PROCESS PLANT DESIGN FOR THE CONVERSION OF 10,000 TONS/DAY OF SUGARCANE BAGASSE TO BIOFERTILIZER

This report presents the design of an industrial-scale process plant for converting 10,000 tons/day of sugarcane bagasse into biofertilizer, with integrated methane production system. Sugarcane bagasse, an abundant agricultural waste in Nigeria, is underutilized and often discarded, contributing to environmental pollution. The design aims to address soil degradation, food insecurity, and reliance on chemical fertilizers through sustainable valorization. Key objectives include developing a process flow, conducting material and energy balances, selecting construction materials, sizing major equipment, proposing plant location and layout, performing cost analysis, and incorporating safety, instrumentation, and control measures. The process involves bagasse pre-treatment, pulverization, anaerobic digestion in continuous stirred-tank reactors (CSTRs), separation, drying, mixing with additives, granulating, and methane processing. Material and energy balances confirmed efficient nutrient recovery and energy utilization. Equipment sizing, such as 10 CSTRs (each 33,125 m³) and a 120 m³ trommel separator, was optimized for scalability. Material selection prioritized corrosion-resistant alloys and reinforced concrete for durability. Locating the plant in Bauchi LGA leverages feedstock availability and infrastructure. Cost analysis estimated total CAPEX at $231.83 billion, with OPEX at $14.32 billion/year, yielding a payback period of 0.13 years and ROI of 783%. The biofertilizer production at 9164.69 tons/day and methane at 238.5tons/day. The design promotes sustainable agriculture, aligning with UN SDGs 2 and 15, by reducing waste, enhancing soil health, and generating renewable energy. Future recommendations include design implementation via pilot testing and hence the process optimization.