Detailed Project Report on BAGASSE PULP MANUFACTURING (CAP: 50 TONS/DAY)

The sugarcane bagasse is the main residue product of the Indian agricultural industry. Sugarcane bagasse pulp is considered a fine raw material for manufacturing paper and sustainable tableware products. The bagasse is a fibrous waste left after the juice is squeezed out from the sugarcane by pressing it.

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ENGINEERS INDIA RESEARCH INSTITUTE
4/54, Roop Nagar, Delhi-110007 (India)
Phone: [phone]
E-mail: [email protected]
Website: www.eiriindia.org



BAGASSE PULP MANUFACTURING (CAP: 50
TONS/DAY)
[EIRI/EDPR/4716] J.C.: 2936INR, 2936US$




The sugarcane bagasse is the main residue product of the Indian agricultural
industry. Sugarcane bagasse pulp is considered a fine raw material for
manufacturing paper and sustainable tableware products. The bagasse is a
fibrous waste left after the juice is squeezed out from the sugarcane by pressing it.

Generally, sugarcane bagasse is yellowish-gray to lemon-colored consisting of
lignin and cellulose fibers. Sugarcane bagasse is a mixture of hard fibers and soft
parenchyma i.e. bagasse pith. Bagasse is rich in cellulose content. The chemical
composition of sugarcane bagasse is majorly 50% cellulose, about 25%
hemicellulose, and about 25% lignin.

Bagasse is the by- product of the sugar industry and is also one kind of
papermaking fiber material. As the foundation of paper and pulp industry, fiber
materials include wood fiber and straw fiber. Except for the sugarcane bagasse,
there are some other materials like wheat straw, reed, bamboo, and kenaf, etc.

Among all kinds of fiber materials, bagasse is low-cost and inexhaustible to make
paper pulp. The bleached bagasse pulp can be mixed to certain quantity of macro
fiber and used to manufacture various high-grade cultural paper and living paper,
such as bodystock paper, copy paper, two-side offset paper, sanitary tissue,
napkin and etc. With the proper manufacturing process, the bagasse pulp also
can be applied to make coated art base paper or newspaper.

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Sugarcane is annual rhizomatous plant; the average length of fiber is usually
1047-3.04mm. After squeezing, the length of bagasse fiber is similar to the
hardwood fiber, is 1.0-2.34mm. Bagasse pith is a parenchyma cell, it reduces the
opacity and strength of paper, and increase the chemicals consumption and
difficulty of manufacture. So the depithing is important for bagasse pulping.

Sugarcane bagasse belongs to the straw fiber, is easy to cook or bleach and
requires fewer chemicals consumption. Because silicon content of bagasse is lower
than other straw fibers, which decide the bagasse pulp process or equipment is
more mature and easy.

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CONTENTS


INTRODUCTION
BAGASSE
USES AND APPLICATIONS OF PULP
BESIDES, THE END USE OF PAPER AND PAPER PRODUCTS ARE,
SUGARCANE BAGASSE PULP ADVANTAGES
PROPERTIES AND COMPOSITION OF BAGASSE
A TYPICAL CHEMICAL ANALYSIS OF WASHED AND DRIED BAGASSE MIGHT
SHOW:
TECHNICAL DETAILS OF BAGASSE PULP
BAGASSE PULP PROCESSING
MATERIAL PREPARATION
BAGASSE PULP COOKING
BAGASSE PULP WASHING
BAGASSE PULP SCREENI NG
BAGASSE PULP BLEACHI NG
ADVANTAGES OF BAGASSE PULP PRODUCTION
PULP BLEACHING PROCESS
PRINCIPLES FOR PULP BLEACHING PROCESSING
BASIC PRINCIPLE OF PULP BLEACHING
OXIDIZING BLEACHING
REDUCTIVE BLEACHING
RELATIVE EQUIPMENT
THE SPECIFIC PROCESS FLOW CHART IS AS FOLLOWS:
PULP WASHING PROCESS
TECHNICAL PRINCIPLE
TECHNICAL REQUIREMENT FOR PULP WASHING
PULP COOKING PROCESS
BATCH COOKING
SUPER BATCHING COOKI NG
PROCESSING OF SUPER BATCHING COOKING:
ADVANTAGES OF SUPER BATCHING COOKING:
DISPLACEMENT COOKING
PROCESSING OF DISPLACEMENT COOKING:
1. RDH COOKING SYSTEM
2. DDS COOKING SYSTEM

