DHAMPUR SUGAR MILLS LTD.
Power & Ethanol

Power

COGENERATION CAPACITY

154.7 MWH and 35.6 MWH under commissioning
(80 MWH GRID INTERACTIVE)






BAGASSE, the residual fiber of sugarcane after crushing and extraction, is a valuable by-product generated during the sugar manufacturing process. It has high calorific value and is therefore used to generate steam and thereby electricity, which is a conventional thermal alternative and eliminates emission of green house gases. 

In 1994, Dhampur was the first sugar company in India to start eco-friendly cogeneration at one of it’s units, with a low project outlay as compared to conventional power plants. Conventionally, this was restricted to providing captive power in order to meet the energy requirements of the sugar factory. However, Dhampur was one of the first to realize the tremendous potential it had towards reducing the power deficit, by supplying to the grid, thereby contributing to the bio-energy effort undertaken by the country.
An additional benefit of using bagasse is that it is a renewable source of fuel and does not contribute to Greenhouse gasses as the sugarcane plantation consumes more carbon dioxide than that generated in burning bagasse. Today, the Group’s combined co-generation capacity stands at 154.7 MWH with 80 MWH of grid interactive power and an additional 35.6 MWH is under commissioning, and is expected to come on line by 31st Jan 2014.
Dhampur was the first in the sugar cogenerater in the world to install and operate105 kg/cm2 boiler and turbine , which has increased efficiencies in bagasse usage and made it perhaps the most efficient cogeneration unit in the world. Dhampur additionally installed energy saving devices which would further increase bagasse savings. This saving would enable the company to run its power plants without external bagasse purchases. Power generation in non-sugar season as well, will result in consistent cash inflows.
Dhampur was the first sugar company in Uttar Pradesh, which was allowed export of power under ‘Open Access’ (during off-season), from 1st October, 2009, resulting in higher realizations.



Ethanol

CAPACITY :
  • Ethanol - 300,000 liters Per Day
  • Rectified Spirit - 300,000 liters Per Day
  • Extra Neutral Alcohol - 150,000 liters Per Day
  • Special Denatured Spirit - 300,000 liters Per Day
  • Anhydrous Alcohol - 300,000 liters Per Day

Ethanol is a generic name for Ethyl Alcohol which can be produced by fermenting sugarcane molasses or juice. It is a volatile, flammable and colourless liquid. Ethyl Alcohol has three principle usages:
  1. Portable – Portable alcohol is used in varying ratios and blends in the production of liquor. There are two main grades of portable alcohol and they are:
    • a) Rectified Spirit or RS, which has a purity of 95%.
    • b) Extra Neutal Alcohol is produced by redistilling RS and is used in the production of portable
  2. Industrial – Industrial Alcohol is produced by denaturing alcohol with bitterants and thereby making it unfit for human consumption. This form of alcohol is called Special Denatured Spirit.
  3. Fuel Ethanol – This grade of alcohol is also termed as Anhydrous Alcohol

Usage of ethanol-blended gasoline began in the late 1970s. Environmentally, the use of ethanol blends has assisted in reducing carbon monoxide emissions. In the United States, one out of every eight gallons of gasoline sold contains ethanol. Most of this ethanol is purchased as blends of 10% ethanol and 90% gasoline, known as E10, and is used as an octane enhancer to improve air quality.
In India we are presently using E5 that is, 5% ethanol blend with gasoline but a government order for 10% blend is expected in the near future.

A SUGAR INDUSTRY PERSPECTIVE & ETHANOL PRODUCTION
Most sugar companies in India are evolving into integrated players as diversification into distillery, ethanol and power has become possible. This has improved the demand for molasses and ensures better economics.
The Government of India has made blending of 5% Ethanol in motor vehicle fuels, compulsory all over India. This directive has provided sugar mills the opportunity to implement forward integration.
A 5% ethanol blend on an all-India basis would require around 500 million liters. The current installed capacity would be adequate to meet this requirement as also for E10 blend, even after fully meeting the requirement of the chemical industry and potable sectors, as India is the second largest producer of sugar in the world.
Ethanol blended fuels are advantageous due to the following characteristics:
  1. Renewable source of energy
  2. Use Molasses which is readily available and is a by-product of the sugar manufacturing process
  3. Diversifies the Sugar Industry
  4. Utilizes industrial installed capacity, improving the economy of the industry
  5. Energy security, trade balance and risk reduction
  6. Reduce use of gasoline and ensures less dependence on imports of oil
  7. Market opportunity for agricultural crops
  8. Rural economic development and boost to the agricultural sector
  9. Environmental benefits (reduced carbon dioxide and carbon monoxide emission. It does not contribute to the harmful greenhouse gasses)
  10. Displaces dangerous and environmentally damaging components in gasoline, such as benzene.

India presently has an installed capacity of over 3,000 million liters per annum but is producing less than 50% of installed capacity.