Jasbir Singh Presentation For Indonesian Sugar Industry
Jasbir Singh Presentation For Indonesian Sugar Industry
Jasbir Singh Presentation For Indonesian Sugar Industry
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• The main objective of NFCSF is to provide Technical
Consultancy services for promotion of Technology for
improving productivity of the sugar factories in the
field of:
– Sugarcane Agriculture,
– Sugar Engineering,
– Sugar Processing Technology,
– Project Cost Estimates,
– Project Financial Management,
– Effective by-product utilization like Cogeneration,
– Ethanol, ENA and downstream products.
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• The technical cell is well informed and keeping track of
technical developments in the sugar industry for
introducing schemes like
– Energy conservation
– Reduction in steam consumption,
– methods for improving bagasse saving,
– optimum level of Cogeneration,
– improving operational efficiency parameters
– Improving cane productivity and better quality of sugar cane in
most economical manner
– financial management feasibility of the project
– Techno-commercial approach of services for improving
feasibility and profitability of the project.
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A) The technical consultancy services are covering the following Areas: 6
❖ Installation of green field projects in Sugar, Cogeneration, Distillery for Ethanol
❖ Modernization, Expansion, Balancing of the existing sugar projects
❖ Improving the technical performance by way of advise in efficient operation,
energy conservation, reduction in steam consumption & power consumption
etc.
❖ Off season repairs & maintenance and approval Budgetary Cost Estimates for
the same
❖ On the spot for investigating the causes of reduction in recovery to reduced
sugar losses and adjustment of the operational bottlenecks and trouble
shooting of the plant
(v) Technical packages for capacity calculations of the plant and for balancing of
the plant for its efficient operation viz.
a) Plant Capacity
b) Plant Balancing and
c) Efficiency & Energy Audit.
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A. Performance Evaluation : 9
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D. Thermography study: 10
E Process Energy:
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• Introduction Shredder/Fiberizor to achieved P.I. > 90.0%
• ACVVVF Drives for mills with Planetary/double helical gear
boxes & rope coupling for energy conservation.
• Improving Milling Performance.
• 0.10 Recovery rise for each one unit rise in RME
• 10 units rise in Primary Extraction gives rise to one unit rise in
overall mill extraction.
• High Pressure boiler 110 Kg cm2g with high super heater steam
temperature of 540 Deg. C with regenerative feed heating to
improve steam fuel ratio to around 2.6 or more. Multi fuel
furnaces are being introduced to burn biomass etc. reducing
moisture % Bagasse emerging from the Mills to 48%.
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• Quintuple effect Evaporator with initial 3 nos. vessel are Falling Film Type 13
and with effective vapour bleeding scheme to reduce steam consumption
to 30-32% on cane.
• Energy Conservation methods have been introduced to reduce in house
power consumption to 25 KW/TCH in electric driven plant.
• No fresh water consumption in the plant by utilizing the recirculation of
water & utilizing excess condensate effectively.
• Zero Liquid Discharge norms are being introduced for distillery effluent
treatment.
• CPCB norms for air and water pollution and online monetary is being
introduced.
• Sugar processing techniques are being improved by providing continuous
pans etc.
• Automation at various stations for consistent working & improved
efficiency.
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– Preparation & Submission of IEM to Industry Deptt. 15
– Selection of site and best suitable layout for efficient working of the
plant and fulfilling the Govt. Rules & Regulations.
– To propose appropriate technology for cane crushing operation and
compare the study- Milling V/s Diffuser System.
– Preparation of Detailed Project Report.
– Designing, Engineering & preparation of Specifications of Plant &
Machinery introducing modern/efficient/automation and state of the
art Sugar Project..
– Preparation of NIT ( Notice Inviting Tender).
– Project Cost Estimates.
– Financial Feasibility / Viability Report study.
– Inviting quotation and negotiation for placing order.
– Preparation of agreement and placing order.
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– To introduce automation in plant for optimization, efficient operation
and quality production of sugar with reducing man power.
– Negotiation and Selection of machinery supplies suitable for timely
commission and quality supply of design and engineering of the
project.
– Preparation of Draft Agreement for machinery supply, commission and
performance along with preparation of project implementation
schedule.
– Vetting of equipment drawings.
– Vetting of designing of Civil Foundation and Execution.
– Stage and Final Inspection/ running trials of machinery at
manufacturers’ workshop as per terms of the agreement.
– Supervision of quality and sequence of erection work of the equipment
at site for timely commissioning.
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– Supervising the test and trials of the equipment for satisfactory
working after commissioning.
– Supervising the performance trial of the plant and machinery as per
terms .
– To supervise the functioning of the plant to achieve the rated capacity
/ efficient and quality of sugar after commissioning and performance
by removing the bottlenecks and weak links.
– To supervise and monitoring the working of plant during the season for
efficient operation.
– To supervise overhauling and maintenance of the plant during off
season for satisfactory and efficient working of the plant during season
to achieve targeted performance parameters and capacity utilization.
