 tons
(Value Rs.180 crores)

Technology is available in India

2

Recovery of Ethanol from Secondary juice & also from the molasses of Primary juice


OR
120 - 130 lakh of Ethanol a year (Value Rs. 25-28 crores)
240 - 2600 lakh of Ethanol a year (Value Rs. 50-56 crores)
480 - 520 lakh of Ethanol a year (Value Rs. 100-112 crores)

Technology is available in India.However, technology for 95% overall recovery is available from Europe.

 

L-Lysine  (L-60)from the mix of Secondary juice & molasses of Primary juice


OR
20,000 tons a year (Value Rs. 80 crores)
20,000 tons a year (Value Rs. 80 crores)
20,000 tons a year (Value Rs. 80 crores)
Basic Engineering & licensing from Europe.Detailed Engineering from China.
 

MSG(Mono Sodium Glutamate) from the mix of Secondary juice & molasses of Primary juice (or from molasses only)


OR
30,000 tons a year (Value Rs.150 crores)
30,000 tons a year (Value Rs.150 crores)
30,000 tons a year (Value Rs.150 crores)
Basic Engineering & licensing from Europe.Detailed Engineering from China.
 

- Fresh yeast from the mix of Secondary juice & molasses of Primary juice (or from molasses only)


OR
10,000 tons a year (Value Rs.30 crores)
10,000 tons a year
(Value Rs.30 crores)
10,000 tons a year (Value Rs.30 crores)
Basic Engineering & licensing from Europe.Detailed Engineering from China.
 
Citric acid  from the mix of Secondary juice & molasses of Primary juice
44,000 tons (Estimated top-leaves) (No value)
88,000 tons (Estimated top-leaves) (No value)
1,76,000 tons (Estimated top-leaves) (No value)
-
3.

Co2, a by-product of Alcohol is used to make new generation Bio-degradable Plastic i.e., Poly Ethylene Carbonate (PEC) presently selling @ Rs. 180 per kg( Note: Ethylene can be procured from the Naphtha Cracking Units or converted from Ethanol, with 58% recovery. Carbon di-oxide is recovered from the Ethanol plants to the extent of 800 grams per litre of Ethanol produced)


OR
13,500 tons of Ethylene is reacted with 11,500 tons of Co2 to produce 25,000 tons of PEC




(Value Rs. 150 crores, based on the price of only Rs. 60 per kg)
27,000 tons of Ethylene is reacted with 23,000 tons of Co2 to produce 50,000 tons of PEC




(Value Rs. 300 crores, based on the price of only Rs. 60 per kg)
54,000 tons of Ethylene is reacted with 46,000 tons of Co2 to produce 1,00,000 tons of PEC




(Value Rs. 600 crores, based on the price of only Rs. 60 per kg)
The first Pilot plant of 5,000 tons of PEC per annum has been built successfully in China. The capacity is being scaled up now
 

-Dehydration of Ethanol into Ethylene and conversion of Ethylene into a host of downstream petro-chemicals, intermediaries, polymers & commodity plastics like Polyethylene, HDPE, LDPE, PVC, Sterene, Polystyrene, ABS, VAM, EO/EG, MEG, N-Butanol, 2 Ethyl Hexonal, Ethylene Di-chloride etc. which are used in commodity plastics, synthetic rubbers, tyres & tubes, polyester staple fibers, polyester filament yarns, polyurethane foams, wire enamelling, chemical intermediates, plasticizers, emulsifiers, solvents, explosives, textiles, printing inks & dyes, polyester resins, paper coatings, perfumes, pesticides etc.  from the mix of Secondary juice & molasses of Primary juice

20,000 - 50,000 tons a year.
(Value Rs.100-250 crores)


30,000 - 75,000 tons a year.
(Value Rs.150-375 crores)


50,000 - 1,00,000 tons a year.
(Value Rs.250-500 crores)


For conversion of Ethanol into Ethylene, the technology is available in India. For further downstream products, technology from Europe & detailedEngineering from China


4

MDF from bagasse (since power generation is restricted, more bagasse is available)


OR
40,000 cubic meters of MDF per year (Value Rs.45 crores)
80,000 cubic meters of MDF per year (Value Rs.90 crores)
1,20,000 cubic meters of MDF per year (Value Rs.135 crores)
Proven technology available from china & Europe.
 

