ackermann - 2010 - mass and energy balance – production of sugar , ethanol and energy comparison...

8/13/2019 Ackermann - 2010 - Mass and Energy Balance Production of Sugar , Ethanol and Energy Comparison of main parameters

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Seminario Internacional de Cogeneracin 2010

Eng. Helgo P. H. Ackermann 1 IPRO do Brasil


13, 14 e 15 de Octubre de 2010

Tecnolgico de Monterrey, Campus Ciudad de Mxico

Cogeneracin en Industrias Azucareras

Helgo Ackermann

IPROSUCAR Consultoria e Engenharia Ltda IPRO do Brasil


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Mass and Energy Balance Production of

Sugar, Ethanol and Energy

Comparison of main parameters


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Mass and Energy Balance Production of Sugar, Ethanol and Energy


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Main Parameters

Diffuser

Milling per day t/d 24.000

Milling per hour t/h 1.000,00

Days of crop t/h 200

Sugar on cane % 14,60

Extraction recovery % 98,00

Industrial recovery % 88,08

Sugar and ethanol production

Mix: Sugar / Ethanol 30:70

Prod. ethanol hidr. m/d 568,00

Prod. ethanol anhydr. m/d 1.010,00

Prod. sugar V.H.P. t/d 963,6

Process vapour consumption kg/TC 407,7

Eletrical energy, installed and generation

Bagasse per hour t/h 277,38

Vapourr total t/h 560,52

Vapour for process t/h 407,67

Vapour for condensation t/h 137,00

Installed capacity MW 35+35+45

Eletr. energy back pressure MW 72,71

Eletr. energy condensation MW 34,91

Eletr. energy total MW 107,62Eletr. energy consumption MW 25,00

Eletr. energy sold MW 82,62

Power potential Kwh/t cane 107,6

Eletr. energy sold crop MWh/crop 396.576

Conceptual study for a new

24.000 tc/d factory - SummaryART split:

30% sugar / 70% ethanol

Notes:

1- Fiber on cane (mean) = 13,50%

2- Boilers - 65 kgf/cm2 485oC

3- 5% storage of bagasse for stops andstart up



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Variation of Parameters

Diffuser and Milling

Production Mix


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Main Parameters

60 % sugar / 40 % ethanol 40 % sugar / 60 % ethanol

Diffuser Milling Diffuser Milling

Total cane t 2.080.000 2.080.000 2.080.000 2.080.000

Time efficiency % 85 85 85 85

Days of crop days 245 245 245 245

Days of milling d 208 208 208 208

Milling per day t/d 10.000 10.000 10.000 10.000

Milling per hour t/h 416,67 416,67 416,67 416,67

Sugar on cane % 15,21 15,21 15,21 15,21


Mix: Sugar / Ethanol 60:40 60:40 40:60 40:60

Prod. ethanol anhydr.. m/d 430,4 425,7 610,9 603,2

m/crop 89.523 88.546 127.067 125.466

Prod. sugar V.H.P. t/d 869,3 857,8 579,1 572,4

t/crop 180.814 178.422 120.457 119.059

Process vapour consumpt. kg/TC 318,6 285,7 303,1 276,0

Potencial on eletrical energy, installed and generation

Bagasse per hour t/h 104,26 104,45 104,06 104,45

Vapour total t/h 207,79 193,39 207,40 193,38

Vapour for process t/h 132,75 119,04 126,30 115,01

Vapour for condensation t/h 63,13 62,67 68,50 66,16

Installed capacity MW 30+20 30+20 30+20 30+20

Eletr. energy back pres. MW 27,9 25,2 26,8 24,5

Eletr. energy condens. MW 18,0 17,9 19,5 18,9

Eletr. energy total MW 45,9 43,0 46,3 43,3

Eletr. energy consumption MW 10,4 12,5 10,4 12,5Eletr. energy sold MW 35,5 30,5 35,9 30,8

Power potential Kwh/t cane 110,2 103,3 111,2 104,0

Eletr. energy sold crop MWh/crop 177.216 152.256 179.213 153.754

Comparative of Main Parameters

Conceptual study for a new10.000 tc/d factory:

Comparison of diffuser milling models

ART split:

[60% sugar/40% ethanol] +

[40% sugar/60% ethanol]

Notes:

1- Fiber mean on cane = 11,66%


3- 5% storage of bagasse for

stops and start up


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Comparative of Main ParametersMain Parameters

