Category Archives: PRODUCTS


Bagasse - Polo Reducer

Bagasse is the main fuel for sugar industries for generation of energy. As It comes out of milling plant in sugar mill, bagasse contains about 45-50% moisture and hence it is known as "Mill Wet Bagasse" It is also known as "Whole Bagasse" or Mill Run Bagasse' or "green Bagasse" In different countries. The composition of mill wet bagasse is as follows.
1. Moisture - 45-50%    2. Fiber (including pith) - 47-50%
3. Sugar - 2.5-4.5%    4. Minerals - 0.5%
WMC© 15 a Bagasse Pol Reducer is designed to extract maximum sugar from the bagasse. WMC© - 15 is a unique Bio-Enzyme polymer product which breaks the boning formation between cellulose and sucrose and separates the sugar portion from bagasse.
WMC© - 15 a Bagasse Pol Reducer also helps to reduce the combustion problem in boiler as after the treatment, bagasse becomes sugar free and its calorific value and combustion can be improved.
Practically it is observed that WMC© - 15 can reduce the bagasse sugar upto 2.0-2.5 unit.
The recommended dose of WMC© - 15 is as follows. Bagasse Pol Reducer is 100% Biodegradable and Ecofriendly Product.
We are a research center and conducting the different industrial and agricultural research. We made the intensive efforts to convert these unwanted pollutant in to bio-fertilizer and results are so encouraging that we must call the final product a "Golden Fertilizer" not even for normal land but also for un-fertile land. Our aim to make Indian sugar industries and distillery pollution free industries, no liquid or solid waste will be discharge and industries will be ZERO-DISCHARGE, ZERO-POLLUCION industries.


Richcore Life science (Sugar enzymes)

We are authorized distributor for Richcore Life Science Pvt. Ltd. for sugar enzyme for starch (Rich Amyl-L) and dextran (Rich Dex-L) reducer.
WHAT IS DEXTRAN
Dextran is complex, branched polysaccharide made up of many glucose molecules and is produced by the action of bacteria Leuconostoc mesenteroides on sucrose. Dextran's straight chain consists of a-1,6 glycosidic_linkages between glucose molecules while branches begin usually from a-1,4 linkages between glucose molecules (can also be a-1,2 and a-1,3 at times).
Dextran presence > 80 ppm is considered as high in sugar cane juice.
WHAT IS STARCH
Starch is a carbohydrate consisting of a large number of glucose units joined by glycosidic bonds Starch consists of 20-25% of Amylose which is a straight chain formed by a-1,4 linkages & 75-80 % of Amylopectin which has branches at a-1,6 linkages Starch concentration >
150 ppm is considered as high in sugarcane juice
DISADVANTAGE OF STARCH & DEXTRAN
Low Quality & High ICUMSA ratings
Higher Viscosity
Higher Cost of Operation
Poor process characteristic - Hampered crystallization
Reduced Yield of Sugar
Increased losses - Higher Molasses Purity
Unpredictable performance - More stoppages
ADVANTAGE OF RICHCORE SUGAR ENZYME Sugar enzymes reduce viscosity of juices and syrups, thus increasing the efficiency of sugar crystallization and recovery process. Increased yields - Lower viscosity results in improved filtration and crystallization. Reduced sugar loss in molasses. Improved quality -by diminishing the amount of starch and Dextran present in sugar crystals. No more hazy sugar solutions. Bigger, whiter crystals. Improved ICUMSA rating. Reduced purity and generation of 'C' molasses. Significantly reduced overall process cost because of major replacement of viscosity reducer, scale softner, etc.


Bio-Enzyem and Micro-Nutrients

Regarding the utilization of distillery spent-wash and bagasse ash for making the bio-fertilizer with the treatment of bio-enzyme and micronutrients. We are giving below the consumption and costing of bio-enzyme and micronutrients for your kind information.


Press Mud - 120 MT
Distillery Spent Wash - 180 MT
Boiler Ash - 40 MT
Total Compost - 340 MT (Moisture Approximate : 55-60%)
Total Compost - 300 MT (on 40-45% Moisture)


FLUID CONDITIONER

Ferrotech is constituted of "Ferrotech" which works on the principle of Electro Static Force. Thus, there is no need to provide extra ionic power for its operation. ferrotech incorporates the principles of Ionic Polarization & Molecular orientation / Molecular Matrix Theory to function. The concept of fluid conditioning is based on Electro magnetic dynamics. Having extremely high flux density to create concentratedsingle focus flux. This effectively polarizes the fluid passing through it.


Benifits

1) Substantial reduction in VISCOCITY of process fluid.
2) Prevents formation of salt and prevents its deposition.
3) Reduces substantially the consumption of energy.
4) It reduces substantially the SURFACE TENSION.
5) It reduces the Boiling point of juice in evaporator.
6) It makes juice Boiling more rigorous which improves extraction extraction & hence exhaustion in final molasses.
7) Environment friendly technique.
The following are some of the pin-points of "FERPOTECH FLUID CONDITIONER"
Enhances mass transfer and mixing
It is a useful concept of process intensification
Cause inorganic ions to be retained in juice rather than Precipitation out on hot surfaces.
Reduces scale without chemicals
Changes the nature of scale from hard scale to soft sludge type.
It works on the principle of Electro-static Force.
It needs no extra external power supply.
It has no recurring expenses involved.
It induces a controlled intensified Electro-Magnetic Field.
In reduces substantially the SURFACE TENSION.
It reduces the Boiling Point of juice in EVAPORATOR.
It makes juice boiling more rigorous.
It aligns molecules in a MOLECULAR MATRIX.
It accelerates ION Velocity.
It enhances the rate of evaporation.
It increases the BRIX in less time using optimum steam and maintains the BIX at consistent levels.
The retention time is alos substantially reduces.
It helps to reduce fixed, variable and over head costs.
It increases productivity & profitability.
It reduces substantially the maintenance cost.
Substantial saving in STEAM consumption.
Surplus baggasse can be sold in the open market.
Cleaning frequency of QUADS is reduced.
Reduced consumption of Additives & Chemicals.
No Metal loss in tubes, thus enhancing their durability.
Reduces down time thereby improving profitability.
No conglomerate formation.
It helps in reducing substantially the losses & improves sugar recovery.


