Sugar Report PDF

Project code: 2012IB17
Final Report
Widening the coverage of PAT Scheme
Sectoral Manual - Sugar Sector
Prepared for
Shakti Sustainable Energy Foundation
D isclaimer
This report is part of Shakti Sustainable Energy Found ation (SSEF) and The Energy and
Resources Institute‟s (TERI) attem pt to stud y the sugar sector energy consum ption trends
and energy efficiency improvem ent opportunities in the sugar sector in Ind ia. The view s
expressed in this d ocum ent d o not necessarily reflect the view of Shakti Sustainable Energy
Found ation. The organization accepts no liability for the content of this d ocum ent, or for the
consequences of any actions taken on the basis of the inform ation provid ed . While every
care has been taken in com piling this report, TERI and Shakti Sustainable Energy
Found ation accepts no claim for any kind of compensation, if any entry is w rong,
abbreviated , om itted or inserted incorrectly either as to the w ord in g space or position in the
report.
I
Acknow ledgement
The Energy and Resources Institute (TERI) places on record its sincere thanks to the Shakti
Sustainable Energy Found ation for provid ing opportunity to und ertake the stud y on
“Wid ening the coverage of PAT schem e for Sugar sector” w hich w as quite challenging and
very interesting. The conclusions of this stud y are expected to support the Found ation
w hich is active on the areas to strengthen the energy security of Ind ia by aid ing d esign and
im plem entation of policies that support energy efficiency and renew able energy.
TERI is grateful to the mem bers of Sugar associations for provid ing valuable inputs, d ata
and inform ation for successful cond ucting of the stud y. TERI likes to acknow led ge the
Ind ian Sugar Mills Association, The Sugar Technologists‟ A ssociation of Ind ia and N ational
Fed eration of Cooperative Sugar Factories Ltd .
Last but not the least, the interactions and d eliberations w ith various m embers of the
ind ustry associations w ho extend ed their support for verification of d ata related to Sugar
sector d uring the stud y w ere very useful and the entire exercise w as a rew ard ing experience
for TERI.
The Energy and Resources Institute (TERI)
II
Preface
The ind ustrial sector represents m ore than one third of both global prim ary energy use and
energy-related carbon d ioxid e em issions. In d eveloping countries, the energy supply
consum ed by the ind ustrial sector is frequently in excess of 50% and so can create tension s
betw een econom ic d evelopm ent goals and a constrained energy supply. Particularly,
countries like Ind ia, w ith an em erging and rapid ly expand ing ind ustrial infrastructure, have
an opportunity to increase their com petitiveness by applying energy -efficient best practices
from the outset in its new ind ustrial facilities.
Despite the potential, policym akers frequently overlook the opportunities presented by
ind ustrial energy efficiency to m ake a significant im pact on clim ate change m itigation,
energy security and sustainability. The com m on perception is that achieving energy
efficiency of the ind ustrial sector is too com plex to be ad d ressed through public po licy and ,
further, that ind ustrial facilities w ill achieve energy efficiency directly through com petitive
pressures in the m arketplace. One such initiative und er the N ational Mission on Enhanced
Energy Efficiency (N MEEE) is the Perform Achieve and Trad e (PAT) schem e. This is a
m arket based m echanism having the objective to enhance energy efficiency (target based ) in
Ind ia w ith an option to trad e the ad ditional energy savings in the form of energy saving
certificates.
In the first phase eight ind ustrial subsectors w ere covered und er the PAT schem e. There are
further plans to w id en the coverage by ad ding new ind ustrial subsectors based on the
energy consum ption levels. Shakti Sustainable Energy Found ation (SSEF) and The Energy
and Resources Institute (TERI) intend to assist the Bureau of Energy Efficiency (BEE) in
expand ing the PAT schem e to new sectors in subsequent phases.
As a part of this exercise, the Ind ia country profile of a few selected subsectors along w ith
their energy intensity has been establish ed . It w as d one after interactions w ith relevant
ind ustrial associations / ind ustry head s and compiling d ata from second ary sources. For
this report on the Sugar sector inputs w ere received from the Ind ian Sugar Mills Association
(ISMA), N ational Fed eration of Cooperative Sugar Factories Ltd (N FCSC) and The Sugar
Technologists‟ Association of Ind ia (STAI). Statistics about sugar mills, crushing capacities,
annual country-w id e crushing and average operational d ay d etails w ere collected from the
Sugar Ind ia Yearbook 12. Second ary d ata available in other public sources w ere also
review ed w hile preparing this report.
We believe that this sector m anual w ill act as a guid e for next steps and establish a need to
stud y the energy consum ption th oroughly to set the threshold limit for eligibility for
d esignated consum ers.
III
Table of contents
D ISCLAIMER.............................................................................................................................. I
A CKN OWLED GEMEN T ............................................................................................................ II
PREFACE ................................................................................................................................. III
TABLE OF CON TEN TS ............................................................................................................. IV
LIST OF TABLES ...................................................................................................................... VI
LIST OF FIGURES .................................................................................................................. VII
A BBREVIATION S ................................................................................................................. VIII
EXECUTIVE SUMMARY............................................................................................................. 1
1.0 IN TROD UCTION ....................................................................................................................... 3
1.1 Sector Importance ..................................................................................................... 3
1.2 Prevailing National / International Scenario ........................................................ 3
1.3 International standing of the subsector ................................................................. 4
1.4 Current/ Future Market Scenario ........................................................................... 4
1.5 Past growth and future prospects .......................................................................... 5
1.5.1 Dom estic d em and op p ortu nity ........................................................................6
1.5.2 International trad e op p ortu nity .......................................................................7
1.5.3 Fu tu re p otential, im p acts and investm ents ....................................................7
1.6 Production of sugarcane and white sugar in India .............................................. 8
1.7 Important stakeholders ............................................................................................ 9
1.8 Product categorisation ........................................................................................... 10
1.9 Major players........................................................................................................... 10
1.9.1 State-w ise segregation of su gar m ills ............................................................10
1.9.2 Classification of su gar m ills based on cap acity ...........................................10
1.9.3 Segregation of Su gar Mills based on Co-generation Facility .....................11
1.10 Sugar policy and regulations in India.................................................................. 11
1.11 Support for bagasse co-generation ....................................................................... 12
1.11.1 MN RE su p p ort and initiatives .......................................................................12
2.0 EN ERGY PERFORMAN CE ....................................................................................................... 13
2.1 Energy performance at sectoral level ................................................................... 13
2.2 International comparison ...................................................................................... 14
2.3 Manufacturing process .......................................................................................... 14
2.3.1 Variou s stages in su gar m anu factu ring p rocess ..........................................15
2.3.2 By-p rod u cts ......................................................................................................17
2.3.3 Cogeneration in su gar m ills ...........................................................................17
2.3.4 Distillery in su gar m ills ...................................................................................18
IV
2.4 Technological movements ..................................................................................... 18
2.5 Capacity utilisation................................................................................................. 19
2.6 Major energy consuming areas ............................................................................. 19
2.7 Energy saving potential ......................................................................................... 19
2.7.1 Scop e for im p roving energy efficiency .........................................................19
2.7.2 Scop e for co-generation p otential ..................................................................20
3.0 A N ALYSIS OF EN ERGY CON SUMPTION D ATA .............................................................. 21
3.1 Energy consumption in sugar mills ..................................................................... 21
3.1.1 Electricity consu m p tion in su gar m ills .........................................................21
3.1.2 Steam consu m p tion in su gar m ills ................................................................23
3.2 Plotting plant vs energy consumption................................................................. 23
3.3 Possible energy efficiency measures in sugar industry ..................................... 24
3.3.1 Im p roved reliability and econom ics of steam & p ow er generating
system s w ith film form ing p olyam ines ........................................................24
3.3.2 Direct p rod u ction of w hite su gar in a cane su gar m ill ...............................24
3.3.3 Su garcane w aste conversion into char ..........................................................25
3.3.4 Qu intu p le 3rd effect vap ou r for su gar m elting .............................................25
3.3.5 Cond ensate flashing system ...........................................................................25
3.3.6 Film typ e su lp hu r bu rner ...............................................................................25
3.3.7 Bagasse d rier .....................................................................................................25
3.3.8 Planetary gearbox for crystalliser ..................................................................26
3.3.9 Ad vanced bagasse based co-generation .......................................................26
3.3.10 Mechanical Vap ou r Com p ression (MVR) technology to recover
low -p ressu re w aste steam ..............................................................................26
3.3.11 Mill Drives ........................................................................................................26
3.3.12 Vertical continu ou s vacu u m p an for m assecu ite boiling ...........................26
3.3.13 Low p ressu re extraction (LPE) system .........................................................26
3.3.14 Mem brane filtration for su gar m anu factu ring.............................................27
3.3.15 H igh p ressu re co-generation system .............................................................27
3.4 Conclusions ............................................................................................................. 27
4.0 REFEREN CES .................................................................................................................... 29
5.0 AN N EXURE 1..................................................................................................................... 31
V
List of tables
Table 1.5 : Sugar factories in operation in India year-w ise ..................................................... 6

Table 1.6.1 : Cane crushing, sugar and m olasses prod uction statistics .................................... 8
Table 1.6.2 : Sugar prod uction and consum ption statistics in Ind ia ......................................... 9
Table 1.6.3 : Sugar im ports and exports from India .................................................................... 9
Table 1.9.1 : State-w ise num ber of sugar m ills .......................................................................... 10
Table 1.9.2 : N um ber of sugar m ills in Ind ia based on capacity ............................................. 11
Table 1.9.3 : Sugar m ills w ith and w ithout co-generation facility in various states ............. 11
Table 2.1 : N um ber of sugar m ills state-w ise w ith 3400TCD and above ............................ 13
Table 2.2 : Average milling capacity of sugar m ills in d ifferent countries ......................... 14
Table 2.6a : Section w ise electricity consum ption in a sugar mill .......................................... 19
Table 2.6b : Section-w ise steam consum ption in a sugar m ill ................................................ 19
Table 2.7.2 : State-w ise bagasse co-generation potential .......................................................... 20
Table 3.1.1 : Electricity consum ption & Specific Energy Consum ption (Electrical)
of sugar m ills ........................................................................................................... 21
Table 3.2 : Energy consum ption of sugar m ills aud ited by TERI ........................................ 24
VI
List of figures
Figure 1.3 : Country-w ise sugar prod uction across the w orld in percentages ...................... 4
Figure 1.5a : Ind ian Sugar Cycle ..................................................................................................... 5
Figure 1.5b : Trend of Sugarcane and Sugar Prod uction in Ind ia ............................................. 6
Figure 1.6 : Year-w ise trend in production of sugarcane and w hite Sugar in India ............. 8
Figure 2.3 : Sugar m anufacturing process ................................................................................. 15
Figure 3.1.2 : Steam consum ption trend over d ecad es ............................................................... 23
Figure 3.4 : Estim ated annual energy consum ption ................................................................ 27
VII
Abbreviations
AC - Alternating Cu rrent
AIDA - All Ind ia Distillers Association
ARTI - Ap p rop riate Ru ral Technology Institu te
BEE - Bu reau of Energy Efficiency
BIS - Bu reau of Ind ian Stand ard s
BOOT - Bu ild , Ow n, Op erate, Transfer
CACP - Com m ission for Agricu ltu ral Costs & Prices
CMIE - Centre for Monitoring Ind ian Econom y Pvt. Ltd .
DC - Direct Cu rrent
DCs - Designated Consu m ers
DEVC - Dou ble Effect Vap ou r Cell
DM - De-Mineralised
DSCL - DCM Shriram Consolid ated Lim ited
ESCerts - Energy Saving Certificates
EU - Eu rop ean Union
FD - Forced Draft
FRP - Fair & Rem u nerative Price
GCV - Gross Calorific Valu e
GDP - Gross Dom estic Prod u ct
GH G - Green H ou se Gas
GoI - Governm ent of Ind ia
HP - H igh Pressu re
ICUMSA International Com m ission for Uniform Method s of Su gar Analysis
ID - Ind u ced Draft
IREDA - Ind ian Renew able Energy Develop m ent Agency
ISEC - Ind ian Su gar Exim Corp oration Ltd
ISMA - Ind ian Su gar Mills Association
kCal - Kilo Calories
kW - Kilo Watt
kWh - Kilo Watt H ou r
LP - Low Pressu re
MSP - Minim u m Su p p ort Price
m TOE - Million Tonnes of Oil Equ ivalent
MW - Mega Watt
N APCC - N ational Action Plan on Clim ate Change
N CDEX - N ational Com m od ity and Derivatives Exchange
N CG - N on Cond ensable Gases
N FCSF - N ational Fed eration of Co-op erative Su gar Factories Ltd
N MEEE - N ational Mission on Enhanced Energy Efficiency
N PC - N ational p rod u ctive Cou ncil
P.A - Per Annu m
PA - Prim ary Air
VIII
PAT - Perform , Achieve and Trad e
PCRA - Petroleu m Conservation Research Association
PDS - Pu blic Distribu tion System
RSCL - Rajshree Su gars & Chem icals Ltd
SA - Second ary Air
SAP - State Ad vised Price
SEC - Sp ecific Energy Consu m p tion
SPM - Su sp end ed Particu late Matter
SSEF - Shakti Su stainable Energy Fou nd ation
STAI - The Su gar Technologists Association of Ind ia
TCD - Tonnes of Cru shing p er Day
TCH - Tonnes of Cru shing p er H ou r
TERI - The Energy and Resou rces Institu te
TOE - Tonnes of Oil Equ ivalent
TPD - Tonne p er Day
TPH - Tonnes Per H ou r
VSD - Variable Sp eed Drive
WTO - World Trad e Organisation
IX
Executive Summary
The Ministry of Pow er and Bureau of Energy Efficiency (BEE) are entrusted w ith the
im plem entation of the National Mission on Enhanced Energy Efficiency (N MEEE) und er the
N ational Action Plan on Clim ate Change (NAPCC). One of the key com ponents of the
m ission is Perform , Achieve and Trad e (PAT) mechanism . This is a m arket based
m echanism to im prove the energy efficiency in large energy intensive industries and
facilities cost-effectively by certifying energy savings that could be trad ed . The PAT
m echanism is d esigned to facilitate the Designated Consum ers (DCs) to achieve their legal
obligations und er the Energy Conservation Act (EC Act) of 2001, w hich w as am end ed in
2010.
The ensuing PAT scheme applies to 8 ind ustrial sub-sectors, w hich are Pow er Plant,
Alum inium , Pulp & Paper, Chlor- Alkali, Cement, Iron & Steel, Textile and Fertilizer.
During the first phase of the PAT cycle (3 years starting from 1st April 2012), as per the
recent notification, 478 designated consum ers (DCs) have been id entified. They are obliged
to red uce their energy consum ption by a specific target set by the BEE. The expected energy
savings from this schem e is about 6-8 m illion tonnes of oil equivalent (mMtoe) in this
period . The over achievers w ill earn tradable Energy Saving (ESCerts) w hereas the und er
achievers w ill be liable to com ply through purchase of ESCerts or by paying penalty.
The BEE plans to w id en the coverage of the PAT schem e in phases by ad d ing new ind ustrial
subsectors d epen ding on the energy consum ption. H ow ever, there is a need to stud y the
energy consum ption in detail for the new ind ustrial segm ents to establish the threshold limit
for the eligibility for DCs. Shakti Sustainable Energy Found ation (Shakti or SSEF) operates as
a partner institution of the Clim ate Works Found ation, and has been focusing its efforts on
clean and secured energy future for all in Ind ia. SSEF in consultation w ith TERI is assisting
the BEE in w id ening the net of the PAT schem e by ad d ing new subsect ors in subsequent
phases of the PAT scheme. The four subsectors identified by SSEF to stud y the energy
consum ption in d etail so as to establish the threshold lim it for the eligibility as DCs are
 Copper & zinc

