SUGAR PRODUCTION, CO–

GENERATION, DISTILLERY AND

PRODUCTION OF INSECTICIDES
BT19614 - INDUSTRY TRAINING

Presented by
Nandita S
Pre-final year
DEPARTMENT OF BIOTECHNOLOGY
RAJALAKSHMI ENGINEERING COLLEGE
CHENNAI-602105
 INTRODUCTION
East India Distilleries (EID) Parry is an Indian public company headquartered in Chennai,
Tamil Nadu that has been in business for more than 225 years. The company is currently
engaged in the manufacture and marketing of sugar and bio-products. The Nellikuppam
Integrated Sugar Complex has a crushing capacity of 6500 metric tonnes per day, its co-
generation facilities produce 24.5 MW of power, and its distillery facilities produce75 kilo litres
per day. Nellikuppam plant has been recognized as a Zero-waste plant because they produce
ethanol and also generate electricity (Co-Gen) with the wastes they recover from sugar
production.
Tagros is one of the India’s fast growing agrochemical companies. It is the subsidiary of the
centenary celebrating business conglomerate – The Jhaver Group. Tagros is the leading
manufacturer of Synthetic Pyrethroids, Herbicides, Fungicides, Pesticide Intermediates and
Special Formulations, producing 2,500 metric tons of active ingredients and exporting them to
over 90 countries. Their major insecticides include permethrin, cypermethrin and deltamethrin.
 SUGAR PRODUCTION
EXTRACTION
Small-scale extraction uses two or three-roll mills,
while larger factories use a single motorized three-roll
mill. Cane is mechanically unloaded, cleaned, and milled
for juice extraction. Juice is strained, clarified, separated
from mud, and evaporated before being washed to
remove sugar before disposal.

JUICE TREATMENT
Juice is filtered before boiling to remove solids.
Large-scale sugar processors add lime to coagulate
impurities, which settle out. Sulphur dioxide neutralizes
the juice, eliminating coloring matters and reducing ferric
salts. Small-scale producers add clarificants like wood ash
and hydros to settle impurities. Hydros releases sulphur
dioxide and lightens the color of the final product. Figure 1 : Sugar production flowchart
FILTRATION AND CLARIFICATION
Filtration is crucial in sugar factories to remove up to 60% of non-sugars from juice, preventing
discoloration and reduced sweetness. Filter presses, mechanical or leaf filters, and continuous rotary
vacuum filters are used. A filter press is expensive for small-scale operations, but reasonable levels can
be achieved by allowing juice to stand for a few hours, pouring it through a fine mesh lid, and settling
it. The juice is then filtered through a cotton cloth and clarified during boiling, trapping particles and
contaminants.

BOILING
Syrup production involves boiling juice until the required concentration is reached, with a strike
made at 105ºC. Over-boiled juice may cause discoloration, under-boiled may cause cloudiness, and
lump sugars require longer boiling times. Sun dried bagasse is used as fuel, with larger factories often
having surpluses.

MOULDING AND PACKAGING

Sugar production involves pouring juice into containers for syrup production and stirring
massecuite in cooling trays for lump sugar production. Shapes are cut or moulded to suit local market
requirements. In Bangladesh, temporary factories remove pans for cooling and crystallization, while
fresh juice is placed on the furnace.
 DISTILLERY
The production process of alcohol primarily involves fermentation and distillation.
Molasses, containing around 50% total sugars, is the main raw material used. During
fermentation, yeast strains convert sugars into alcohol, with a continuous process involving
the addition of fresh nutrients. The proposed unit adopts a continuous fermentation process,
allowing for minimal shut-down.

After fermentation, the alcohol is separated from the fermented wash and concentrated
to 95% using the Rectified Spirit (RS). This is achieved using the Exhaust Steam Bagasse
Boiler e Power Sugar + Allied Units Surplus to Electricity Grid Deaerator HP Heater Captive
Power Steam Turbo Generator method. The remaining part is the effluent, which includes
spent wash and spent lees. Extra Neutral Alcohol (ENA) is prepared by re-distilling the
rectified spirit to remove impurities like higher alcohols, aldehydes, and methyl alcohol.

