Sugarcane cultivation requires a tropical or subtropical climate, with a minimum of 600 mm (24 in) of annual moisture. It is one of the most efficient photosynthesizers in the plant kingdom, able to convert up to 2 percent of incident solar energy into biomass. In prime growing regions, sugarcane can produce 20 kg for each square meter exposed to the sun.
Sugarcane is propagated from cuttings, rather than from seeds; although certain types still produce seeds, modern methods of stem cuttings have become the most common method of reproduction. Each cutting must contain at least one bud, and the cuttings are usually planted by hand. Once planted, a stand of cane can be harvested several times; after each harvest, the cane sends up new stalks, called ratoons. Usually, each successive harvest gives a smaller yield, and eventually the declining yields justify replanting. Depending on agricultural practice, two to ten harvests may be possible between plantings. Sugarcane is harvested mostly by hand; increasingly the industry realizes the need to mechanize sugarcane harvesting. However, as of now, hand harvesting accounts for more than half of the world's production, and is especially dominant in the developing world. Cane Knives or Machetes if used with a skilled harvester can cut 500 kg of sugarcane in an hour. With mechanical harvesting, a sugarcane combine (or chopper harvester), a harvesting machine originally developed in Australia, is used. The machine cuts the cane at the base of the stalk, separates the cane from its leaves, and deposits the cane into a cart while blowing the cut leaves back onto the field. Such machines can harvest 30 tonnes of cane each hour.
RSCL Bio-D is a consortium of live aerobic microorganisms specially developed for composting or degrading organic wastes like sugar factory pressmud, distillery spent wash, cow dung, poultry manure, coir pith, sugarcane trash, bagasse, city garbage and other agricultural wastes. This ecofriendly microbial compost starter culture helps to accelerate the organic matter decomposition with increased himification and shortened composting time. RSCL Bio-D is harmless to human beings, animals, birds and plants. It is fully biodegradable.
Advantages:
RSCL - Bio D is mainly used for aerobic composting of organic solid wastes and effluents.
It accelerates the decomposition process to reach a more balanced C: N ratio range between10:1 and 15:1 within 6 - 8 weeks.
It accelerates and sustains temperature rise in compost heaps from 60-70 ° C. Pathogens, pests and weed seeds are totally eliminated by this high temperature decomposition.
It minimizes odour nuisances.
It produces growth stimulants that are required for plant growth.
It helps in maintaining hygienic conditions in farms, compost yards, waste collection sites and garbage dumping yards.
Dosage: 1 to 2 kgs of RSCL Bio-D/MT of organic wastes RSCL BIO-D is mixed with water @ 1 kg / 10 lit of water. Aerate this 10 % suspension for 24 hours and apply it on the compost heaps or compost pits.
Application: RSCL Bio-D is mixed with water @ 1 kg / 10 lit of water. Aerate this 10 % suspension for 24 hours and apply it on the compost heaps or compost pits.
Packing & Storage:
RSCL Bio-D is packed in 50 kg HDPE bags and 1 kg packets. RSCL Bio-D can be stored for 1 year in a cool and dry place with temperature less than 30 0C and should be kept away from direct sunlight.
The process adopted in the manufacture of sugar is Double Sulphitation Process.
Sugar Factory consists of the following five main stations:
Mill House
Boiler House
Power House
Clarification and Evaporation House
Boiling and Curing House
Mill House: Mill house is the cane crushing unit which consists of cane carrier, cane cutter having cutting knives, milling tandem, bagasse carrier and conveyor. Cane feeding to the cane carrier is done by unloaders and feeder table. As the cane carrier moves, the cane kicker evens out cane load in the cane carrier and then two sets of cane knives cut the cane into small pieces. This process of cane cutting is called 'cane preparation. These cane pieces then, pass through different mills and the juice is extracted. The mills are driven by D.C.motors. The residue which comes out of the mill after extraction of juice is called bagasse.