 Glass & ceram ics
 Sugar
 Vegetable oil refineries
The initial task has been to m ap the id entified four sub sectors in the Indian context and
prepare a broad sectorial report. This subsector overview report on Sugar Ind ustry covers
inform ation on large and m ed ium m anufacturers, num ber of plants existing, prod uction
capacity, technology types and technological d evelopm ent in the last d ecad e, capacity
utilization, energy efficiency levels, estim ated energy saving potential, GH G inventory,
m itigation potential and barriers to im plem ent energy efficiency m easures, and regulatory
and policy issues having a bearing on im proving the efficiency in the sector.
The purpose of the sectorial report is m ainly to und erstand the energy intensity of the
subsector, technology adopted and its energy efficiency levels. It also assesses the potential
for red uction in energy consum ption across the subsector and the gaps in technology. It
1
Wid ening the coverage of PAT Schem e – Su gar Sector
provid es an overall energy scenario about the subsector to all the stakehold ers. This
overview report is prepared based on secondary inform ation available in the public d om ain.
Inform ation and d ata w ere also collected by interacting w ith ind ustrial associations and
ind ustrial experts in this subsector.
The sugar ind ustry is one of the largest energy users am ong ind ustry sector using bagasse
for m eeting both therm al energy and electricity requirem ents. Out of the 527 operating sugar
m ills in Ind ia, about 99 sugar m ills have installed capacities of 5000 TCD and above. These
sugar m ills can be brought und er tw o broad categories viz. (1) sugar m ills w ith steam d riven
m ills and (2) sugar mills w ith electrical m otor d riven m ills. H ence the sugar m ills above
5000TCD capacity m ay be taken up for d etailed stud y in the upcom ing phase. The estim ated
annual energy consum ption of these sugar m ills vary betw een 45,000 toe per year to 90,000
toe per year. A large num ber of these sugar m ills have ad opted cogeneration route to m eet
their overall energy requirem ents. As per the collected inform ation and d iscussions w ith
stakeholders d uring the sectoral w orkshop, there exists a significant energy saving potential
of about 20% in sugar ind ustries. Therefore it is suggested that these 99 large sugar m ills
(w hich operate either separately or as a group) m ay be consid ered as DCs und er the PAT
schem e w ith a threshold lim it of 30,000 toe as the m inim um annual energy consum ption per
m ill.
2
1.0 Introduction
1.1 Sector Importance
The sugar ind ustry is a sector of significant im portance to the national econom y. While
sugar consum ption has been grow ing over the years, the prod uction has been cyclical.
Currently, the sugar industry is regulated across the value chain from prod uction t o end
consum er. Investm ents to generate by-prod ucts are at a nascent stage, and the sector has
struggled to generate a return on invested capital in excess of its cost of capital in m ost
years, prim arily d ue to a high m and ated fixed cane price and a volatile sugar price.
Sugarcane is primarily grow n in nine Ind ian states: And hra Prad esh, Bihar, Gujarat,
H aryana, Karnataka, Maharashtra, Punjab, Uttar Prad esh and Tamil N ad u. More than 50
m illion farm ers and their fam ilies are d epend ent on sugarcane prod uce for their livelihood .
The sugar ind ustry caters to an estim ated 12% of rural population in these nine states
through d irect and ind irect em ploym ent. Effectively, each farm er contributes to the
prod uction of 2.9 m etric tonnes of sugar every year.
The sugar ind ustry is a green ind ustry and is largely self-sufficient in energy need s through
use of bagasse for generating electricity and steam. In fact, the sugar ind ustry generates
surplus exportable energy through cogeneration and contributes in red ucing the en ergy
d eficit that Ind ia is currently facing. The sugar ind ustry is also the prim ary source of raw
m aterial for the alcohol ind ustry in India. The annual econom ic contribution of the sugar
ind ustry to the exchequer through ind irect taxes am ounts to m ore tha n IN R 2800 Crores.
The sugarcane price accounts for approxim ately 70% of the ex-m ill sugar price. H ow ever,
fund am ental changes in the consum er profile and the d em onstrated ability of the sector to
continuously ensure availability of sugar for d omestic consum ption has d iluted the need for
sugar to be consid ered as an essential com m od ity. Accord ing to a recently cond ucted nation -
w id e survey, nearly 75% of the total non -levy sugar is consum ed by ind ustrial, sm all
business and high income household segm ents.
1.2 Prevailing N ational / International Scenario

Sugar is prod uced in 115 countries across the w orld . It is extracted from d ifferent raw
m aterials such as sugarcane and sugar beet. Sugarcane is cultivated in tropical clim ate, w hile
sugar beet is grow n in tem perate regions. Of the 115 sugar prod ucing countries, 67 prod uce
sugar from cane, 39 from beet and 9 from both cane and beet. Brazil, Ind ia, Thailand ,
Australia and Cuba are the largest sugarcane prod ucers. The beet sugar prod ucing countries
includ e the US, Turkey, Ukraine, Poland and Russia.
The Indian sugar ind ustry also has a significant stand ing in the global sugar space. Like in
Brazil and Thailand , the sugar sector is highly regulated in India too. Since 1993, the
regulatory environm ent has consid erably eased , but sugar still continues to be listed as an
essential com m odity und er the Essential Com m od ity Act. There are regulations across the
entire value chain, w hich includ es land d em arcation, sugarcane price, sugarcane
procurem ent, sugar prod uction and sale of sugar by m ills in d om estic and international
m arkets.
3
Ind ia‟s sugar sector competes w ith Brazil‟s as the largest in the w orld , and is the second
largest agriculture-based ind ustry in Ind ia, after textiles. A m ajority of its prod uction is
d estined for d om estic markets. The num ber of sugar factories in operation in Ind ia d uring
the crushing season 2010-11 w as 527 and the total sugar prod uction w as 24.39 m illion
tonnes. Based on cane crushing, m ill size ranges from 1250 to m ore than 10,000 Tonnes
Crushed per Day (TCD). The average crushing capacity of the sugar mills in Ind ia is 3,650
TCD.
Approxim ately 40% of Ind ia‟s sugar sector is ow ned and run by farm ers through co -
operatives, a situation that is unique to the country, w hile private sugar m ills in Ind ia are the
second largest prod ucers. The co-operative system generally suffers from poor coord ination
and is therefore less efficient than the plantation system m ost com m on in other sugar
prod ucing countries such as Brazil.
1.3 International standing of the subsector

Ind ia is the largest consum er and second largest prod ucer of sugar in the w orld only next to
Brazil. Ind ia accounted for about 14.75% of the total w orld sugar prod uction d uring 2011 -
12. The country-w ise sugar prod uction across the w orld d uring 2011-12 is represented in
Figure 1.3.
Source: http://www.vsisugar.com/india/statistics/international_sugar.htm
Figure 1.3: Cou ntry-w ise su gar p rod u ction across the w orld in p ercentages
1.4 Current/ Future Market Scenario

The 10 largest sugar prod ucing nations represent roughly 78% of the w orld sugar
prod uction. Brazil accounts for alm ost 22% of the w orld prod uction and its share is
increasing, although the country‟s output has w itnessed som e setback since the 2008-2009
crisis. There w as consid erable expansion in sugar prod uction till 1980, w hen w orld sugar
consum ption reached nearly 90 m illion tonnes, i.e. an annual grow th rate of 3.1%. Since
4
1.0 Introd u ction
early 2000 sugar consumption has grow n at a good rate, notably in Asia (+4.9% p.a.), the
Mid d le-East (+4.6% p.a.) and Africa (+4.1% p.a.). The w orld population com prising 7 billion
people, of w hich 4.0 billion are concentrated in Asia, consum es about 165 m illion tonnes of
sugar. The 10 largest sugar consum ing nations consum e roughly tw o-third s of the total
w orld ‟s sugar. White sugar consum ption in d eveloped countries can be consid ered as
saturated m arkets (flat/ low population grow th and m aturity of food m arkets), w hereas
d eveloping countries are considered as grow ing m arkets, particularly in Asia, and , to a
lesser extent in Mid d le-East and Africa.
1.5 Past grow th and future prospects

Sugar p rod uction in India is closely linked to sugarcane prod uction. Sugarcane prod uction
has increased from 279.59 m illion tonnes to 339.17 m illion tonnes from 1997-98 to 2010-11. It
fell to 233.86 million tonnes in 2003-04. An increase in sugarcane prod uction thereafter w as
again follow ed by a d ecline in 2008-09 to 285.09 million tonnes. In India sugar prod uction
follow s a 5-7 year cycle. Sugar prod uction increases over a 3-4 year period , reaches a high,
w hich in turn, results in low er sugar prices. Low er sugar price and increased sugarcane
arrears results in low er sugarcane prod uction for the next 2-3 years. A graphical
representation of the Indian Su gar Cycle is given in Figure 1.5a. The sugarcane and sugar
prod uction trends in India are given in Figure 1.5b.
Figure 1.5a: Ind ian Su gar Cycle
5
Figure 1.5b: Trend of Su garcane and Su gar Prod u ction in Ind ia

Source: Directorate of Economics and Statistics, M inistry of A griculture and Department of Food and Public Distribution,
Government of India
The num ber of sugar factories in operation in India from 2006-07 to 2010-11 is given in Table
1.5.
Table 1.5: Sugar factories in operation in Ind ia year-w ise

N umber of sugar
Year factories in operation
2006-07 504
2007-08 516
2008-09 489
2009-10 490
20010-11 527
1.5.1 Dom estic d em and opportu nity

In 2010-11, the d om estic sugar consum ption w as 20.7 m illion tonnes. It is expected that the
d rivers for consum ption i.e. the GDP grow th and population grow th w ill continue to grow
at current rates. Based on the past 10 years' grow th in consum ption and estim ates from
various ind epend ent sources, it is expected that the d om estic sugar consum ption in 2017
w ould be approxim ately 28.5 Million tonnes. (Source KPMG Analysis). Given the high cost
of im ports and the strategic im portance of food security, India w ill need to set its prod uction
targets in excess of its d om estic consum ption. Given the past trend in production cyclicality,
sugar equivalent to 1.5 months of consum ption i.e. an ad ditional 3.5 m illion tonnes of sugar
w ill need to be prod uced by 2017. (Source KPMG Analysis).
6
1.0 Introd u ction
1.5.2 International trad e opportu nity