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SPECIFICATIONS:
CONTINUOUS COOKING
HORIZONTAL TUBE CONT INUOUS DIGESTER
VERTICAL CONTINUOUS DIGESTER
ADVANTAGES OF CONTINUOUS COOKING
CHEMI-MECHANICAL PULPING
PROCESS OF APMP PULPING
PRINCIPLE FOR APMP PULPING
THE FUNCTION OF NAOH:
THE FUNCTION OF H2O2
MAIN EQUIPMENT OF APMP PRODUCTION LINE
SCREW CONVEYOR:
TEARING MACHINE:
HEAT RECOVERY EQUIPMENT:
CONDENSING EQUIPMENT :
ADVANTAGES OF APMP PRODUCTION LINE
COMMON PULPING PROCESS
IMPORTANT BENEFITS WHEN BAGASSE IS USED FOR MAKING PAPER:
COOKING
WASHING
SCREENING
BLEACHING
BAGASSE PULP PROCESSING
MATERIAL PREPARATION
BAGASSE PULP COOKING
BAGASSE PULP WASHING
BAGASSE PULP SCREENI NG
BAGASSE PULP BLEACHI NG
PRODUCTION STEPS AND SUSTAINABILITY OF BAGASSE OF BAGASSE
PRODUCTS
PRODUCTION STEPS OF BAGASSE PRODUCTS:
SUSTAINABILITY
PRODUCING BAGASSE PULP
PROCESSING DETAILS FOR BAGASSE PULP
DEPITHING
DEPITHING OPERATION
TYPICAL ARRANGEMENT OF A BANK OF DEPITHERS
CHEMICAL PULPING AND BLEACHING OF BAGASSE

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DIGESTION
BLACK LIQUOR
BLEACHING
MECHANICAL AND CHEMI -MECHANICAL PULPING
SEQUENCES OF BAGASSE PULP PROCESSING
MATERIAL PREPARATION
BAGASSE PULP WASHING
BAGASSE PULP SCREENI NG
BAGASSE PULP BLEACHI NG
MARKET POSITION OF BAGASSE PULP
BAGASSE PULP HAS ADVANTAGES
INTENSE MARKET COMPETITION
THE DOWNSTREAM MARKET IS VAST
REGION OVERVIEW:
TAMIL NADU NEWSPRINT AND PAPERS LTD
GUANGXI YANGPU NANHUA SUGAR INDUSTRY
FOOD GRADE
INDUSTRIAL GRADE
APPLICATION OVERVIEW:
FOOD PACKAGING
PAPER
KEY COMPANIES IN THE GLOBAL BAGASSE PULP MARKET COVERED IN
CHAPTER 3:
PROCESS FLOW DIAGRAM FOR BAGASSE PULP
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
SPECIFIC FACTORS
6. TRANSPORTATION:
A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
7. WASTE DISPOSAL:
8. LABOR:

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9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
8. TOTAL LOAD:
9. LAND AREA/MAN POWER RATIO:
PROJECT IMPLEMENTATI ON SCHEDULES
INTRODUCTION
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
IMPLEMENTATION SCHEDULE
INDIAN SUPPLIERS OF PLANT AND MACHINERY
OVERSEAS SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF RAW MAT ERIALS
SUPPLIERS OF RAW MAT ERIALS
UTILITIES
POWER
WORKING
TOTAL MANPOWER AND PAYROLL
UTILITIES
WATER
WATER QUALITY PARAMETERS FOR PROCESSED WATER:
STEAM
POWER
EFFLUENT TREATMENT AND DISPOSAL
TOLERANCE LIMITS FOR INDUSTRIAL EFFLUENT DISCHARGE
WASTE TREATMENT

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PRIMARY TREATMENT
ANAEROBIC TREATMENT
ANAEROBIC TREATMENT HAS THE ADVANTAGES OF
SECONDARY TREATMENT
TERTIARY TREATMENT
SOLIDS CONCENTRATION
TYPICAL WASTE SOLIDS CHARACTERISTICS
EQUIPMENT REQUIREMENT
EQUIPMENT REQUIREMENTS
DOCUMENTS REQUIRED FOR LICENSES
LIST OF DOCUMENTS:
MACHINERY PHOTOGRAPHS
SWOL ANALYSIS
STRENGTHS
OPPORTUNITIES
WEAKNESS
LIMITATIONS
ORGANIZATION CHART
LIST OF TURNKEY CONSULTANT
FLOW DIAGRAM OF MATERIAL BALANCE

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APPENDIX – A:

01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

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COST ESTIMATION

Plant Capacity 50 MT/Day

Land & Building (16,000 sq.mt.) Rs. 10.80 Cr

Plant & Machinery Rs. 15.00 Cr

Working Capital for 1 Month Rs. 5.03 Cr

Total Capital Investment Rs. 32.99 Cr

Rate of Return 23%

Break Even Point 59%