Boiler House: Boiler generates steam by burning the bagasse. The steam is used in powerhouse, boiling house, curing house. The steam required by the Sulphitation process varies from 42 - 45 % on cane crushed per hour.
Power House: The high pressure steam generated by the boiler is utilized for production of power by the turbo-alternators. The power produced is used for captive needs and the surplus power is exported to the government grid. The low pressure steam that comes out from the turbo alternator is utilized for boiling the extracted juice.
Clarification & Boiling House: The juice extracted by the mills is measured by juice flow system. The measured juice is heated in juice heater in two stages. First the juice is heated by the vapours from fourth and third bodies of evaporator in different heaters. This heating is called primary heating. The heated juice is treated with milk of lime and sulphur-di-oxide to coagulate maximum impurities and sent for secondary heating. The secondary heating is done with vapours from second body of evaporator and vapours from the first body or exhaust steam. The treated juice is passed to clarifier, where in clear juice is removed from the top and settled mud at the bottom is separated. To extract sugar from the mud, it is taken to vacuum filter in which juice and filter cake are separated. Juice is taken back to process and the mud is disposed as solid waste. Clear juice from clarifier is taken to evaporator for evaporating its water content. First body is heated by exhaust steam, and other bodies by the vapours of the previous body.
The total water evaporated in the evaporator is 75-80 % percent. The juice after evaporation is called as syrup. This syrup is normally of 60 % solids of its total weight. The syrup is then sulphited in syrup Sulphitation tower.
At Rajshree Sugars, we provide Concept to Commissioning consultancy and detailed engineering services for integrated sugar complexes
The Scope of work for providing concept to commissioning consultancy of an integrated sugar complex will include the following:
Sugar cane availability and Development:
Cane cultivation intensity survey, Cultivation feasibility study, Projection of cane area and productivity, Sugarcane development strategy, Study of climate factors and impact on sugarcane cultivation. Assessment of cultivable lands, soils and suitability for cane cultivation.
Assessment of irrigation potential in the cane command area favoring cane cultivation and cropping pattern study.
Sugarcane area registration, planting & ratoon management program, cane harvest, procurement and supply chain management
Sugarcane nursery program, Assessment of varieties cultivated at present and recommendation of new varieties.
Pest and disease prevalence study.
Detailed plan for establishment of a Sugarcane R&D department for production of bio inputs like bio fertilizers, bio control agents and organic manures.
Sugar Plant:
Detailed Engineering, Preparing Specifications, evaluation of offers, draft purchase order preparation, Carry out Inspection, Supervise Erection, Commissioning.
Preparation of basic schemes for process area, raw material, utilities, raw water, condensate, cooling water, process water, compressed air, LP & MP steam system of an integrated sugar complex.
3. Review and finalization of overall plant layout drawings for sugar plant. .Thermal design and preparation of heat and mass balance for the plant.
Preparation of detailed tender specification for major equipment and system Packages.
Steam and power balance studies, Energy conservation studies and performance improvement study.
In house power distribution system design and engineering.
Assistance in preparation of power purchase agreement.
Site supervision services.
Distillery:
Review of availability and quality of molasses, water and fuel.
Preparation of basic schemes for process area, raw material and utilities.
Preparation of basic schemes for raw water, condensate, cooling water, process water, compressed air, LP & MP steam system.
Thermal design and preparation of heat and mass balance for the plant.
Preparation of raw water and waste water balance of distillery.
Preparation of detailed tender specification for major equipment and system packages which will include fermentation technology, culture development activity, distillation technology, effluent storage system, effluent treatment system, solid waste disposal method and alcohol storage.
We provide concept to commissioning consultancy and detailed engineering services for waste management projects:
Consultancy for setting up of a compost yard for the treatment and utilisation of distillery effluent by composting technology based on the principles of aerobic solid state fermentation.
Consultancy for the treatment and utilization of municipal solid wastes by composting technology.