Process Chemicals

Mill Sanitation Chemicals
These are specifically developed organic biocides for improved sanitation / hygiene in sugar cane juice and sugar mills. They are vastly superior to conventional chemicals like ammonium bifluoride, bleaching powder and other halogen compounds.
Benefits
Effective control of biological growth in sugar juice Prevention of loss of vital sugar by avoiding inversion Improved sanitation of mill surroundings
Antiscalent
These water-soluble surfactants have high dispersing power towards inorganic salts. In the evaporators, they inhibit scale formation by modifying the crystals, improving heat transfer and crushing capacity between cleanings.
Benefits
Improved heat transfer through clean evaporating surfaces Reduced steam / fuel consumption Minimum number of cleaning per season Prevention of over-loading of vacuum pans Enhanced equipment life
Colour Precipitant
This is a highly effective cationic polymer designed for improving colour of sugar remelt / syrup in sugar mills and sugar refineries. It also removes certain high molecular weight impurities present in sugar remelt and syrup. Additionally, it helps to convert impurities into primary flocs in the subsequent process of phosflotation.
Benefits
Removes certain colouring matter from sugar remelt / syrup Improves colour of sugar remelt / syrup
Viscosity Reducers
These organic chemicals have been exclusively developed for lowering the viscosity of massecuites in the pan. By reducing surface tension, they improve boiling efficiency, crystallisation, centrifugation and exhaustion of molasses - all resulting in improved sugar crystals and sugar recovery.
Benefits
Improved fluidity Reduced boiling time Improved circulation


Water Treatment Chemical

Specially developed for sugar boilers, these are boiler water treatment chemicals with multipurpose formulations containing hardness treatment chemicals, instant oxygen scavenger, corrosion control agents, polymeric sludge conditioners and sequestrants to provide trouble-free operation and a clean boiler.


Benifits

1) Economical and easy to handle
2) Prevention and removal of deposits
3)Protection of system from corrosion

Fireside Chemical

These are specialty developed fireside chemicals for sugar boilers having multi-purpose formulation to reduce problems like clinker formation and deposits, resulting in higher boiler efficiency.
Benefits
Increased combustion efficiency
Reduced deposit formation
Reduction of unburnts
Reduced frequency of soot blowing
Reduced fuel consumption
Elimination of glassy scales


Cooling Water Chemical

The cooling tower, an integral part of the cogeneration plant, requires to be run at maximum efficiency with low operation cost. Ion Exchange are specialists in state-of-the-art technology for cooling water treatment chemical
Benefits
Prevention of cooling water related problems such as corrosion, scale fouling and microbial growth in cooling water systems
Our cooling water treatment programmes ensure consistency in heat transfer at the metal surface


ZENON assimilator System - A Boon to sugar factory Co-Generation

Salient features
No modification, no alteration in the mill , very low power consumption, fully automatic. users friendly, extremely economical & eco friendly.
Reducing moisture from bagasse by ZENON assimilator system technology is an optimum solution to enhance efficiency of boiler in sugar factory, though bagasse has high calorific value (NCV) but due to the moisture content (about 50 %) it is not possible to use the full heat effectively. The present work suggest to place "ZENON" assimilator at the falling chute of the milling tandem and arrest the vapour extraction piping out of the bagasse as well as from the intra-fibrous of bagasse as discharged from the last mill. Without coming in to physical contact of bagasse, the free radical escaping vapour from the freely sliding bagasse and from within the intra-fibrous of bagasse mass is extracted and condensed and discharged, thus reducing the moisture of the bagasse by < 4% which results in increase in calorific value of bagasse (NCV) and boiler efficiency. Keywords : bagasse, boiler efficiency, moisture assimilator


Introduction

Sugar mill engineering is a specialized branch of engineering and involves almost all the faculties of engineering - mechanical, electrical, process engineering, civil engineering, power plant engineering, thermal engineering, metallurgy, pipe line systems, pressure vessels, lifting tackles etc. This calls for a very wide knowledge on the part of the sugar engineers working in the mill. This concept specifically deals with the identification of areas of conservation of energy in the sugar factory. In broader terms, the scope of conservation of energy is applicable to almost all the points in the sugar mill - proper and timely lubrication of various mechanical transmission systems, preventive maintenance of various elements of power transmission, efficiency of hear transfer at various points of process are a few to name.
Chemical composition of dry bagasse
Bagasse % Carbon = 47, Hydrogen = 6.5, Oxygen = 44, Ash = 2.5
Gross calorific value (G.C.V) of dry bagasse
8280 B.T.U./1b = 4600 kcal/kg
Nett calorific value (N.C.V) of dry bagasse
7650 B.T.U./1b = 4250 kcal/kg
Most conspicuous of all these processes 'wasting' energy is the amount of moisture contained in bagasse leaving the last mill roller and fed to the boiler / s for combustion to generate steam and consequently electric power. The moisture carried with bagasse takes away major part of the useful heat energy generated in the boiler / s by combustion of bagasse. Hence, the top most priority in the area of energy conservation in a sugar mill is to reduce the moisture content in bagasse before it is fed to the boiler / s. 1% reduction of approximately moisture in bagasse increases 0.5% boiler efficiency. Hence removing of moisture from bagasse will enhance boiler efficiency proportionately.

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