Anhydrous alcohol (AA) is a crucial product required by the industry, being nearly 100%
pure or water-free. Indian distilleries produce rectified spirit, which is 94.68% alcohol. To
remove water, a special process is required, including azeotropic distillation, Molecular
Sieves, and pervaporation/vapor permeation systems.
 CO-GENERATION
Co-generation is the process of producing two forms of energy
from one fuel, with one being heat and the other being electrical
or mechanical. In sugar factories, the back-pressure steam turbine
is particularly useful. By producing steam at 25 kg/cm2 and
360°C, a factory can use about 750 kcal per kg (lb.) of steam,
which can provide all the power needed and spare energy. The
exhaust of the turbine contains more than 600 kcal, making it
cost-effective to produce all the power necessary in the factory.
This is significantly less than the difference between the
consumption of steam for heating in a poorly organized and
poorly equipped factory and that of a well-designed factory that
uses its heat logically and economically. Power costs in sugar
factories are almost free, while producing steam for heating
purposes is indispensable. The Central Electricity Regulatory
Commission (CERC) regulates various aspects of generation and
supply systems at national levels, while State Regulatory Figure 2 : Extraction and backpressure type
Commissions in each state handle tariff and regulation of cogeneration
generation, supply, and distribution of energy.
SYNTHESIS OF CYPERMETHRIC ACID CHLORIDE

Cypermethric acid chloride (CMAC) can be produced from

acrylonitrile in a two-step process:
1.Acrylonitrile is reacted with carbon tetrachloride to form
tetrachlorobutyro nitrile (TBN). This reaction is catalyzed by an
acid, such as hydrochloric acid or sulfuric acid.
2.TBN is hydrolyzed to form cypermethric acid chloride. This
reaction is catalyzed by a base, such as sodium hydroxide or
potassium hydroxide.

This step is common for production of cypermethrin and

permethrin. The overall reaction can be represented by the
following equations:
→
CH₂=CHCN + CCl₄ CCl₃CH₂CH₂CN (TBN)
Figure 3 : Structure of CMAC
CCl₃CH₂CH₂CN + H₂O →CCl₃CH₂CH₂COCl (cypermethric acid
chloride)
 PERMETHRIN PRODUCTION
CHLORINATION OF CMAC
The process of chlorination involves introducing chlorine atoms into
cypermethric acid chloride to form permethrin. The starting material is
cypermethric acid chloride derived from acrylonitrile, which is dissolved in a
solvent like dichloromethane. The chlorination reaction uses chlorine gas as the
chlorinating agent, resulting in cis-permethrin or trans-permethrin. After the
reaction, the mixture is processed to separate and isolate permethrin from by-
products and unreacted materials.

PURIFICATION AND ISOLATION

Chromatography is a chemistry technique used to separate and purify
components of a mixture based on their interactions with a stationary and mobile
phase. It involves loading a mixture, elution, separation, and collection of the
Figure 4 : Structure of permethrin
resulting eluent. The collected fractions are then analyzed using HPLC to
determine the presence and purity of permethrin. Pure permethrin is then isolated
as a solid residue.

FORMULATION
Permethrin can be processed into insecticide formulations, including
Emulsifiable Concentrates (EC), which are stable emulsions for spraying,
combining other additives and carriers for specific properties and application
methods.
 CYPERMETHRIN PRODUCTION
ESTERIFICATION
Cypermethrin acid chloride is converted into cypermethrin
ester through a reaction with 3-phenoxybenzyl alcohol, typically
with a catalyst like triethylamine. This process eliminates
hydrogen chloride as a by-product and forms cypermethrin
ester, eliminating hydrogen chloride.