Ind ia has the potential to export to m ajor Ind ian Ocean m arkets, d ue to freight
com petitiveness w ith respect to key com petitors such as Brazil and Thailand . With the EU
exports red ucing by 4.5 m illion tonnes, the w orld price per m etric tonne of sugar is expected
to increase in the range of USD 50 to USD 100. This could potentially m ake exports m ore
viable for Ind ia. H ow ever, d ue to the increasing em ergence of d estination refineries, key
m arkets are im porting a greater share of raw sugar, and Ind ia's com petitiveness for raw
exports is relatively low er currently. Ind ia's com petitiveness is higher in markets, w here the
share of w hite sugar im ports as a percentage of cum ulative im ports is higher. Going
forw ard , Ind ia w ill need to build the capability to prod uce raw sugar and refined sugar of
international quality stand ard s, in ord er to leverage the export opportunity .
The target m arkets are estim ated to im port 10 m illion m etric tonnes of sugar by 2017. In d ia
w ould be able to leverage this opportunity through prod uctivity im provem ents and
alignm ent of cane and sugar prices in the d om estic m arket. Ind ia's com petitiveness can also
be increased by enhancing export infrastructure. Since the current cost structu re of the
Ind ian ind ustry is uncom petitive for exports, in case of a large sugar surplus, the
governm ent could consid er using WTO com pliant subsidies to enable exports w hile creating
stability in the d om estic m arket. The ind ustry could also explore w ays of collectively sharing
losses d ue to exports, if any, since exports w ill lead to low er availability of stocks in the
d om estic m arket, thus benefiting both m ills and farm ers through higher sugar realization.
(Source KPMG Analysis)
1.5.3 Fu tu re potential, im pacts and investm ents

The potential, im pacts and investm ents related to the various opportunities in sugar sector
by 2017 are sum m arized below .
(i) Dom estic consum ption

The d om estic consum ption is expected to rise by 5 m illion tonnes of ad d itional sugar. This
w ould require about Rs 6000 crores of investm ent to m eet the d om estic d em and .
(ii) By-prod ucts

Sugar ind ustry provid es good opportunities for prod uction of by-prod ucts such as ethanol,
electricity, etc that w ould help in energy security related issues through green sources. The
estim ated investm ents is about Rs 52,320 crores.
(iii) Prod uctivity im provem ents

It has been estim ated that Ind ia can m eet about 82% of the estim ated increm ent in d om estic
consum ption (4.1 m illion tonne of sugar) by 2017 by im proving prod uctivity through
m arginal acreage increase, farm practices and infrastructure im provem ents.
(iv) Prod uct innovations

There is also significant potential for prod uct innovation i.e. sugar based prod ucts based on
consum er need s. It w ould be necessary for the sugar ind ustry to invest in R&D activities for
this purpose.
7
1.6 Production of sugarcane and w hite sugar in India

The prod uction of sugar in Ind ia is highly d epend ent on the availability of sugarcane. A
schem atic representation of sugarcane and w hite sugar prod uction in India is given in
Figure 1.6.
Figure 1.6: Year-w ise trend in p rod u ction of su garcane and w hite Su gar in Ind ia
The d etails of sugarcane crushing, sugar prod uction, percentage recovery of sugar from
cane, m olasses prod uction and m olasses recovery percentage from cane for the seasons in
2010-11 is given in Table 1.6.1.
Table 1.6.1: Cane crushing, sugar and m olasses prod uction statistics
S.N o Particulars Crushing season
2010-2011
1 N u m ber of su gar factories in op eration 527
2 Average actu al cru shing cap acity (m illion TCD) 1.92
3 Average cru shing p eriod (Days) 136
4 Annu al Cru shing Cap acity (m illion tonnes) 261.6
5 Annu al Su garcane Cru shed (m illion tonnes) 239.8
6 Cap acity Utilization (%) 92
7 Su gar Prod u ced (m illion tonnes) 24.4
8 Recovery % from Cane 10.17
9 Yield of su garcane (tonnes p er hectare) 70.1
10 Molasses p rod u ction (m illion tonnes) 10.74
11 Molasses recovery from cane (%) 4.57
Source: Sugar India Y ear Book – 2012
8
1.0 Introd u ction
The sugar prod uction & consum ption trends from 1999-2000 to 2010-2011 is given in Table 1.6.2.
Table 1.6.2: Sugar prod uction and consum ption statistics in Ind ia
Year Sugar Production (Million tonnes) Sugar Consumption (Million tonnes)
1999-00 18.2 15.5
2000-01 18.5 16.2
2001-02 18.5 16.8
2002-03 20.1 18.4
2003-04 13.5 17.3
2004-05 12.7 18.5
2005-06 19.3 18.9
2006-07 28.4 20.2
2007-08 26.4 22.0
2008-09 14.5 23.0
2009-10 18.9 21.0
2010-11 24.4 20.7
Source: Sugar India Y ear Book – 2012
Ind ia is the 3rd largest exporter of sugar after Brazil and Thailand . The sugar im port and
export trend s from 1999-2000 to 2010-2011 is given in Table 1.6.3.
Table 1.6.3: Sugar im ports and exports from Ind ia

Year Sugar Import (Million tonnes) Sugar Export (Million tonnes)
2003-2004 0.07 1.20
2004-2005 0.93 0.11
2005-2006 0.56 0.32
2006-2007 0.00 1.75
2007-2008 0.00 4.64
2008-2009 0.36 3.33
2009-2010 1.97 0.04
2010-2011 1.00 3.25
Source: DGCI & S, Kolkata
1.7 Important stakeholders

The key stakehold ers of the sugar ind ustry are farm ers‟ associations, millers, private &
cooperative m ills' associations, international traders, policy m akers. The different ind ustry
associations in the sugar ind ustry includ e the follow ing:
 The Sugar Technologists Association of Ind ia - (STAI)
 Ind ian Sugar Mills Association – (ISMA)
 N ational Fed eration of Co-operative Sugar Factories Ltd – (N FCSF)
 All Ind ia Distillers Association - (AIDA)
 Ind ian Sugar Exim Corporation Ltd – (ISEC)
 Regional and state level sugar & d istillers‟ associations
These ind ustrial associations are involved in issues such as technology, pricing, policy, sales
and exports / im ports related issues. The Research and d evelopm ent institutes in the sugar
sector includ e (i) N ational Sugar Institute, (ii) Vasantd ad a Sugar Institute and (iii) Sugar
Research Institute. These institutes are involved in activities such as consultancy, setting
sugar stand ard s, co-ord inated research, patents and analytical services.
9
1.8 Product categorisation

Sugar com es in three form s: Large crystals (L-grad e), Med ium crystals (M-grad e) and Sm all
crystals (S grad e). M and S grad es form about 80% of total sugar prod uction and are trad ed
on the N CDEX platform . The quality of sugar is gauged using a param eter know n as the
ICUMSA num ber, w hich assesses the chemical properties of sugar for grad ing. The low er
the ICUMSA num ber, the better the quality.
1.9 Major players

1.9.1 State-w ise segregation of su gar m ills
There w ere 671 sugar m ills in Ind ia in 2010-11 includ ing the closed / non -operating m ills.
Based on ow nership, these can be classified as (i) p ublic, (ii) p rivate and (iii) co-operative
sugar m ills. Private sugar m ills account for highest num ber of m ills follow ed by co-
operative sugar m ills. The state-w ise breakup for num ber of sugar m ills in Ind ia is given in
Table 1.9.1. Maharashtra and Uttar Prad esh have the m axim um num ber of sugar m ills.
Table 1.9.1: State-w ise num ber of sugar m ills

State Public Private Co-operatives Total
Pu njab - 9 15 24
H aryana - 4 12 16
Rajasthan 1 1 1 3
Uttar Prad esh 23 106 28 157
Uttarakhand 2 4 4 10
Mad hya Prad esh 2 12 5 19
Chhattisgarh - - 3 3
Gu jarat - 2 22 24
Maharashtra - 56 153 209
Bihar 15 13 - 28
Assam - 1 2 3
Orissa - 4 4 8
West Bengal 1 1 - 2
And hra Prad esh 1 30 14 45
Karnataka 3 49 15 67
Tam il N ad u 3 27 16 46
Pond icherry - 1 1 2
Kerala - 1 1 2
Goa - - 1 1
N agaland 1 - - 1
Dad ar N agar & - - 1 1
H aveli
Total 52 322 297 671
*Includes closed down mills based on ownership
Source: Sugar India Y earbook’12
1.9.2 Classification of sugar m ills based on capacity

The sugar m ills are classified into five categories based on their installed crushing capacity
(Tonnes of Cane crushed per Day – TCD) and the classification num ber of sugar m ills
10
1.0 Introd u ction
classified based on capacity is given in Table 1.9.2. The country w id e average crushing
capacity in 2010-11 w as 3650 TCD and the average crushing d uration w as 136 d ays.
Table 1.9.2: N um ber of sugar m ills in Ind ia based on capacity

Capacity N umber of sugar mills
H igher than 10000 TCD 11
5001 to 10000 TCD 88
3501 to 5000 TCD 85
2001 to 3500 TCD 234
Up to 2000 TCD 104
1.9.3 Segregation of Su gar Mills based on Co-generation Facility

Many of the sugar m ills have co-generation facilities w hich prod uce steam and pow er used
in the sugar prod uction process. The num ber of sugar m ills in operation state-w ise and
those having co-generation facility are given in Table 1.9.3. Out of the 527 sugar m ills in
operation, only 144 of them have Co-generation facilities.
Table 1.9.3: Sugar m ills w ith and w ithout co-generation facility in various states
Sl.N o State/ Location Mills in operation Mills w ith co-generation
1 Pu njab 16 5
2 H aryana 14 2
3 Rajasthan 1 1
4 Uttar Prad esh (East) 42 11
5 Uttar Prad esh (Central) 83 15
6 Uttar Prad esh (West) 34 6
7 Uttarakhand 10 1
8 Mad hya Prad esh 13 0
9 Chhattisgarh 3 1
10 Gu jarat 19 0
11 Maharashtra (Sou th) 167 34
12 Bihar 10 3
13 Orissa 5 1
14 West Bengal 1 0
15 And hra Prad esh 37 21
16 Karnataka 59 30
17 Tam il N ad u 44 19
18 Pond icherry 2 0
19 Goa 1 0
Total 527 144
(Source: Sugar India Y ear Book-2012)
1.10 Sugar policy and regulations in India

Ind ia d oes not have a reasonable d egree of pred ictability in its prod uction and trad e policy
w ith respect to sugar. The sector is characterised by controls across the entire value chain of
sugar prod uction and sale, w hich not only ham pers its efficiency but also exacerbates the
cyclicality in sugar and sugarcane prod uction. This characteristic of unpred ictability in
sugarcane prod uction, coupled w ith the controls, d oes not allow the sugar sector to tap its
full potential and thereby ad versely im pacts the interests of stakehold ers (sugarcane
grow ers, sugar m ills and consum ers) across the value-chain. Som e im portant policies in
sugar ind ustry includ e the follow ing:
11
i. Trade policy for sugar

Depend ing on m ill-w ise m onthly prod uction and stocks, local prod uction levels and w orld
m arket conditions, quantitative controls on both exports and im ports are com m on in the
sector. This is an avoid able source of uncertainty for the ind ustry.
ii. Regulations relating to by-products

There are several regulatory hurd les w ith respect to the by-prod ucts of the sugar ind ustry.
With respect to the m olasses, these are d ecisions at the state governm ent level related to
fixation of quotas for d ifferent end uses of m olasses, restrictions on m ovem ent (particularly
across state bound aries), etc. With respect to co-generation from bagasse, there are
regulatory and im plementation issues relating to freed om of selling pow er to
consum ers other than the local pow er utility. The state governm ents or their electricity
board s resort to restriction on open access sale by frequent or routine invocation of
statutory provisions m eant to d eal w ith emergencies.
Other policies related to Ind ian sugar ind ustry includ e (i) cane sugar area and bond ing, (ii)
sugarcane pricing, (iii) levy sugar obligation and (iv) regulated release of free sale (non -levy)
sugar).
1.11 Support for bagasse co-generation
The existing capacity of bagasse based cogeneration is 711 MW. The estimated co -generation
potential in Ind ian Sugar Mills is around 6000M W (Source: Industrial Cogeneration India,
V ol.X IX , October, 2010). Over the last d ecad e, bagasse co-generation faced a d ynam ic and
varied set of substantial inform ation , technical, regulatory and financial barriers. Each of the
program m es d esigned to support bagasse co-generation had a role to play in supporting the
711 MW of bagasse co-generation currently installed . H ow ever none of these program m es
w ould have been successful on its ow n. The promotional policies of the Ministry of N ew
and Renew able Energy (MN RE) includ ing capital and interest subsid ies, and a variety of tax
benefits and guid elines to the states to im plem ent the preferential tariffs mad e bagasse co-
generation cost-effective for im plem entation in Ind ia. Various m ultilateral lines of credit
w ere offered through IREDA to som e of the m ills w ho w ere unable to access cred it through
other institutions. H ow ever, till date support program m es have d one little to ad d ress the
unique financial barriers facing the cooperative mills d ue to institutional structure of these
m ills.
1.11.1 MNRE su pport and initiatives