Consultancy for aerobic solid state composting/co-composting technology for other agro industries Coffee, Sago and Coir industries for the treatment and conversion of solid and liquid wastes into value added compost.
Cogeneration involves the use of high pressure Boilers for producing steam and Turbo generators for generating power. The high pressure steam passes through the turbine and generates power. The low pressure steam from the turbine is used in the processing of sugar. This process of utilization of steam for generating power and for processing of sugar is called cogeneration.
The cogeneration unit configuration at the respective units is as follows:
12 MW plant at Unit-1, Varadaraj Nagar, Theni District
22 MW plant at Unit-2, Mundiampakkam, Villupuram District
20.5 MW plant at Unit-3, Semmedu, Villupuram district
The cogeneration units generate 54 MW of “Green power" using bagasse as fuel. After meeting the captive requirement, surplus power of about 32 MW is supplied to the state grid. The cogeneration units generate 195.16 million units of power annually. The surplus power of 120.52 million units is supplied to the state grid every year.
The 22 MW plant at unit-2 has been registered as a CDM project on January 15th, 2006. This project reduces 81,628 tonnes of Co2 equivalent per annum. For each ton of Co2 emission that is avoided by this project, we get a Carbon Emission reduction Certificate (CER) This project generates 81,628 CER’s per annum. These CER’s are sold to countries that have emission reduction commitments. This cogeneration plant is the first plant in India to install Air cooled condensers instead of water cooled condensers for its turbines. Even though the Air cooled condensers incur a much higher investment cost than the water cooled condensers, it is environment friendly and they totally eliminate the use of water. This is an important environment feature given the scarcity of water in the region and a positive step towards water conservation.
RSCL has adapted clean technologies in all its cogeneration plants which have led to reduction in greenhouse gas emissions. With the adaptation of clean technologies for power generation, we have made this world a better place.
India is the original home for Sugar. From Sharkara in Sanskrit to Sugar in English, it has been a long journey of time and space with quite a few intermediaries. Alexander and his troops were amazed by this honey without bees. But it was the Arabs who introduced Sugarcane to Europe and from there the Spaniards took it to the Americas.
Sugarcane or Saccharum is a genus of 6 to 37 species of tall perennial grasses (family Poaceae, tribe Andropogoneae), native to warm temperate to tropical regions. They have stout, jointed, fibrous stalks that are rich in sugar and measure 2 to 6 meters tall. All of the sugarcane species interbreed, and the major commercially cultivated species are complex hybrids.
Sugar occurs in greatest quantities in sugar cane and sugar beets from which it is separated for commercial use. There is no difference in the sugar produced from either cane or beet. Sugar cane, a giant grass, thrives in a warm, moist climate, storing sugar in its stalk. The sugar beet grows best in a temperate climate and stores its sugar in its white root. Sugar from both sources is produced by nature in the same fashion as all green plants produce sugar-as a means of storing the sun's energy. Sugarcane is an industrial crop with acreage of about 4 million hectares and production to the tune of 300 million tonnes in India. It provides employment to over a million people directly or indirectly besides contributing significantly to the national exchequer. In commercial agriculture, cane is subjected to various weather conditions and stresses. In the Indian subtropics erratic availability of moisture and frequent occurrence of red rot disease severely impair the productivity of cane. In addition to this, acute water scarcity in many areas would need the development of drought tolerant / water use efficient cane genotypes to sustain the cane industry.
We are a leading manufacturer and supplier of agricultural fertilizers which includes azospirillum biofertilizer, foliar fertilizer and agricultural foliar fertilizer.
Engaged in manufacturing and supplying fertilizers that includes agricultural fertilizers, chemical fertilizers, organic fertilizers, bio fertilizers, plant growth regulators, plant growth promoters and soil nutrients.
Exporter, wholesaler and supplier of fertilizer which includes bio fertilizers and agricultural fertilizers that are available in various specification.
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