PURIFICATION
Chromatography is a widely used method in chemical and
pharmaceutical industries to purify and isolate specific
compounds from complex mixtures. The process involves
preparing a chromatography column, loading the mixture, and
elution. The cypermethrin ester has specific interactions with
the stationary phase, allowing it to be retained in the column. Figure 5 : Structure of cypermethrin
The eluent is passed through the column, and the resulting
fractions are analyzed to determine the presence of the
cypermethrin ester. Once identified, the fractions are pooled
together to obtain a concentrated solution of the purified
cypermethrin ester. This process is crucial for separating
cypermethrin from other impurities in the mixture.
SAPONIFICATION
Saponification is a chemical process that breaks down an ester into its corresponding carboxylic acid and
alcohol. It is used in industrial production of cypermethrin to convert the cypermethrin ester back into
cypermethrin acid and the alcohol used in the esterification step. The process begins with the cypermethrin ester
dissolved in a solvent, followed by the addition of a strong base, typically sodium hydroxide (NaOH). The base
attacks the ester bond, forming cypermethrin acid and 3-phenoxybenzyl alcohol as separate products. After the
saponification reaction, the mixture may need to be neutralized to remove excess base.

FORMATION OF ISOMERS
Cypermethrin, a pesticide, is produced in two main isomeric forms: cis-cypermethrin and trans-cypermethrin.
The cis-form is more toxic to insects. The synthesis process produces a mixture of these isomers, with the goal to
maximize active cis-cypermethrin and minimize trans-cypermethrin. The isomeric composition is monitored and
analyzed using techniques like gas chromatography or HPLC to ensure quality control.

FORMULATION
The final stage of cypermethrin industrial production involves converting purified cypermethrin into various
pesticide products for various applications. Common formulation types include emulsifiable concentrates (EC)
and wettable powders (WP), which are liquid formulations for spray application or solid powders for suspension.
 DELTAMETHRIN PRODUCTION
SYNTHESIS OF DELTAMETHRIC ACID CHLORIDE
The process of synthesizing deltamethric acid chloride
involves a chemical reaction between phenoxybenzyl alcohol
and Thionyl chloride (SOCl₂). The reaction is carried out in a
vessel with a reflux condenser, where the alcohol is mixed with
the chlorinating agent (SOCl₂) and heated under controlled
conditions. The mixture cools, and excess thionyl chloride or
phosphorus pentachloride is removed under reduced pressure,
leaving the crude deltamethric acid chloride product.

ESTERIFICATION
The process of forming Deltamethrin involves the
esterification of deltamethric acid chloride, which forms the
intermediate form. This reaction is carried out under controlled Figure 6 : Structure of deltamethrin
conditions and with a catalyst, such as pyridine or
triethylamine. The crude Deltamethrin product is then
separated from the reaction mixture. The third step is
purification, which removes impurities to obtain a high-purity
Deltamethrin suitable for commercial use. The process is carried
out under controlled conditions and with a catalyst.
PURIFICATION
Chromatography is a purification technique used in chemical and pharmaceutical industries to separate and
isolate individual components from a mixture. Preparative high-performance liquid chromatography (HPLC) is
commonly employed. The chromatography column is packed with a stationary phase material and a mobile
phase containing solvents. The crude Deltamethrin sample is dissolved in a solvent and injected into the
chromatography system using an autosampler. The mobile phase moves through the column at a controlled flow
rate, interacting with the stationary phase to varying degrees. Fractions containing the components are collected
as they elute from the column. Analytical HPLC is used to assess the purity of each fraction, identifying which
fractions contain pure Deltamethrin and which may contain impurities. The pooled fractions are concentrated to
remove solvents used in the chromatographic separation, and the concentrated solution is dried to obtain the
final solid form of pure Deltamethrin.

FORMULATION
Deltamethrin, a pure insecticide, is formulated into various pesticide products for ease of use and effectiveness.
Common formulation types include emulsifiable concentrates (EC), wettable powders (WP), and suspension
concentrates (SC), which are used in various applications for insecticide use.
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THANK
YOU