MN RE initiated new co-generation projects for co-operative/ public sector sugar m ills w hich
are based on the Build , Ow n, Operate, Transfer (BOOT) m od el. Tw o BOOT m od el co-
generation projects in co-operative sugar m ills of Maharashtra, 12 co-operative/ public sector
sugar m ills in Tamil N adu are provid ed assistance und er this initiative. The Ministry has
also initiated in 2012, a new schem e for provid ing Central Financial Assistance for boiler up -
grad ation of co-generation project in co-operative sugar m ills. Three co-operative sugar m ills
in Maharashtra w ith an aggregate capacity of 36 MW (20 MW export d uring season) w ere
provid ed financial assistance.
12
2.0 Energy Performance
2.1 Energy performance at sectoral level
Sugar m ills are energy intensive and are notified as energy intensive ind ustries as per „The
Energy Conservation Act, 2001‟. Energy consumption in sugar m ills d epend s on various
factors such as (1) capacity, (2) steam generation param eters, (3) age of installed equipm ent
and (4) type of equipm ent used . The specific electricity consum ption per tonne of sugar
prod uction varies from 200~500 kWh / tonne of Sugar Prod uced (Source: CMIE Database)
based on the year of prod uction. The average cane crushing in Ind ian m ills in 2010-11 w as
3650 TCD. The average energy consum ption in an Ind ian sugar m ill is about 26~ 40 kWh /
tonne of cane (Source: TERI Energy A udit reports). The total pow er requirem ent in a stand ard
sugar m ill of 3400 TCD crushing capacity is about 4.0 MW. The steam consum ption varies
from 30% to 50% of steam per tonne of cane based on capacity, evaporator vapour bleed ing
arrangem ent and age of equipm ent used .
The cane to bagasse ratio is around 30% in the Indian Sugar m ills and the GCV of bagasse
w ith 50% m oisture is around 2200kCal/ kg. This is equivalent to 0.22 toe/ tonne of bagasse.
Consid ering 239.8 m illion tonnes of cane d uring 2010-11, the bagasse generation is about
71.94 m illion tonnes and the total energy availability is 15.83 toe. Based on the national
average of 136 d ays of cane crushing in 2010-11, sugar m ills w ith a crushing capacity of
3400TCD and above w ill fall und er the category of energy intensive ind ustries. The input
energy (bagasse) available in each of these sugar m ills is 30,000 m etric tonnes of oil
equivalent and above. The number of sugar m ills state-w ise having a crushing capacity of
3400TCD and above is given in Table 2.1. The d etails of the 230 sugar m ills are given in
annexure 1.
Table 2.1: N um ber of sugar m ills state-w ise w ith 3400TCD and above
State N umber of sugar mills
Pu njab 7
H aryana 3
Uttar Prad esh 91
Uttarakhand 6
Gu jarat 8
Maharashtra 42
Bihar 6
And hra 18
Prad esh
Karnataka 28
Tam il N ad u 21
Total 230
13
2.2 International comparison
The size of the sugar m ills in Ind ia is sm all by international stand ard s. The average m illing
capacity at d ifferent countries is given in Table 2.2.
Table 2.2: Average m illing capacity of sugar m ills in d ifferent countries

Country Average cane crushing capacity (TCD )
US Cane 14500
Au stralia 11000
Thailand 10,300
EU 9500
Brazil 9000
Sou th Africa 7500
Colom bia 6,000
Ind ia 3,650
(Source: http://www.indiansugar.com)
The sugar m ills in Southeast Asia use low pressure cycle for co-generation plants and m ost
of the mills are inefficient. In som e of the sugar m ills, up to 40 kWh electricity is consum ed
and up to 600 kg of steam is consum ed for m illing every tonne of sugar ca ne. As low as 30
kWh of electricity is prod uced from the bagasse generated from m illing one tonne of sugar
cane. Som e of the sugar m ills are even installed w ith „used ‟ co-generation equipm ent. There
is a huge potential in existing sugar mills to red uce th e steam and electricity requirem ent for
m illing process. In the new co-generation plant, it is possible to prod uce electricity up to
110-125 kWh for every tonne of sugar cane milled .
In the 1960‟s, efficient bagasse co-generation w as pioneered in Mauritius and H aw aii. The
im plem entation of higher pressure (60 bar and higher) and higher tem perature (450 d eg C
and higher) boilers, and correspond ing turbines allow ed the m ore efficient burning of
bagasse w ith exp ort of electricity to the grid . There w as a phenom enal grow th in sugar co-
generation in Ind ia for the past 15 years. Ind ia started im plem enting the 67 bar cycle 15
years ago. Based on the experience gained and lessons learnt from the operation of those
plants, several 87 bar cogeneration systems w ere installed few years before. N ow , the
ind ustry is m oving tow ard s very high pressure system s of up to 110 bar. Few such system s
are alread y in operation and there are m ore than 25 projects und er various stages of
im plem entation. Several d evelopm ents are also taking place on the processing sid e. Due to
several innovative energy efficiency m easures, technology options and improved house
keepings, the steam consum ption has com e d ow n to as low as 350 to 360 kg of steam per
tonne of cane milled .
2.3 Manufacturing process
Sugar occurs in greatest quantities in sugarcane, from w hich it is extracted . The natural
sugar stored in the sugarcane is separated from the plant material through a process
schem atically represented in Figure 2.3.
14
Energy Perform ance
Figure 2.3: Su gar m anu factu ring p rocess
2.3.1 Various stages in su gar manu factu ring process

The sugar m anufacturing process norm ally com prises
1. Juice extraction
2. Juice clarification and evaporation
3. Crystallization
4. Centrifuging
5. Drying and packing
Steam and electricity generation using bagasse as the fuel, m ostly through backpressure
turbines, form s an im portant part of any sugar factory.
15
1. Juice Extraction
The juice extraction plant consists of cane handling, cane preparation and m illing sections.
a) Cane handling
Cane, brought to the m ill, is m echanically unloaded by a grab type attachm ent. A truck
tippler is som etim es provid ed to unload cane, facilitating load ing of sugar cane to cane
carrier.
b) Cane preparation
The sugarcane is levelled in the leveller before it is fed to the cutter. The cutter shred s the
cane to sm aller sizes and prepares it for the fibrizer w here the cane is converted to a pulp -
like m ass.
Juice extraction from the prepared cane is d one by tw o types of processes. About 95~97% o f
the sugar factories follow m illing process and 3~5% of the sugar factories follow d iffusion
process.
c) M illing
The prepared cane is passed through a m illing tand em com posed of four to six three-roller
m ills. The juice is extracted from the cane by squ eezing und er high pressure in these rollers.
Extraction is m axim ised by leaching the d isintegrated exposed cane w ith w eak juice and
m ake-up w ater in a counter current system . The fibrous m atter or bagasse', w hich is left after
m illing, is used as a fuel for steam generation.
d) Diffusion
Diffusion process is based on a system atic counter current w ashing of the cane or bagasse by
m eans of im bibition w ater. Water is ad d ed at the d ischarge end of the conveyor and
percolates through the bed of bagasse and the perforated slats of the conveyor. The w ater
d issolves the sugar in the bagasse and the thin juice thus form ed is collected in a hopper.
This juice is m oved forw ard one stage by pum ping and the process is repeated until the juice
reaches maxim um concentration at the feed end of the diffuser. The diffuser m ay be
cond itioned either for single-flow or for parallel-flow s juice circulation.
2. Juice clarification
The purification of juice involves (a) juice heating (b) sulphitation (c) clarification and (d )
filtration.
The m ixed juice from the m ills is heated in raw juice heater(s). The heated juice is treated
w ith chem icals to precipitate various d issolved impurities in the m ixed juice. The
precipitated im purities are separated to obtain clear sparkling juice in clarifiers. The clear
juice is again heated to obtain a tem perature of about 105 0C.
3. Evaporation
The juice is concentrated from 15 Brix to around 60 Brix in a m ultiple-effect evaporator. The
vapours are bled from the evaporators for juice heating in various heat exchangers and for
boiling of m assecuite (a m ixture of m olten liquid and crystals) in vacuum pans. This is the
m ajor steam consum ing section of the plant.
16
Energy Perform ance
4. Crystallisation
Crystallisation is an im portant unit operation, w hich in sugar ind ustry is know n as Pan
boiling. A m ajor part of the crystallization process is d one in m ost of the sugar m ills in batch
type vacuum pans. The m assecuite is then transferred to crystallizers w here the process is
com pleted by cooling the m ass und er stirred condition.
5. Centrifuging
The m assecuite from the vacuum pans is sent to the centrifuges, w here the sugar crystals are
separated from the m olasses. These centrifugal machines can be batch type or continuous
type. There are separate centrifugal m achines for `A' type, `B' type and `C' type m assecuites.
The m olasses separated out from this section is a useful by -prod uct, w hich is an excellent
raw m aterial for d istilleries.
6. D rying, grading and packing

The m oist crystals obtained from centrifugal m achines norm ally contain about 15-20%
surface m oisture. They are d ried in traditional d ryers, grad ed accord ing to crystal sizes and
then packed in bags.
2.3.2 By-prod u cts

The m ain by-prod ucts from any su gar ind ustry are (i) bagasse, (ii) m olasses and (iii) filter
cake. The d etails are given below .
i. Bagasse
Bagasse is an im portant by-prod uct of sugar. It is used as a m ajor substitute raw m aterial in
the paper and pulp ind ustry, replacing w ood and bam boo th us red ucing deforestation.
Presently, alm ost all the sugar m ills utilize this bagasse as an in -house fuel in boilers for
steam generation. A num ber of m ills are now planning to utilise bagasse efficiently in high -
pressure boilers for co-generating electricity for export to the grid / neighbouring units.
ii. M olasses
Molasses, the other im portant by-prod uct, is a storehouse of organic chemicals. Ind ustrial
alcohol is prod uced from m olasses, w hich in turn can be used to m anufacture chem icals like
ethyl benzene, lactic acid, tartaric acid , citric acid , d iethyl phthalate, etc. Ind ustrial alcohol
can be used as a fuel extend er as a substitute to the scarce petroleum products.
iii. Filter cake

When cane juice is clarified and filtered , the resulting cake is know n as filt er m ud or filter
cake. It contains m ost of the colloid al m atter precipitated d uring clarification and has
around 63% organic m atter. This cake is of great m anur e value and is m ostly taken by
grow ers using their ow n transport, after d elivering cane to the factory, for use in their field s.
2.3.3 Cogeneration in sugar m ills

The sugar ind ustry by its inherent nature can generate surplus energy in contrast to other
ind ustries, w hich are only consum ers of energy. With liberalization and increased
com petition, the generation and selling of excess pow er to electricity board s, offers an
excellent source of revenue generation to the sugar m ills. This is referred to as com m ercial
co-generation and has been only m arginally tapped in our country. The sugar m ills have
17
been ad opting co-generation right from the beginning. H ow ever, the co-generation has been
restricted to generating pow er and steam only to m eet the operational requirem ents of the
plant. Only in recent years, w ith an increasing pow er d em and and shortage, com m ercial co-
generation has becom e attractive, both from the state utility and the sugar m ill point of view .
The sugar m ills d erive ad d itional revenue by selling pow er to the grid , w hile the state is able
to m arginally red uce the 'd em and -supply' gap, w ith red uced investments.
2.3.4 Distillery in su gar m ills

An associated d istillery m ay em ploy batch or continuous ferm entation, follow ed by
d istillation, to prod uce ethanol w ith a purity of 95%. This ethanol can be used in other
ind ustries or further processed and blend ed w ith gasoline. Waste from the d istillation
process is know n as vinasse or spent w ash. Anaerobic d igestion of this w aste is used to
prod uce biogas, w hich can be utilized for the prod uction of boiler fu el for the d istillery or to
fuel com bined heat and pow er engines. The remaining w aste can be returned to agricultural
field s and / or used in the com posting of organic solid s em anating from processing.
2.4 Technological movements

Various technologies for energy efficiency im provem ent are discussed briefly. Many of these
technologies are alread y in use in Ind ia w hile some are in the d evelopm ent phase or not yet
com m ercialized in Ind ia. Besid es these technologies, one im portant step that the Ind ian
sugar m ills can ad opt is to prod uce sm aller sized sugar instead of bold er sugar grains. This
is because the prod uction of bold er grain sugar lead s to an increased consum ption of 2 to 3%
energy by the ind ustry. Som e of the technological m ovem ents that are im plem ented / can be
im plem ented are listed below :
 Capacity enhancem ent
 Ad option to co-generation to m eet both steam and pow er d em and
 Installation of electrical m ill d rive based sugar extraction in place of steam m ill d rives
 Changing the evaporator configuration to (DEVC + Quad to Quintuple/ quad ruple
m od e)
 Mod ification in vapour bleed ing arrangem ent system (For plants using quintuple
effect system)
 H ot cond ensate m anagem ent: Using hot cond ensate from 2nd bod y of m ultiple effect
evaporators for superheated w ash w ater heating instead of exhaust steam or vapour
bled from m ultiple effect evaporator bod ies
 Use of low grad e vapour for pan boiling by em ploying m echanical circulators
 Step-w ise recovery of flash heat steam from the cond ensate from evaporators , juice
heater and pans
 Selective incorporation of d irect contact heaters for juice heating, syrup, filtrate and
m olasses cond itioning
 Use of low tem perature vapours for pan w ashing
 H eating the air by hot cond ensate at sugar d ryer/ hopper
 Chilled w ater generation using hot vapour cond ensate in vapour absorption system
18
Energy Perform ance
2.5 Capacity utilisation

The capacity utilisation of the sugar m ills plays a m ajor role in the overall energy
consum ption of the plant. During the start and end of crushing seasons, w hen cane
availability is less than requirem ent, the sugar plant energy consum ption w ill be m uch
higher com pared to full capacity operation. Failure of equipm ent, d uring the season, also
forces the plants to be operated at low er capacity till the m aintenance of equipm ent is
com pleted and brought back to line. Und er capacity utilisation of plant and over sizing of
equipm ent consid ering future exp ansion also lead s to higher energy consum ption. The
average capacity utilization of the sugar factories in India d uring 2010-11 w as 92%.
2.6 Major energy consuming areas

The section w ise electrical energy consum ption and steam consum ption in sugar m ill is
given in Table 2.6a and Table 2.6b respectively. The m ajor user areas of steam are m ultiple
effect evaporators, final juice heaters and sulphur m elter. Plants installed w ith d istillery
m ake use of steam in d istillation colum ns.
Table 2.6a: Section w ise electricity consum ption in a sugar m ill