Particleboard from bagasse


OR
50,000 cubic meters of Particleboard per year (Value Rs.42 crores)
80,000 cubic meters of Particleboard per year (Value Rs.67 crores)
1,50,000 cubic meters of Particleboard per year (Value Rs.126 crores)
Proven technology available from china & Europe.
 

CTMP (Chemi - thermo mechanical pulp) from bagasse,combined with Tissue paper or Craft paper or Newsprint project


OR
45,000 tons of CTMP per year with 12,000 tons of Tissue paper per year or 75,000 tons of multi-layer Craft paper per year or 75,000 tons of Newsprint per year (Value Rs. 405 crores)
90,000 tons of CTMP per year with 12,000 tons of Tissue paper per year or 75,000 tons of multi-layer Craft paper per year or 75,000 tons of Newsprint per year(Value Rs. 450 crores)
1,80,000 tons of CTMP per year with 12,000 tons of Tissue paper per year or 75,000 tons of multi-layer Craft paper per year or 75,000 tons of Newsprint per year (Value Rs. 540 crores)
Proven technology available from china & Europe.
5.

Xylitol (Low calorie sugar)from bagasse


OR
10,000-15,000 tons per year (Value Rs.100-150 crores)
10,000-15,000 tons per year (Value Rs.100-150 crores)
10,000-15,000 tons per year (Value Rs.100-150 crores)
Technology for Xylitol from Corn cob is available & the first Pilot plant from bagasse is being set up in China
6.

Furfuralfrom bagasse pith


OR
3,000 tons per year (Value Rs.10 crores)
3,000 tons per year (Value Rs.10 crores)
3,000 tons per year (Value Rs.10 crores)
Technology for Furfural from Corn cob is available in China
7.

Recovery of wax,vitamin D2and mineral supplements for animal feeding from Press mud


OR
500 tons of vegetable wax per year, 10 tons of vitamin D2 per year & 4,000 tons of mineral supplements per year (Value Rs. 8 crores)
1,000 tons of vegetable wax per year, 20 tons of vitamin D2 per year & 8,000 tons of mineral supplements per year (Value Rs. 16 crores)
2,000 tons of vegetable wax per year, 40 tons of vitamin D2 per year & 16,000 tons of mineral supplements per year (Value Rs. 32 crores)
The technology has been successful in the laboratory level and a Pilot plant needs to be set up to familiarize the process
8.

- Dried green fodder from Sugarcane top leaves


OR
12,000 tons of Dried top leaves (Value Rs.6 crores)
24,000 tons of Dried top leaves (Value Rs.12 crores)
48,000 tons per year (Value Rs.24 crores)
Technology for cutting & drying can be adopted from Particleboard or MDF plants. Cuba is already exporting this green fodder to Japan
9.

Bagasse Drier to dry bagasse from 50% to 40% moisture,using waste heat from the chimney & saving 10% of bagasse,which can be used for MDF / Particleboard / Co-generation


OR
Saving of 12,000 tons of bagasse,valued at Rs.1.20 crores
Saving of 24,000 tons of bagasse,valued at Rs.2.40 crores
Saving of 48,000 tons of bagasse,valued at Rs.4.80 crores
Technology is available from China, based on Particleboard / MDF Driers.
10.

Co-generation of power & steam from the remaining bagasse; from the remaining pith & from baled sugarcane trash, the calorie value of which is equal to bagasse


OR
Co-generation is restricted to captive requirement of steam & power. No exportable surplus. (No extra earnings)
Co-generation is restricted to captive requirement of steam & power. No exportable surplus.( No extra earnings)
Co-generation is restricted to captive requirement of steam & power. No exportable surplus. ( No extra earnings)
Balers for lifting & compressing sugar cane trash are already working in India. Boilers and combustion chambers are to be suitably modified to enable the burning of trash with higher sand & silica. The technology is available in China
 
Total investment with optimum mix of the above projects
Rs. 200 - 250 crores
Rs. 350 - 450 crores
Rs. 500 - 750 crores
 
 

Turnover per year
 
Rs. 200 - 250 crores
Rs. 400 - 500 crores
Rs. 800 - 1,000 crores
 
 

Pay-back period
 
5 years
4 years
3 years
 
 

For more details,please contact-
Goodrich Sugar & Chemical Complex Limited
No.16 II Main,II cross,AECS Layout III stage,
Sanjaynagar,Bangalore-560 094,India.
Ph:0091-80-23411400
Fax:0091-80-23410388
Email:rao@goodrichsugar.com
Website:www.goodrichsugar.com

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