– Training of the staff for efficient operation of the plant.
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– To prepare Detailed Project Report for Cogeneration in existing Plant
and Green Field Project.
– Optimum power generation study at most suitable and economical
steam pressure and temperature configuration.
– Selection of Cycle for power generation through Back Pressure &
Condensing Mode for minimum steam consumption and maximum
power production.
– Selection of Electrical Equipment for minimum power consumption,
minimum transmission losses by improved cabling layout, Better
Electrical Distribution System Design and Automatic power factor
control system application.
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- To provide complete know-how for Modernization and
Expansion of existing molasses and grains based units and
to prepare DPR for Stand alone / Integrated Distillery of any
capacity for manufacture of Rectified Spirit, ENA, Ethanol,
Country Liquor, IMFL & Bottling Plant etc.
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- To provide complete know-how and preparation of
Detailed Project Report for production of Refine Sugar
with existing / new project. Proposals for preparation of
DPR for production of sugar without use of Sulphur using
Defeco Raw Melt Phosphoflotation process for production
of White Sugar having colour value below 50-60 ICUMSA.
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S.NO PARTICULARS
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Boilers : 24
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Boiling House :
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• Vapour bleeding scheme need to be suitably modified alongwith flash recovery system
so that the steam consumption % cane in process should be reduced to around 30% of
cane.
• Reducing cost of production.
• Sugar losses should be reduced to around 1.7 – 2.0 % on cane below 80 ICUMSA by
suitably modified process scheme.
• Production of quality sugar
Roadmap for modernization of sugar plant at a glance:
• Capacity utilization of the plant should be improved up to 100% or more.
• Sugar recovery should be improved to as per the bench marking of each sugar plant.
• Bagasse savings of the plant should be suitably improved.
• The detailed project report for each of the plant should be prepared as per the cast
study by NFCSF for improving Energy Consumption, Fuel, Steam , Power & Water
Balance..
• Cogeneration, Ethanol & By-products utilization for converting them “Sugar Industrial
Complex” for operating as a business hub for improving profitability.
• Fixing Performance parameter targets for efficient operation of the plant.
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• The experts are having long working experience, professionally qualified
and well informed about the present innovations/progress in the field.
• All experts are having four decades practical experience in their respective
field.
• Specialized professional are in field of Agriculture, Sugar Engineer, Sugar
Processing, By Products Utilization Distilleries/Ethanol/ENA etc.
• Financial Management and Cost Accounts
• Administration and Govt. Liaison work
• Project Management team from Concept to Commissioning in Sugar,
Cogeneration, Ethanol Project is available.
• NFCSF is having a total strength about 40 Nos. employees.
• Technical cell has been re-structured so that innovative and modern
technologies may be introduced to meet the challenges being faced by the
sugar industry, to improve its productivity, technical feasibility and
financial viability (List of officers given in later slide).
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S.No Name Qualification Designation 27
7. Sh. S. Somasundaram B.Sc,, A.V.S.I (Sugar Technology), MBA Dy. Tech. Adviser
(Finance) (Sugar Technology)
9. Sh. B.C.Gitte B.E. (Mech.), PG Dip. AVSI (Sugar Dy. Tech. Adviser
Engineering) (Sugar -Engineering)
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• Commissioning of Green Field Sugar
Projects/Modernization & Expansion Projects
– 200 Nos. new factories & expansion of projects
– 25 Nos. of ethanol projects
– 20 Nos. bagasse based Cogeneration projects
– 05 Units syrup & melt/ filtrate
clarification/adoption of latest technology to
produce quality sugar of 80 ICUMSA.
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Etheopia 2
Madagascar 3
Sudan 1
Nepal 1
Niger 1
Ghana 1
Fizi Sugar Corporation 3
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S. No. Projects Description of projects 31
2 M/s Sahyadri SSK Ltd., Preparation of DPR for green field project of
Kolhapur, 2500 TCD alongwith Cogen and Ethanol plant.
6 M/s Uttam Sugar Mills Ltd., Preparation of DPR for 8500 TCD from
Unit Barkatpur existing sugar plant of 7000 TCD
7 The Karnal Cooperative Preparation of DPR for 3500 TCD Sugar plant
Sugar Mills Ltd., with refinery and Cogeneration
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S. No. Projects Description of Projects 33
14. The Kichha Sugar Co. Ltd., Modernization and Balancing at 4000
(A Uttrakhand Govt. TCD with appropriate cogeneration
Undertaking)
15. Maholi (Sitapur) Sugar Mills Preparation of DPR of 5000 TCD with
unit of U.P. Sugar Corporation 27 MW Cogeneration.
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• It is indeed our pleasure that the delegation from the Indonesian
Sugar Industry has given us an opportunity to have an interaction
regarding development in the sugar industry in India and Indonesia.
Their visit and sincere deliberations in the discussion found to be
very fruitful for us.
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