Section Percentage
Cane H and ling 5~10%
Cane Prep aration 15~20%
Milling 25%
Ju ice p u rification 10~15%
Su gar Crystallization 5~10%
Su gar Centrifu gal 10~15%
Co-generation 5~10%
Table 2.6b: Section-w ise steam consum ption in a sugar m ill

Sugar mills w ith electric Sugar mills w ith steam
Section drives for milling (%) drives for milling (%)
Medium pressure steam
Mills 0% 40~50%
Tu rbine & generator 90~100% 40~50%
Low pressure steam
Evap oration 93~95% 93~95%
De-aerator 2~3% 2~3%
Su lp hu r m elting 1~2% 1~2%
Distillery 3~5% 3~5%
2.7 Energy saving potential

2.7.1 Scope for im proving energy efficiency
Analysis of the energy consum ption pattern in the sugar m ills reveals that there exists a
significant scope for im proving the energy efficiency in the Ind ian sugar ind ustry. The m ajor
reason for the high energy consum ption in the industry is the presence of a large num ber of
old , sm all capacity sugar m ills w hich have not invested m uch over the years in m od ernizing
19
or upgrad ing their process equipm ent. The period ic expansion of the plant and installation
of new equipm ent as per the plant expansion has led to increased use of many num bers of
sm all capacity equipm ent w hich can be replaced w ith m inim um num ber of higher capacity
equipm ent to im prove energy efficiency and reduce m aintenance cost. By incorporating the
latest energy efficient process equipment mentioned in section 3.4 (technological
m ovem ents) around 20% of electrical energy consum ption and 25% steam consum ption can
be red uced in the sugar m ills.
2.7.2 Scope for co-generation potential

The all-Ind ia potential of bagasse-based cogeneration w ith the im plem entation of extra high
pressure (87 kg/ cm 2 or 110 kg/ cm 2)/ tem perature (515 or 540 d eg C) configuration, is
around 6,000 MW. For the co-generation opportunity, in 2017, there is a total exportable
pow er potential of approxim ately 9,700 MW (KPMG analysis- 2017 forecast). This can fulfill
alm ost 6% of the ad d itional pow er requirem ent of 128 GW by 2017. As of 31 March 2010,
only 1,344 MW (134 projects) of capacity have been com m issioned , w hile another 530MW of
capacity (39 projects) are und er construction. This m eans that only 31% of the potential has
been actually achieved . Table 2.7.2 gives the state-w ise potential for bagasse based co-
generation projects.
Table 2.7.2: State-w ise bagasse co-generation potential

States Potential MW
Maharashtra 1,500
Uttar Prad esh 1,500
Tam il N ad u 540
Karnataka 540
And hra Prad esh 360
Bihar 360
Gu jarat 420
Pu njab 360
H aryana & others 420
Total 6,000
Source: Industrial Co-generation India, V ol.X IX , October 2010
20
3.0 Analysis of energy consumption data
3.1 Energy consumption in sugar mills

The energy requirem ents in a sugar m ill are in the form of steam for process heating/ turbo
d rives and electricity for running various d rives. The sugar ind ustry has the unique
ad vantage of utilizing a captive fuel (bagasse), to m eet its energy requirements. H ow ever,
d epend ing upon factors like fibre content in the cane, quantity of juice, type of clarification
process and evaporation effects, type of prim e m overs (steam d riven or electric d riven) etc.,
som e sugar m ills prod uce a sm all quantity of surplus bagasse w hile others are d eficient by a
sm all quantity. The sugar m ills d epend , in a very lim ited w ay, on external fuels like fuel oil,
LSH , coal etc., to supplem ent their energy requirem ents. Som e sugar mills d uring the season
can prod uce a m arginal surplus pow er w hile others w ould be d eficient in pow er by a sm all
m argin and hence the d epend ence on grid pow er is m inim al.
3.1.1 Electricity consu m ption in su gar mills

Table 3.1.1 provid es the electricity consum ed and specific energy consumption (Electrical) of
sugar m ills / group of plants und er single ow ner for prod uction from 2010 to 2012. The
electricity pow er consumption includ es electricity purchased from grid , electricity generated
from steam generator and electricity generated by d iesel generators.
Table 3.1.1: Electricity consum ption and Specific Energy Consum ption (Electrical) of sugar m ills
S.N o Plant Capacity, Electricity Estimated SEC
TCD Consumption, (Electrical),
Million kWh* kWh/MT of cane#
Year 2010 2011 2012 2010 2011 2012
1 And hra Su gars Lim ited 16,000 287 331 337 32 33 38
2 Bannari Am m an Su gars Ltd . 19,000 51 90 101 28 28 28
3 Ganp ati Su gar Ind s. Ltd . 5,000 28 9 61 26 24 24
4 Gayatri Su gars Ltd . 7,000 8 43 41 36 70 74
5 God avari Biorefineries Ltd . 12,000 118 206 N .A. 16 26 N .A.
6 Ind ian Su crose Ltd . 5,000 24 10 17 37 34 N .A.
7 Jeyp ore Su gar Co. Ltd . 8,500 16 22 12 25 24 23
8 J K Su gar Ltd . [Merged ] 5,000 18 16 22 35 38 35
9 Kakatiya Cem ent Su gar & Ind s. Ltd . 3,200 32 35 35 56 4 31
10 K C P Su gar & Ind s. Corp n. Ltd . 11,500 31 42 45 50 42 47
11 Mysore Pap er Mills Ltd . 2,500 170 171 172 43 43 31
12 N ahar Ind u strial Enterp rises Ltd . 2,500 272 288 384 52 40 49
13 N ava Bharat Ventu res Ltd . 4,000 9 311 394 32 26 27
14 Parrys Su gar Ind u stries Ltd . 12,500 20 49 109 35 89 76
15 Rai Bahad u r N arain Singh Su gar Mills 8,400 579 68 75 37 38 37
Ltd .
16 S B E C Su gar Ltd . 8,000 22 25 26 28 30 32
17 Sir Shad i Lal Enterp rises Ltd . 11,250 36 42 38 32 29 29
21
S.N o Plant Capacity, Electricity Estimated SEC

TCD Consumption, (Electrical),
Million kWh* kWh/MT of cane#
18 Shaku m bari Su gar & Allied Ind s. Ltd . 5,500 14 13 13 43 40 44
19 Su d alagu nta Su gars Ltd . 2,500 9 10 13 35 28 15
20 Trid ent Su gars Ltd . 3,000 7 10 12 22 25 28
21 Uttam Su gar Mills Ltd . 23,750 93 127 134 38 39 41
22 Wahid Sand har Su gars Ltd . 7,000 11 18 22 18 51 52
23 Wave Ind u stries Pvt. Ltd . 18,800 21 45 N .A. 30 31 N .A.
24 Kanoria Su gar & General Mfg. Co. Ltd . 6,000 9 8 N .A. N .A. N .A. N .A.
25 Dew an Su gars Ltd . 3,125 8 12 13 23 22 22
26 Gobind Su gar Mills Ltd . 7,500 16 18 22 25 25 25
27 Kesar Enterp rises Ltd . 7,200 20 20 22 23 22 22
28 Lakshm i Su gar Mills Co. Ltd . 4,500 12 16 N .A. 28 32 27
29 Ou d h Su gar Mills Ltd . 28,700 51 73 83 36 32 32
30 Tikau la Su gar Mills Ltd . 5,000 30 38 N .A. 38 N .A. N .A.
31 Up p er Ganges Su gar & Ind s. Ltd . 18,000 33 37 45 25 26 27
32 Venu s Su gar Ltd . 3,500 4 4 N .A. 49 N .A. N .A
33 Bajaj H ind u sthan Su gar & Ind s. Ltd . 40,000 89 N .A. N .A. 27 35 37
[Merged ]
34 Bajaj H ind u sthan Ltd . 136,000 195 298 363 N .A. N .A. N .A
35 Balram p u r Chini Mills Ltd . 76,500 133 330 225 27 28 28
36 Dw arikesh Su gar Ind s. Ltd . 21,500 121 213 213 N .A. N .A. N .A
37 Ind ia Su gars & Refineries Ltd . 2,500 2 1 4 29 21 20
38 Kaship u r Su gar Mills Ltd . 6,250 8 12 9 N .A. N .A. N .A
39 Rana Su gars Ltd . 15,000 125 237 201 115 123 123
40 Sarasw ati Su gar Mills Ltd . 13,000 26 39 N .A. 32 N .A. N .A
41 Sri Sarvaraya Su gars Ltd . 4,000 3 1 N .A. 23 N .A. N .A
42 Shree Renu ka Su gars Ltd . 48,250 399 652 1,089 11 19 N .A
43 Sim bhaoli Su gars Ltd . 20,100 55 78 N .A. 210 N .A. 320
44 Thiru Arooran Su gars Ltd . 8,500 35 23 N .A. 35 N .A. 31
45 Triveni Engineering & Ind s. Ltd . 61,000 147 315 349 28 33 34
* CM IE database; # Based on 10% sugar recovery
The specific pow er consum ption of sugar mills is also evaluated based on pow er
consum ption and tonnes of cane. The typical specific energy consum ption w ill be in the
range of about 26~32kWh/ tonne of cane. The break-up of section w ise specific p ow er
consum p tion is given below :
 Milling tand em includ ing cane hand ling – 10~12 kWh/ tonne of cane
 Clarification, Boiling, curing & sugar handling – 7~8 kWh/ tonne of cane
 Pow er plant includ ing ESP – 7~8kWh/ tonne of cane
 Factory lighting & other utilities – 2 kWh/ tonne of cane
With the im plem entation of the latest energy efficient technologies the specific pow er
consum ption can be brought d ow n to 22kWh/ tonne of cane.
(Source: A ll India seminar on latest energy efficient technologies in Indian sugar industry – organised by STA I)
22
Analysis of Energy Consu m p tion Data
3.1.2 Steam consum ption in su gar mills

Som e im portant features of steam consum ption in sugar m ills are given below .
 Steam consum ption is about 30 to 50% on cane (i.e., 300kg to 500kg per tonne of cane
crushing)
 Less num ber of vapour bleed ing stages results in less steam econom y
 Lot of H P steam is also used for process viz. sulphur burner, pan w ashing, sugar
d rying & m elting, m olasses conditioning and centrifugal station
 N on-utilization of the heat available in condensers, w aste gases (N CG), v apours going
to atm osphere and flue gas
 Steam generation/ fuel ratio in average sugar ind ustry is 1.9/ 2.00%. H ard ly 2% of the
sugar ind ustry has achieved 2.6% steam -fuel ratio
The trend of steam consum ption share on cane over the past in Ind ian sugar m ills is given in
Figure 3.1.2.
Trend of Steam Consumption in Sugar Mills

70%
Steam Consumption % on
60%
50%
40%
cane
30%
20%
10%
0%
1900 1930 1950 1975 1995 2000 2005 2008 Future
Year
Figure 3.1.2: Steam consu m p tion trend over d ecad es

(Source: A ll India seminar on latest energy efficient technologies in Indian sugar industry – organised by STA I)
The specific steam consum ption d ata of ind ivid ual sugar m ills is not published in public
d om ain. Based on the energy aud its carried out by TERI in various sugar m ills across Ind ia,
the range of steam consum ption in sugar m ills w hose installed capacity lies betw een 3000
TCD and 5000 TCD is varying from as low as 28% on cane to as high as 45% on cane
d epend ing upon the type of juice extraction process and subsequent vapour bleed ing
arrangem ent.
3.2 Plotting plant vs energy consumption

Based on the energy audits carried out by TERI, energy consum ption pattern in som e of the
sugar m ills is given in Table 3.2.
23
Table 3.2: Energy consum ption of sugar m ills aud ited by TERI
N ame of the sugar mill Technology Crushing Specific energy Steam Co-
Capacity consumption consumption generation
(TCD ) (kWh/tonne of (% of cane) Capacity
cane) (MW)
EID Parry, H aliyal Diffu ser 4,800 26-27 40-41% 24.2
Mad hu con Su gar & Mills 3,200 25-26 45% 24.2
p ow er Ind u stries Ltd ,
And hra Prad esh
N avabharat Ventu res Ltd , Mills 3,500 22-23 28-30% 9.0
Su gar Division, And hra
Prad esh
EID Parry, Sankili, Mills 4,000 22-23 31-33% 16.0
And hra Prad esh
Rajshree Su gars, Mills 5,000 32-33 39-40% 22.0
Villu p u ram , Tam il N ad u
Rajshree Su gars, Theni, Mills 3,000 38-40 44-45% 12.0
Tam il N ad u
EID Parry, Bagalkot Mills 4,500 23-25 36-37 15.5
3.3 Possible energy efficiency measures in sugar industry

