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Simbhaoli Sugar Mills Group, Uttar Pradesh
Tata Chemicals Ltd. – Fertilizer Works at Barbala
Badarpur Thermal Power Station (NTPC)

Simbhaoli Sugar Mills Group, Uttar Pradesh

The Simbhaoli Sugar Mills Group has two sugar mills in Uttar Pradesh, one at Simbhaoli and the other at Chilwaria, with a combined crushing capacity of 11,000 TCD ; it laso has a 40 KLPD distillery at Simbhaoli. The Group's speciality sugar product range, marketed under the brand TRUST, includes cubes, sachets (white & brown), icing sugar, table sugar and pharma sugar, besides refined sugar in packing of 1, 5 and 50 kgs.

The sugar mill at Simbhaoli, one of the modern sugar mills in India with refined sugar production of 750 TPD, commands a major share of the institutional market. It decided to go in for sugar decolourisation in crushing season 2003 - 2004 and selected our INDION ion exchange process for the project. Our system, designed for sugar melt flow rate of 48 m³/h and comprising two resin columns, enables production of refined sugar of <45 ICUMSA.

Dr. CS Rao

Dr G.S.C. Rao, Executive Director (GSCR) and Mr. A.K. Srivastava (AKS), General Manager (Projects) of the Simbhaoli Sugar Mills Group talk about their experience with our sugar decolourisation process as well as with the company, as we have also serviced a number of contracts for water treatment equipment and sugar process chemicals over the years.

What triggered the decision to go in for the sugar decolourisation?
GSCR: The globalisation of the Indian economy has opened new markets and opportunities for the sugar industry. Sugar decolourisation, we were convinced, would help us to encash this opportunity, adding value to our existing business -through economy of scale, product cycle, and change in the entire manufacturing process, thereby delivering quality products.

How exactly will this project be of benefit ?
GSCR: I believe that by producing quality refined sugar (< 45 ICUMSA) as compared to conventional sugar (100 - 150 ICUMSA), we will be able to carve a niche into the speciality sugar market. We would also be able to reach institutional buyers with our product - the institutional market is 50 - 55%, and yet to be tapped. Also, this project will help in running the plant for the entire year with processing of raw sugar.

What made you select our ion exchange process over others?
AKS: World over two processes are adopted for decolourisation of sugar remelt i.e. carbonation followed by activated carbon, and phosflotation followed by ion exchange process. Based on our extensive research, we concluded that the ion exchange technology is the best suited for Indian conditions, as the plant and resins used in this process are manufactured indigenously, thereby offering the advantage of low recurring cost.

What is your experience with the performance of our system validate its selection?
GSCR: We are indeed happy and very satisfied with its performance; the technology is quite adaptable; we are also satisfied with the system engineering. Commissioning, after sales service and support from Ion Exchange India has been very good.

What is the company's current production of refined sugar using our sugar decolourisation process?
AKS: We have had a total production of 750 tons per day of refined sugar for 300 days during the crushing season 2004 - 2005.

What are the other products of our company that Simbhaoli Sugar uses?
GSCR: We use several of your sugar refining chemicals, including the INDION 1951 colour precipitant and INDFLOAT 100 Floatation Polymer. We you're your demineralisation plant supplied along with annual maintenance contract, and we are also procuring resins and spares from you.

What do you look for in a vendor? How would you rate Ion Exchange India?
GCSR: Qualities that we look for in a good vendor include

Transparency in working
Commitment to execute and deliver
Good reputation and technological backup
Long term relationship

We give weightage to quality more than merely price.

Being a professional organisation, Ion Exchange India meets our expectations well and we enjoy a good relationship with your company. If ever a problem does crop up, it is solved promptly.

If you had to zero in on one point about our company that makes a favourable impression, what would that be?
GCSR: The fact that Ion Exchange India is very professional, customer commitment runs high through the organization and people at all levels deliver.

What status does Simbhaoli enjoy in the sugar industry? What are the company's plans?
GCSR: The sugar industry can be classified into two categories, based on the number of factories. There are those that have more than than four factories like Birla Sugar, Bajaj Hindustan, Balrampur Chini Mills, Triveni Engineering. The second category comprises those with two factories such as the DSCL Group and SIEL. We are comfortably positioned in this second group.

Currently we have two sugar mills, one at Simbhaoli and the other at Chilwaria, in Uttar Pradesh, with a combined capacity of 11,000 TCD. We are planning to expand production to 15,500 TCD for the next crushing season. We are also thinking of starting sugar decolourisation at Chilwaria.

Tata Chemicals Ltd. – Fertilizer Works at Barbala

The Problem	The DM plant - two strong acid cation exchangers in series - had been manufactured, erected & commissioned by the client using resins supplied by IEI. The scheme was based on the expected water quality at site. However, during commissioning, it was found that the acid consumption was very high and the actual water analysis showed high M-alkalinity and hardness; and the sodium to total cation ratio was differing from the design. As the original resins were supplied by Ion Exchange India (IEI), the matter was referred to them. During the visit for troubleshooting, IEI suggested that, based on the actual water quality, the scheme of two strong acid cation in series required review and the resin in the first vessel needed to be replaced with weak acid cation resin to improve regeneration efficiency. The original scheme envisaged such flexibility for changeover in future if necessitated by water quality.
Solution	IEI immediately offered weak acid cation resin with short delivery.
Challenge	The amount of saving estimated was such that the client was not fully convinced, as it seemed too good to be true. IEI then supported the proposal with thorough design calculations and guaranteed the implementation of the project all of which helped the client to decide to try it in one of the three streams.
Results	The scheme, when implemented in the first vessel, was an immediate success. Based on the savings achieved, the client immediately placed an order for the balance two streams.These also gave similar results.
Savings	The total cost of Rs.2.7 million involved in the project was received in a period of just six months. The unit is benchmarked in the industry for low chemical consumption.

Badarpur Thermal Power Station (NTPC)

The Problem	Due to pretreatment problems on account of high suspended solids, muck and turbidity, the middle collector system frequently failed. Because of this the system had to be operated in co-flow mode – resulting in high acid consumption, high sodium slip and inconsistent quality.
Solution	A new type of a much sturdier middle was specifically designed to tackle the problem. With the new collecting system, the client could go back to countercurrent operation and obtain full benefits of the countercurrent system such as consistently low sodium slip and reduced acid consumption. After much followup with the client, our proposal was accepted on condition that it be first tried in only one of the four vessels.
Results	The system was implemented in one of the strong acid cation vessels, executed while the plant was in operation, within the stipulated time. The vessel was commissioned and the system ran successfully without any problem.
Savings	The client was able to achieve a 30% reduction in chemical cost due to implementation of this project. The cost of Rs.600,000, incurred in modifying one vessel, was recovered in one year’s time due to savings in chemical consumption. Additional benefits were consistent quality. And low sodium slip resulting in lower silica slips from strong base anion. The client decided to go in for a similar modification in the balance three vessels and the system has now been successfully commissioned in al four vessels.