Biochemical Conversion Division, Sardar Swaran Singh National Institute of Bio-Energy, Kapurthala, Punjab, India, Doctoral Research Scholar, Centre for Energy and Environment, Dr.B.R. Ambedkar National Institute of Technology, Jalandhar, Punjab, India
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Principal, Muzaffarpur Institute of Technology, Muzaffarpur, Bihar, India, Professor (Higher Administrative Grade), Centre for Energy and Environment, Dr.B.R. Ambedkar National Institute of Technology, Jalandhar, Punjab, India
Associate Professor, Department of Biochemical Engineering, Harcourt Butler Technical University, Nawabganj, Kanpur, Uttar Pradesh, India
This study focuses on a systematic techno-economic feasibility analysis of an integrated sugarcane processing complex in India. The comprehensive process modelling was performed using SuperPro Designer. The economic viability of an integrated sugarcane processing complex was assessed with significant economic parameters and other financial indices. The process model was developed for a processing capacity of 9,000 TPD sugarcane. The model estimates 738 TPD of sugar crystals, 140 KLPD of ethanol from 492.38 TPD of B-heavy molasses, and 36.62 MW of captive power from residual sugarcane bagasse. The estimated CAPEX and OPEX of the process model were INR 13,942 and INR 11,803 million, respectively. The proposed model shows strong economic feasibility, with an ROI of 15.10%, an IRR of 13.37%, an NPV of 6,952 million INR and a payback period of 6.62 years. The sensitivity analysis highlights sugarcane cost as the most sensitive parameter in the minimum selling price of ethanol, which can affect process economics over the long run. The proposed integrated sugarcane processing complex offers an advantage in achieving zero liquid discharge. This is accomplished by treating vinasse through anaerobic digestion, which recovers energy while managing liquid waste. Through an integrated approach, such as sugar processing, ethanol production, and cogeneration, the facility contributes to the Sustainable Development Goals and to energy self-sufficiency. Thus, it serves as a circular biorefinery model that demonstrates resource efficiency and effective waste management.
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