Sugar m ills cannot control the energy prices, Governm ent policies and the Global econom y.
But they can im prove the w ay they m anage their energy. Im proved energy perform ance can
provid e rapid benefits for the ind ustry by m aximizing the use of energy sources and energy
related assets, thus red ucing both energy cost and consum ption. Various technologies for
energy efficiency im provem ent are discussed briefly. Many of these technologies are alread y
in use in Ind ia w hile some are in the d evelopm ent phase or not yet com m ercialized in India.
Besid es these technologies, one im portant step that the Ind ian sugar mills can ad opt is to
prod uce sm aller sized sugar instead of bold er sugar grains. This is because the prod uction of
bold er grain sugar lead s to an increased consum ption of 2 to 3% energy by the ind ustry.
3.3.1 Im proved reliability and econom ics of steam & pow er generating
systems w ith film form ing polyam ines
Corrosion and scaling in boilers and turbines continue to cause heat insulating d eposits in
boilers resulting in failures, loss of efficiency, frequent cleaning and increased cost of
operations. A “film barrier approach" has been gaining increasing acceptance. It utilizes the
film form ing properties of aliphatic am ines on d ivalent w et m etal surfaces provid ing m uch
superior protection to the m etal surfaces in boilers and turbines against corrosion scaling
and carryover.
3.3.2 Direct prod uction of w hite su gar in a cane su gar mill

White sugar can be d irectly prod uced from clarified juice through an econom ical process.
Juice from a cane sugar m ill, or sugar beet juice, is first contacted w ith hyd rogen peroxid e,
before passing through granular activated carbon. The juice is then passed through cationic
and anionic resins to remove inorganic com pounds, colorants, and other im purities. Then
the juice m ay be concentrated and sugar crystallized . White sugar is produced d irectly,
24
w ithout the need for interm ed iate raw sugar crystallization and the process is thereby
econom ical.
3.3.3 Su garcane w aste conversion into char

The Appropriate Rural Technology Institute (ARTI) in Pune has d eveloped a charring
process for converting sugarcane trash into high value char. Char obtained by this process
can be converted into briqu ettes easily by a variety of w ell-established briquetting m ethod s.
The kiln has a conversion efficiency of 30 per cent and operates as a continuous -batch
process.
3.3.4 Qu intu ple 3rd effect vapou r for su gar m elting

In a m ultiple effect evaporator, vapour bleed ing in the later bod ies w ill bring steam
econom y. But extensive use of this vapour is presently lim ited to first tw o bod ies d ue to low
tem perature of vapours and high scaling patterns in later bod ies. Extensive use of vapour of
the third bod y in a quintuple effect evaporator can be planned . With an increase in pressure
of the exhaust steam used at the first bod y of evaporator, the pressure cond itions of
ind ivid ual bodies changes to higher sid e m atching w ith the pressures of the quad ruple
effect. Steam saving upto 3.5% is achieved through extensive use of vapour from the third
bod y by converting the evaporator system into quintuple from quad ruple. Use of this
system w ould help in red ucing the steam consum ption.
3.3.5 Cond ensate flashing system

When juice is concentrated by separating w ater content in m ultiple effect evaporation, the
vapour cond ensate takes aw ay heat utilized for heating, often into the d rain. As w as the case
of red ucing pressure in bod ies of m ultiple effect evaporators in sequence, it is proper to use
flash heat in hotter vapour cond ensates, in subsequent bod ies by circulating the cond ensate
sequentially.
3.3.6 Film type su lphu r bu rner

Sugar juice clarification (purification) process requires sulphur d ioxid e as a clar ification and
bleaching agent. In Ind ian factories, it is prod uced from expensive (im ported ) sulphur in the
conventional tray type batch burners, w hich are inefficient resulting in high processing cost,
poor clarification and poor sugar quality. The new "film type sulphur burner" prod uces SO2
w ith consistent quality, high efficiency, low consum ption and w ell regulated operation
m ad e possible by the new 'film burning' concept and requisite autom ation. The film type
sulphur burner technology has been ad opted in m ore than 64 sugar factories all over Ind ia.
Operation of the burner is controlled in accord ance w ith process d emand s i.e. SO2 quantity
and quality, sulphur feed rate etc. through use of instrum entation and control system etc.
3.3.7 Bagasse d rier

Bagasse Drier is a novel concept of d rying bagasse as w ell as controlling air pollution. It is a
unique d evice w herein the hot flue gases are m ixed w ith the w et bagasse from m ills. This
w et bagasse gets d ried up and accum ulates all the ash and unburnt carbon w ith it. The
system w ould help in improving the efficiency and in pollution control.
25
3.3.8 Planetary gearbox for crystalliser

Planetary gearbox is energy efficient, cost effective com pact alternative to the conventional
d rive com prising gear trains and also hyd raulic drive. Som e plants have successfully
replaced the existing w orm w heel red uction system w ith the planetary gearbox arrangem ent
for all the crystallizers.
3.3.9 Ad vanced bagasse based co-generation

Sugar m ills em ploy co-generation system having 480 d eg C and 65 bar (atm ). With
technological advancement, som e sugar mills in Ind ia have im plem ented the ad vanced co-
generation system of 515 d eg C and 105 bar (atm ) pressure for increasing energy efficiency
and financial profitability.
3.3.10 Mechanical Vapou r Com pression (MVR) technology to recover

low -pressu re w aste steam
The need for red ucing energy costs has led to m ulti-effect plants, then to therm al vapour
com pression and finally to the use of m echanical vapours com pression system s. In
m echanical vapour compression, positive displacem ent com pressions or m ulti-stage
centrifugal com pressors are generally used to raise the pressure and tem perature of the
generated vapours. Since m echanical com pressors d o not require any m otive steam , all
vapours can be com pressed to elevated pressure and tem perature, elim inating the need for a
subsequent recovery system . The energy supplied to the com pressor constitutes the
ad d itional energy input to the vapours. After the com pression of the vapour and its
subsequent cond ensation , through transfer of heat to process fluid , the hot cond ensate
leaves the system , w hich can be used as feed w ater/ liquid for boilers.
3.3.11 Mill Drives

DC m ill d rives are used in m ost sugar m ills in India to d rive the m illing tand em w ith four to
five 500-1000 H P d rives. This is in vogue in m ost of the plants now , w ith conversion of
turbo-steam d rive to electrical d rive w ith co-generation of pow er for export being popular.
H ow ever, the new d evelopm ent of using AC d rive instead of DC d rive has the follow ing
ad vantages. The ad vantages includ e the follow ing:
 Efficiency of AC m otor is higher than DC m otor
 Low m aintenance cost than DC m otor
 Less harm onics than DC m otor
 Overall pow er saving of 3-5% is possible w ith AC d rive for m illing tand em in place of
DC d rives
3.3.12 Vertical continu ou s vacu u m pan for m assecu ite boiling

The use of batch type vacuum pans in m ost of the m ills results in consid erable fluctuations
of steam consum ption and irregular sugar quality. It results in variation in the syrup brix.
The use of fully auto controlled continuous pan helps in m aintaining a stead y consum ption
of vapours thus elim inating the problem s associated w ith fluctuating vapour flow s. This
ensures the uniform functioning of the evaporator station, an d also boiler steam generation.
3.3.13 Low pressure extraction (LPE) system

The new LPE system is an efficient alternative to conventional method s of juice extraction,
w hich utilizes com bination of solid -liquid extraction and conventional milling technology at
low hyd raulic pressures. The system uses perforated rollers in m od ules of 2. A total of eight
26
m od ules (16 rollers) w ere used d uring the trial runs. H yd raulic pressure of 110 bar is used .
Due to perforations in the rollers, the extracted juice is quickly d rained out. Re-absorption of
juice is negligible. The system is d riven by electric m otors and operation is autom atically
controlled.
3.3.14 Mem brane filtration for su gar manufactu ring

Mem brane filtration is the process for prod uction of sulphur free, refined quality sugar
w ithout going through conventional refining. In this process, high tem perature tolerant
polym eric m em brane mod ules are em ployed for sugarcane juice clarification for prod uction
of high quality sugar. These m em brane m od ules are capable of w ithstand ing continuous
exposure to hot juice w ithout any visible signs of d eterioration.
3.3.15 H igh pressure co-generation system

Apart from im proving the end use efficiency in the plants, the other m ost prom ising en ergy
conservation measure for the ind ustry is to install extra high pressure (87 kg/ cm 2 or 110
kg/ cm 2)/ tem perature (515 or 540 d eg C) configuration co-generation system s.
3.4 Conclusions
The sugar ind ustry is one of the largest energy users am ong ind ustry sector using bagasse
for m eeting both therm al energy and electricity requirem ents. Out of the 527 operating sugar
m ills in Ind ia, about 99 sugar m ills have an installed capacity of 5000 TCD and above. These
sugar m ills can be brought und er tw o broad categories viz. (1) sugar m ills w ith steam d riven
m ills and (2) sugar mills w ith electrical m otor d riven m ills. The sugar m ills above 5000TCD
capacity may be taken up for d etailed stud y in the first phase. The estim ated annual energy
consum ption of these sugar m ills vary betw een 45,000 toe per year to 90,000 toe per year.
The estim ation of annual energy consum ption w as based on sugar recovery and average
crushing period of sugar m ills in Ind ia. A large num ber of these units have ad opted
cogeneration route to m eet their overall energy requirem ents. As per the collected
inform ation and discussions w ith stakehold ers d uring the sectoral w orkshop, there exists a
significant energy saving potential of about 20% in sugar ind ustries. Therefore it is
suggested that these 99 sugar m ills (w hich operate either separately or as a group) m ay be
consid ered as DCs und er the PAT scheme w ith a threshold limit of 30,000 toe as m inim um
annual energy consum ption per plant (figure 3.4).
5000 to 7000 7000 to Above 10000
Figure 3.4: Estim ated annual energy consum ption
27
4.0 References
1. Barbara H aya, Malini Ranganathan and Sujit Kirpekar, 2009. “Barriers to sugar m ill co -
generation in Ind ia: Insights into the structure of post-2012 clim ate financing
instrum ents” Clim ate and Developm ent, USA.
2. Central Electricity Authority, 2011. “CO2 Baseline Database for the Indian Pow er
Sector”. N ew Delhi, India.
3. Confed eration of Ind ian Ind ustry, 2008. “Build ing a Low - Carbon Econom y” Gurgaon,
Ind ia
4. De Sm et, 2010. “Sugar Cane Diffusion”. De Sm et S.A. Engineers & Contractors,
Belgium .
5. Departm ent of Food and Public Distribution, 2012. “Annual Report 2011–20012”, N ew
Delhi, India.
6. Gangakhed Sugar & Energy Lim ited . “Technological up -grad ation”.
[http:/ / w w w .gangakhed icpp.com / ?link=techupgrad n, accessed pn 11 Decem ber
2012]
7. Ind ian Sugar Manufacturers Association (ISMA)
[http:/ / w w w .ind iansugar.com / Statics.aspx]
8. Ind ian Renew able Energy Agency Limited (IREDA). “Energy Efficiency and
Conservation (includ ing DSM) – Technology”.
[http:/ / w w w .ired a.gov.in/ hom epage1.asp?parent_category=2&sub_category=26&cat
egory=138, accessed on 10 Decem ber 2012]
9. IREDA - Confed eration of Indian Ind ustry. “Investors Manual For Energy Efficiency”
Chennai, India
10. KPMG – “The Indian Sugar Ind ustry Sector Roadm ap 2017”, June 2007, Ind ia.
[http:/ / w w w .in.kpm g.com / pd f/ Ind ian_Sugar_Ind ustry.pd f]
11. Kulkarni D.P. “Cane Sugar Manufacture in India”. The Sugar Technologists'
Association of Ind ia, N ew Delhi, Ind ia.
12. Ministry of N ew and Renew able Energy, 2012. “Annual Report 2011–2012”, N ew
Delhi, India.
13. Ministry of N ew and Renew able Energy, 2012. “Biom ass Pow er and Co-generation
Program m e”. [http:/ / mnre.gov.in/ schem es/ grid -connected / biom ass-pow ercogen/ ,
accessed on 6 Decem ber 2012]
14. N atu S.C, 2005. “Bagasse Based Co-generation, Ind ia Marching Ahead”. MITCON
Consultancy Services Ltd ., Pune, India
15. Petroleum Conservation Research Association. “Developm ents in Sugar Technology”,
Chapter-13. PCRA
16. Rajshree Sugars. “Sugar Process”.
[http:/ / w w w .rajshreesugars.com / im ages/ stories/ rajshree/ Sugar_Process.pd f,
accessed 4 on Decem ber 2012]
17. Rangarajan C, Chairm an, Econom ic Advisory Cou ncil to the PM, 2012. “Report of the
Com m ittee on the Regulation of Sugar Sector in Ind ia: The Way Forw ard ”. N ew Delhi,
Ind ia.
18. Singh N .P, 2010. “Ind ustrial Co-generation Ind ia” Vol XIX. Ministry of N ew and
Renew able Energy (MN RE), N ew Delhi, India.
19. Sugar Ind ia, 2012. “Year book 2012”, Pulse of Ind ian Sugar Ind ustry.
20. Sucd en.com “http:/ / w w w .sucd en.com / statistics/ 4_w orld -sugar-consumption”
29
21. Sugarind ustry.com . “Manufacturing Process and Technology”.

[http:/ / w w w .sugarind ustry.com / sugarprocess.htm , accessed 4 on December 2012]
22. Sugar Technologists Association of Ind ia, May 2011, “ All Ind ia Seminar on Latest
Energy Efficient Technologies in Indian Sugar Ind ustry” Kanpur, U.P.
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Technology Mission”.
[http:/ / w w w .tifac.org.in/ ind ex.php?option=com_content&view =article&id =49&Item
id =205, accessed 4 Decem ber 2012]
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Decentralized Energy, Ed inburgh
30
5.0 Annexure 1
State Wise Sugar Plant Information
N ame of the State: AN D HRA PRADESH Season: 2010-11

Sl. N ame of the Plant Crushing Sugar Co-generation
No Capacity Produced Capacity
(M.T) (Lakh/Qtl) (MW)
1 The Chod avaram Co-op . Su gars Ltd ., Chod avaram 4,000 5.19 6.25
2 N CS Su gars Ltd . 6,000 3.99 20
3 Parry Su gar Ind u stries Ltd ., Varalakshm i 5,000 4.04 16
4 K.C.P. Su gar And Ind u stries Corp oration Ltd ., 7,500 8.06 15
Vu yyu ru
5 K.C.P. Su gar And Ind u stries Corp oration Ltd ., 4,000 2.5 5
Lakshm ip u ram
6 N ava Bharat Ventu res Ltd ., (Su gar Division), 4,000 4.01 9
Sam alkot
7 Sri Sarvaraya Su gars Ltd ., Chellu ru 5,000 3.31 12.65
8 The And hra Su gars Ltd ., Tanu ku 5,000 2.24 -
9 The And hra Su gars Ltd ., Tad u vai 5,500 3.55 7
10 The Jeyp ore Su gar Com p any Ltd ., Chagallu 8,500 9.53 25
11 The And hra Su gars Ltd ., Bhim ad ole 5,500 1.89
12 Mad hu con Su gar & Pow er Ind u stries Ltd ., 3,500 1.98 20
Rajesw arap u ram
13 Gayatri Su gars Ltd ., N .C.S. Gayatri 3,500 3.29 6
14 Ganp ati Su gar Ind u stries Ltd ., Sangared d y, 5,000 5.62 15
15 VDB Su gars Ltd ., G.S. Com p lex 3,500 2.25
16 Mad hu con Su gar & Pow er Ind u stries Ltd ., 3,500 1.36 24
Rajesw arap u ram
17 Sagar Su gars & Allied Prod u cts Ltd ., N elavoy 4,000 1.87 20.4
18 N SL Krishnaveni Su gars Ltd ., Krishnaveni 3,500 1.08 28
N ame of the State: Bihar Season: 2010-11

1 Riga Su gar Co. Ltd ., Righa 5,000 4.45
2 Jay Shree Su gar Mill, Majhau lia 5,000 3.87
3 N ew Sw ad eshi Su gar Mills 7,500 6.4 5
4 H arinagar Su gar Mills Ltd ., H arinagar 10,000 9.17 14.5
5 Bharat Su gar Mills, Sid hw alia 5,000 3.69 15
6 Vishnu Su gar Mills Ltd ., Gop alganj 3,500 3.85
31
N ame of the State: GUJARAT Season: 2010-11
Sl. N ame of the Plant Crushing Sugar

No Capacity Produced
(M.T) (Lakh/Qtl)
1 Shree Khed u t Sahakari Khand Ud yog Mand li Ltd ., Bard oli 10,000 20.27
2 Sahakari Khand Ud yog Mand al Ltd ., Gand evi 5,000 12.79
3 Shree Mad hi Vibhag Khand Ud yog Sahakari Mand li Ltd ., 7,000 13.49
Mad hi
4 Shree Chalthan Vibhag Khand Ud yog Sahakari Mand li Ltd ., 5,000 9.82
Chalthan
5 Shree Mahu va Prad esh Sahakari Khand Ud yog Mand li Ltd ., 3,500 7.41
Mahu va
6 Shree Sayan Vibhag Sahakari Khand Ud yog Mand li Ltd ., 5,000 10.97
Sayan
7 Shree Valsad Sahakari Khand Ud yog Mand li Ltd ., Valsad 5,000 5.25
8 Shree Ganesh Khand Ud yog Sahakari Mand li Ltd ., Vataria 4,000 6.94
Name of the State: HARYAN A Season: 2010-11
Sl. N ame of the Plant Crushing Sugar

No Capacity Produced
(M.T) (Lakh/Qtl)
1 Sarasw ati Su gar Mills Ltd ., Yam u nanagar 13,000 12.62
2 Piccad ily Agro Ind u stries Ltd ., Bhad son 5,000 3.19
3 The Shahabad Co-op .Su gar Mills Ltd ., Shahabad 3,500 4.42
N ame of the State: KARN ATAKA Season: 2010-11

1 Corom and el Su gars Ltd ., (A Unit of Ind ia Cem ents 3,500 7.65 2X6
Ltd .,)
2 The Mysore Su gar Co.Ltd ., Mand ya 3,500 2.81 -
3 The Pand avap u ra S.S.K. Ltd ., Mysu gar Unit-II 3,500 2.81 -
4 Sri Cham u nd esw ari Su gars Ltd ., Cham u nd esw ari 4,000 8.14 26
5 N SL Su gars Ltd ., Kop p a 3,500 9.75 -
6 The Ugar Su gar Works Ltd ., UgarKhu rd 10,000 18.12 44
7 Shri H iranyakeshi Sahakari Sakkare Karkhane 5,000 9.77 26
N iyam it, Sankeshw ar
8 Shri Malap rabha S.S.K. N iyam it, Malap rabha 3,500 5.19 -
9 Shree Dood haganga Krishna S.S.K. N iyam it, 5,500 11.19 20.7
Chikod i
10 Shree Renu ka Su gars Ltd ., Manoli 7,500 16.81 35.5
11 Athani Farm ers Su gar Factory Ltd ., Mad bhavi 4,500 8.49 24
12 Venkateshw ara Pow er Project Ltd ., 5,000 9.05 21
Venkateshw ara
13 Satish Su gars Ltd ., H u nshyal 7,500 12.15 31
32
Annexu res

14 Vishw anath Su gar & Steel Ind u stries Ltd ., Bellad 5,500 8.84 39
Bagew ad i
15 Shree Renu ka Su gars Ltd ., Bu rlatti 15,000 15.82 38
16 The Bid ar Sahakari Sakkare Karkhane Ltd ., Bid ar 3,500 3.95 -
17 The God avari Biorefineries Ltd ., Sam eerw ad i 14,000 19.34 45.56
18 N irani Su gars Ltd ., Mu d hol 6,250 12.38 32
19 GEM Su gars Ltd . 5,000 10.16 16.5
20 Shri Prabhu lingeshw ar Su gars & Chem icals Ltd ., 8,500 14.08 38.5
Sid d ap u r
21 Sad ashiva Su gars Ltd ., Sad ashiva 3,500 4.07 15.5
22 Ind ian Cane Pow er Ltd ., Uttu r 5,000 10.44 -
23 The N and i S.S.K. N iyam it., Bijap u r 5,000 10.14 18.1
24 Davangere Su gar Co.Ltd ., Davangere 3,500 4.49 24.45
25 Bannari Am m an Su gars Ltd ., Bas 7,500 12.73 36
26 Shree Renu ka Su gars Ltd ., Unit V, H avalaga 10,000 11.82 25. 5
27 Core Green Su gar & Fu els Pvt. Ltd . 5,000 0.63 -
28 Vijayanagar Su gars Pvt.Ltd ., Mu nd argi 5,000 3.94 26
N ame of the State: MAHARASHTRA Season: 2010-11

1 Baram ati Agro Ltd ., Shetp halgad e 4,000 8.81 -
2 Bhim a Sahakari Sakhar Karkhana Ltd ., Patas 5,000 11.39 -
3 Shri Chhatrap ati Sahakari Sakhar Karkhana Ltd ., 3,500 9.51 -
Bhavaninagar
4 Dau nd Su gar Ltd ., Alegaon 3,500 9.32 18
5 Karm ayogi Shankarroji Patil Sahakari Sakhar 5,000 15.48 -
Karkhana Ltd ., Ind ap u r
6 The Malegaon Sahakari Sakhar Karkhana Ltd ., 4,000 10.58 -
Malegaon
7 Shri Som eshw ar Sahakari Sakhar Karkhana Ltd ., 3,500 10.49 -
N ira
8 Shri Vighnahar Sahakari Sakhar Karkhana Ltd ., 5,000 12.73 -
Ju nnar
9 Yashw ant Sahakari Sakhar Karkhana Ltd ., Theu r 3,500 1.73 -
10 Shri Pand u rang Sahakari Sakhar Karkhana Ltd ., 3,500 12.69 9
Pand u rang
11 Sahakar Maharshi Shankarao Mohite-Patil S.S.K. 4,500 12.06 -
Ltd ., Aklu j
12 Shree Sid d heshw ar Sahakari Sakhar Karkhana 5,000 9.6 -
Ltd ., Ku m athe
13 Shri Vitthal Sahakari Sakhar Karkhana Ltd ., 5,000 14.21 -
Gu rsale
14 Vitthalrao Shind e Sahakari Sakhar Karkhana Ltd ., 3,500 15.99 10.5
33

Pim p alner
15 Dr. Babu rao Bap u ji Tanp u re Sahakari Sakhar 4,250 6.85 -
Karkhana Ltd ., Rahu ri
16 Pad m ashri Dr. Vitthalrao Vikhe Patil S.S.K. Ltd ., 4,000 11.63 30
Pravaranagar
17 Shri Dnyaneshw ar Sahakari Sakhar Karkhana Ltd ., 5,000 12.15 12
Bhend e
18 Mu la Sahakari Sakhar Karkhana Ltd ., Sonai 3,500 9.83 16
19 Shri Saikru p a Su gar & Allied Ind u stries Ltd ., 7,500 2.69 -
H irad gaon
20 Sahakar Maharshi Bhau saheb Thorat Sahakari 3,500 11.22 -
Sakhar Karkhana Ltd ., Sangam ner
21 The Shrigond a Sahakari Sakhar Karkhana Ltd ., 3,500 7.52 -
Shrigond a
22 N ip had Sahakari Sakhar Karkhana Ltd ., N ip had 3,500 4.81 -
23 Jai Mahesh Su gar Ind u stries Ltd ., (A u nit of N SL 7,000 5.11 30
Su gars Lim ited ), Paw arw ad i
24 Majalgaon Sahakari Sakhar Karkhana Ltd ., 3,500 6.01 -
Majalgaon
25 Gangakhed Su gar & Energy Ltd . 6,000 6.21 -
26 N atu ral Su gar & Allied Ind u stries Ltd ., Rajani 5,000 7.85 22
27 Terna Shetkari Sahakari Sakhar Karkhana Ltd ., 5,000 2.59 14
Terna
28 Shree Bhogaw ati Sahakari Sakhar Karkhana Ltd ., 4,000 6.95 -
Bhogaw ati
29 Shree Chhatrap ati Shahu S.S.K.Ltd ., Kagal 3,500 8.68 12.5
30 Shree Datta Shetkari S.S.K. Ltd ., Shirol 7,000 15.93 30
31 Dau lat Shetkari S.S.K. Ltd ., Dau lat 3,500 3.86 -
32 Shree Du d hganga Ved ganga S.S.K. Ltd ., Bid ri 4,500 8.75 -
33 Deshbhakta Ratnap p anna Ku m bhar Panchganga 5,000 6.82 30
S.S.K.Ltd ., Ichalkaranji
34 Jaw ahar Shetkari Sahakari Sakhar Karkhana Ltd ., 7,500 18.5 15
H u p ari
35 Shri Tatyasaheb Kore Warana S.S.K. Ltd ., Warana 7,500 16.35 -
36 H u tatm a Kisan Ahir S.S.K. Ltd ., H u tatm a 3,500 8.19 -
37 Rajaram bap u Patil Sahakari Sakhar Karkhana Ltd ., 4,000 11.60 -
Rajaram nagar, (Plant N am e- Walw a, Cod e-15501)
38 Vasantd ad a Shetkari Sahakari Sakhar Karkhana 5,000 7.81 -
Ltd ., Sangli
39 Kisanveer Satara Sahakari Sakhar Karkhana Ltd ., 4,000 11.56 2
Bhu inj
40 Sahyad ri Sahakari Sakhar Karkhana Ltd ., 7,500 15.99 -
Yashw antnagar, Tal. Karad , Dist. Satara 415 115,
41 Yashw antrao Mohite Krishna S.S.K. Ltd ., Krishna 7,200 14.82 16
34
Annexu res
N ame of the State: PUN JAB Season: 2010-11

1 Wahid Sand har Su gars Ltd ., Phagw ara 4500 2.38 18 MW.
2 Bhagw anp u ra Su gar Mills, Dhu ri 3500 2.84 -
3 Rana Su gars Ltd ., Baba Bakala 5000 4.05 46 MW.
4 Ind ian Su crose Ltd ., Mu kerian 5000 4.86
5 A.B. Su gars Ltd ., Dasu ya 7000 4.54 33 MW.
6 N ahar Ind u strial Enterp rises Ltd ., Am loh 5000 3.07 8 MW.
7 Chad ha Su gars & Ind u stries Ltd ., Kiri 5000 2.18
N ame of the State: TAMIL N AD U Season: 2010-11

1 E.I.D. Parry (Ind ia) Ltd ., N elliku p p am 5000 10.96
2 Shree Am bika Su gars Ltd . 7500 7.86 40 MW.
3 Rajshree Su gars and Chem icals Ltd ., Mu nd iyam p akkam 5000 9.76 22 MW.
4 Sakthi Su gars Ltd ., Sakthi 7500 14.46
5 E.I.D. Parry (Ind ia) Ltd ., Pu galu r 4000 8.89 22.6 MW
6 Thiru Arooran Su gars Ltd ., Thiru Arooran 3500 5.55 18.68 MW
7 Shree Am bika Su gars Ltd ., Kottu r 4000 0.63 16.2 MW.
8 Thiru Arooran Su gars Ltd . 6000 3.45 28.42 MW,
9 N PKR Ram asam y Co-op . Su gar Mills Ltd ., 3500 3500
Mailad u thu rai
10 Bannari Am m an Su gars Ltd ., Bannari 4000 4.42 20MW.
11 Sakthi Su gars Lim ited , Shivganga 4000 4.22
12 Dharani Su gars & Chem icals Ltd ., Polu r 4000 5.83 15 MW.
13 E.I.D. Parry (I) Ltd ., Aranthangi 4000 6.53 18.5 MW.
14 Kothari Su gars & Chem icals Ltd ., Sath iyam angalam 5000 3.47
15 Sakthi Su gars Ltd ., Unit IV, Mod aku richi 4000 1.82
16 Rajshree Su gars & Chem icals Ltd ., Sem m ed u 3500 6.61 20.5 MW
17 Dhanalakshm i Srinivasan Su gars Pvt.Ltd ., Ud u m biyan 3500 3.66 23 MW
18 Dharani Su gars & Chem icals Ltd ., Kalayanallu r 3500 8.1
19 Bannari Am m an Su gars Ltd ., (Unit IV), Tiru vannam alai 5000 7.71 28.8 MW
20 Em p ee Su gars Ltd ., Id aikkal 7500 0.65
21 Mad ras Su gars Lim ited , Thiru kovilu r 3600 1.88 25 MW
N ame of the State: U.P Season: 2010-11

1 The Sim bhaoli Su gars Ltd ., Chilw aria 4.41 3.97 11.75 + 22
2 Parle Biscu its Pvt.Ltd ., Parsend i 3.73 3.2 18.23 + 9
3 Rau zagaon Chini Mills, (A Unit of Balram p u r Chini 5.34 5.12 29.75
Mills Ltd .),
35

4 Bajaj H ind u sthan Ltd ., Pratap p u r 2.15 2.01
5 The Kanoria Su gar & General Manu factu ring Co. Ltd ., 3.27 3
Cap tainganj
6 Triveni Engineering & Ind u stries Ltd ., Ram kola 5.01 4.92
7 The United Provinces Su gar Co.Ltd ., Seorahi 5.2 4.76
8 Saraya Su gar Mills, Sard arnagar 2.43 2.21
9 J.H .V. Su gar Ltd ., Gad au ra 2.78 2.58 20
10 The Basti Su gar Mills Co. Ltd ., Basti 2.88 2.56
11 Govind nagar Su gar Ltd ., (Unit of Bajaj H ind u sthan 3.05 2.75
Ltd .)
12 Balram p u r Chini Mills Ltd ., Babhnan 8.74 8.22 5
13 Balram p u r Chini Mills Ltd ., Balram p u r 10.85 9.92
14 Tu lsip u r Su gar Co., (Unit of B.C.M. Ltd .), Tu lsip u r 5 4.78
15 H aid ergarh Chini Mills, (A Unit of Balram p u r Chini 3.24 2.95 23.25
Mills Ltd .), H aid ergarh
16 K.M. Su gar Mills Pvt. Ltd ., K.M. Su gar 5.48 5.18
17 The Seksaria Bisw an Su gar Factory Ltd ., Bisw an 8.81 8.26
18 The Ou d h Su gar Mills Ltd ., H argaon 12.48 11.79 15
19 Dalm ia Chini Mills, Ram garh 6.26 5.8 25
20 Kam lap u r Su gar & Ind u stries Ltd ., Kam lap u r
21 Akbarp u r Chini Mills, (A Unit of Balram p u r Chini Mills 6.63 6.45
Ltd .) (Plant N am e- Akbarp u r, Cod e- 56501),
22 Dalm ia Chini Mills, (Plant N am e- Jaw aharp u r, Cod e- 7.19 6.68 27
69401)
23 Ku m bhi Chini Mills, (Plant N am e- Ku m bhi, Cod e- 9.62 9.34
59301),
24 Mankap u r Chini Mills, (A Unit of Balaram p u r Chini 8.22 7.7 37
Mills Ltd .),
25 Bajaj H ind u sthan Ltd ., (Plant N am e- Kham barkhera, 8.63 8.03
Cod e- 57701),
26 J.H .V. Distilleries & Su gar Mills Ltd , (Form erly 1.67 1.49
Caw np ore Su gar Works Ltd .,) (Plant N am e- Pad rau na,
Cod e- 08001),
27 Bajaj H ind u sthan Ltd , Ru d hau li 2.01 1.83
28 Bajaj H ind u sthan Su gar & Ind u stries Ltd ., Ku nd arki 8.01 7.5
29 Bajaj H ind u sthan Ltd , Ita Maid a 4.38 4.11 33
30 Gu laria Chini Mills (A Unit of Balram p u r Chini Mills 8.99 8.4 31.3
Ltd .), Gu laria
31 N ew Ind ia Su gar Mills Ltd ., (Unit - The Ou d h Su gar 5.05 4.88
Mills Ltd .)
32 Rosa Su gar Works, Rosa 3.18 2.71
33 Kesar Enterp rises Ltd ., Baheri 7.38 7.18
34 J.K. Su gar Ltd . 4.19 3.74 19 + 7.0
35 L.H . Su gar Factories Ltd ., Pilibhit 8.57 7.82 46
36 Up p er Ganges Su gar & Ind u stries Ltd ., Seohara 11.61 11.35
37 The Dham p u r Su gar Mills Ltd ., Dham p u r 12.74 12.75 60 MW
36
Annexu res

38 Dw arikesh Su gar Ind u stries Ltd ., Dw arikesh 6.88 7.1 7.5 MW,
39 Dw arikesh Su gar Ind u stries Ltd ., Dw arikeshp u ram 5.87 5.56
40 Bajaj H ind u sthan Ltd ., Bilai 8.34 8.55
41 Uttam Su gar Mills Ltd ., Pu d rikhu rd 6.95 6.68
42 Wave Ind u stries Pvt. Ltd ., Dhanau ra 8.29 7.6
43 Venu s Su gar Ltd ., Venu s 0.83 0.64
44 DSM Su gar Mills Asm oli , Asm oli 7.34 6.71 30 MW
45 Dew an Su gars Ltd ., Agw anp u r 2.83 2.54
46 DSCL Su gar, Ru p ap u r 5.84 5.08
47 Gobind Su gar Mills Ltd ., Aira 8.26 7.44
48 Bajaj H ind u sthan Ltd ., Gola 13.99 13.73
49 Bajaj H ind u sthan Ltd ., Palikalan 11.84 11.04
50 Sarjoo Sahakari Chini Mills Ltd ., Belrayan 6.28 5.51
51 Kisan Sahakari Chini Mills Ltd ., Sam p u rnanagar 4.73 4.18
52 DSCL Su gar - Ajbap u r, J.B. Ganj 11.83 11.17 38 MW.
53 Anand Agrochem Ind ia Ltd ., Anand gop i 0.65 0.49
54 Triveni Engineering & Ind u stries Ltd ., Chand anp u r 4.95 4.39
55 Triveni Engineering & Ind u stries Ltd ., Milak 3.85 2.99
N arayanp u r
56 Triveni Engineering & Ind u stries Ltd ., Rani N angal 3.94 3.73
57 DSCL Su gar - H ariaw an, H ariaw an 5.8 5.5 15 MW.
58 DSCL Su gar -Loni, Loni 6.22 5.6 25 MW
59 Bajaj H ind u sthan Ltd ., Barkhera 6.77 6.2
60 DSM Su gar – Rajp u ra 5.6 5
61 Dalm ia Chini Mills, N igohi 7.36 6.91
62 Rana Su gars Ltd , Belw ara 4.8 4.22 25 MW.
63 Bajaj H ind u sthan Ltd , Maqsu d ap u r 4.82 4.48
64 Rana Su gars Ltd ., Dhad ha Bu ju rg 4.3 3.63
65 Dw arikesh Su gars Ind u stries Ltd ., Dw arkad ishd ham 6.11 5.22
66 Baghau li Su gar & Distillery Ltd ., Bikap u r 1.59 1.32
67 Maw ana Su gar Works, Maw ana 12.96 12.13
68 SBEC Su gar Ltd ., Malakp u r 8.97 7.64
69 Dau rala Su gar Works, Dau rala 14.03 12.73
70 Bajaj H ind u sthan Ltd ., Kinau ni 10.97 9.4 10 MW.
71 N anglam al Su gar Com p lex, N anglam al 5.34 4.81 20 MW.
72 DSM Su gar Mansu rp u r, Mansu rp u r 7.42 6.79
73 Triveni Engineering & Ind u stries Ltd ., Khatau li 13.03 11.89 45 MW.
74 Up p er Doab Su gar Mills, Sham li 8.13 7.28
75 Titaw i Su gar Com p lex, Titaw i 10.28 9.09 28 MW
76 UN N Su gar Com p lex, UN N 4.6 4.1
77 Tikau la Su gar Mills Ltd ., Tikau la 6.26 5.96 10 MW
78 Bajaj H ind u sthan Ltd ., Unit Bhaisana, Bhaisana 9.1 8.29
79 Bajaj H ind u sthan Ltd ., Unit Thanabhaw an, 7.07 6.26
Thanabhaw an
80 Mod i Su gar Mills., Mod inagar 6.08 5.39
37

81 Sim bhaoli Su gars Ltd ., Sim bhaoli 8.72 7.95
82 Anam ika Su gar Mills Pvt. Ltd . 2.51 2.23
83 Triveni Engineering and Ind u stries Lim ited ., Sabitgarh 5.47 4.69
84 Triveni Engineering and Ind u stries Lim ited , Deoband 9.82 9.38 22 MW
85 Daya Su gar Ltd ., N aya Bans 1.5 1.27
86 Kisan Sahkari Chini Mills Ltd ., N anau ta 5.18 4.35
87 Shaku m bari Su gar & Allied Ind u stries Ltd ., Tod arp u r 3.28 2.9
88 Bajaj H ind u sthan Ltd ., Gangnau li 4.1 3.76
89 Uttam Su gar Mills Ltd ., Khaikheri 3.24 2.89
90 Uttam Su gar Mills Ltd ., Sherm au 4.67 4.16
91 Sim bhaoli Su gars Ltd ., Brijnathp u r 3.57 3.14
N ame of the State: UTTARAKHAN D Season: 2010-11

1 Kaship u r Su gar Mills Ltd ., Kaship u r 6250 2.16
2 Kichha Su gar Com p any Ltd ., Kichha 4000 2.82
3 The Bazp u r Co-op . Su gar Factory Ltd ., Bazp u r 4000 2.55
4 Rai Bahad u r N arain Singh Su gar Mills Ltd ., Lhaksar 8400 7.82 30 MW
5 Lakshm i Su gar Mills Com p any Ltd ., Iqbalp u r 4500 4.07
6 Uttam Su gar Mills Ltd ., Libberheri 6250 4.38
38

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Project code: 2012IB17

Widening the coverage of PAT Scheme

Sectoral Manual - Sugar Sector

The Energy and Resources Institute (TERI)

Table 1.5 : Sugar factories in operation in India year-w ise ..................................................... 6

 Copper & zinc

1.2 Prevailing N ational / International Scenario

1.3 International standing of the subsector

1.4 Current/ Future Market Scenario

1.5 Past grow th and future prospects

Figure 1.5a: Ind ian Su gar Cycle

Figure 1.5b: Trend of Su garcane and Su gar Prod u ction in Ind ia

Table 1.5: Sugar factories in operation in Ind ia year-w ise

1.5.1 Dom estic d em and opportu nity

1.5.2 International trad e opportu nity

1.5.3 Fu tu re potential, im pacts and investm ents

(i) Dom estic consum ption

(ii) By-prod ucts

(iii) Prod uctivity im provem ents

(iv) Prod uct innovations

1.6 Production of sugarcane and w hite sugar in India

Table 1.6.3: Sugar im ports and exports from Ind ia

1.7 Important stakeholders

1.8 Product categorisation

1.9 Major players

Table 1.9.1: State-w ise num ber of sugar m ills

1.9.2 Classification of sugar m ills based on capacity

Table 1.9.2: N um ber of sugar m ills in Ind ia based on capacity

1.9.3 Segregation of Su gar Mills based on Co-generation Facility

1.10 Sugar policy and regulations in India

i. Trade policy for sugar

ii. Regulations relating to by-products

1.11 Support for bagasse co-generation

1.11.1 MNRE su pport and initiatives

2.1 Energy performance at sectoral level

2.2 International comparison

Table 2.2: Average m illing capacity of sugar m ills in d ifferent countries

2.3 Manufacturing process

Figure 2.3: Su gar m anu factu ring p rocess

2.3.1 Various stages in su gar manu factu ring process

6. D rying, grading and packing

2.3.2 By-prod u cts

iii. Filter cake

2.3.3 Cogeneration in sugar m ills

2.3.4 Distillery in su gar m ills

2.4 Technological movements

2.5 Capacity utilisation

2.6 Major energy consuming areas

Table 2.6a: Section w ise electricity consum ption in a sugar m ill

Table 2.6b: Section-w ise steam consum ption in a sugar m ill

2.7 Energy saving potential

2.7.2 Scope for co-generation potential

Table 2.7.2: State-w ise bagasse co-generation potential

3.1 Energy consumption in sugar mills

3.1.1 Electricity consu m ption in su gar mills

S.N o Plant Capacity, Electricity Estimated SEC

3.1.2 Steam consum ption in su gar mills

Trend of Steam Consumption in Sugar Mills

Figure 3.1.2: Steam consu m p tion trend over d ecad es