Diffuser Milling Difference

Total cane t 2.080.000 2.080.000

Time efficiency % 85 85

Days of crop days 245 245Days of milling d 208 208

Milling per day t/d 10.000 10.000

Milling per hour t/h 416,67 416,67

Sugar on cane % 15,21 15,21

Extraction recovery % 98,0 97,0

Industrial Recovery % 91,2 90,0 + 1,2

Spec. ethanol prod. l/t 40,15 39,61 + 0,54


Mix: Sugar / Ethanol 60:40 60:40

Prod. ethanol hidr. m/d 401 396 + 5

m/crop 83.408 82.368 + 1.040

Prod. Sugar V.H.P. t/d 869,3 857,8 + 11,5

t/crop 180.814 178.422 + 2.392

Proc. vapor consumpt. kg/TC 322 289 + 33


Bagasse per hour t/h 104,3 104,5 - 0,2

Vapour total t/h 207,8 193,4 + 14,4

Vapour for process t/h 140,7 126,7 +14,0

Vapour for condensation t/h 63,1 62,7 +0,4

Installed capacity MW 30+20 30+20

Eletr. energy back pres. MW 27,9 25,1 + 2,3

Eletr. energy condens. MW 18,0 17,9 + 0,1

Eletr. energy total MW 45,9 43,0 + 2,9

Eletr. energy consumption MW 10,4 12,5 - 2,1

Eletr. energy sold MW 35,5 30,5 + 5,0

Power potential Kwh/t cane 110,2 103,2 +7,0

Eletr. energy sold crop MWh/crop 177.216 152.256 + 24.960

Conceptual Study for a new10.000 tc/d factory:


ART split:


Notes:



3- 5% storage of bagasse forstops and start up


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Main Parameters

Diffuser Milling Difference

Total cane t 2.080.000 2.080.000







Industriel Recovery % 91,2 90,0 + 1,2

Spec. ethanol prod. l/t 60,22 59,42 + 0,8



Prod. ethanol hidr. m/d 602 594 + 8

m/crop 125.216 123.552 + 1.664

Prod. Sugar V.H.P. t/d 579,6 571,9 + 7,7t/crop 120.557 118.959 + 1.598

Proc. vapour consumpt. kg/TC 307 280 + 27


Bagasse per hour t/h 104,1 104,45 - 0,35

Vapour total t/h 207,4 193,4 + 14,0

Vapour for process t/h 134,9 123,2 +3,5

Vapour for condensation t/h 68,5 66,2 +11,7


Eletr. energy back pres. MW 26,7 24,4 + 2,3

Eletr. energy condens. MW 19,5 18,9 + 0,6

Eletr. energy total MW 46,3 43,3 + 3,0

Eletr. energy cons. MW 10,4 12,5 - 2,1

Eletr. energy sold MW 35,8 30,8 + 5,0

Power potential Kwh/t cane 111,0 103,9 +7,1

Eletr. energy sold crop MWh/crop 178.906 153.708 + 25.198

Comparative of Main Parameters

Conceptual Study for a new10.000 tc/d factory:


ART split:


Notes:


2- Boilers 67 kgf/cm2 520oC



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Cane sugar split to crystal sugar and ethanol % ART - 30% sugar/70% ethanolSucrose in cane

1.000,00 t/h cane

14,60% sucrose content

0,71% AR (invert sugar)

16,08 % ART

146,00 t /h sucrose160,78 t/h ART

100,0 %sucrose Bagasse losses

2,0 % 278,20 t/h bagasse

% sucrose 2,87 t/h sucrose

% invert 3,13 t/h ART

Filter losses

0,00% 0,00 t/h (filter mud)



3,7 % Undetermined & other losses

% sucrose 5,40 t/h sucrose% invert 5,95 t/h ART

6,16% Distillery losses



88,08 %Industrial efficiency

Sucrose to process

128,73 t/h sucrose

141,62 t/h ART

28,5 %sucrose 59,6%sucrose 11,8%sucrose

27,3 %ART 60,8%ART 11,9%ART

Pure Sucrose in bag Sucrose & Invert to Ethanol Sum of losses

41,67t/h sucrose 87,07t/h sucrose 17,27 t/h sucrose

43,86t/h ART 97,76t/h ART 19,17 t/h ART

1000 t pure sucrose per day 1544 m ethanol per day (water free)


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Humidity 50 a 52 %

(influence on generation of electrical power)


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60 % sugar / 40 % ethanol 40 % sugar / 60 % ethanol

Diffuser Milling Diffuser Milling

Total cane t 2.080.000 2.080.000 2.080.000 2.080.000 2.080.000 2.080.000 2.080.000 2.080.000

Time efficiency % 85 85 85 85 85 85 85 85

Days of crop days 245 245 245 245 245 245 245 245

Days of milling d 208 208 208 208 208 208 208 208

Milling per day t/d 10.000 10.000 10.000 10.000 10.000 10.000 10.000 10.000

Milling per hour t/h 416,67 416,67 416,67 416,67 416,67 416,67 416,67 416,67

Sugar on cane % 15,21 15,21 15,21 15,21 15,21 15,21 15,21 15,21


Mix: Sugar / Ethanol 60:40 60:40 60:40 60:40 40:60 40:60 40:60 40:60

Prod. ethanolanhydr.. m/d 430,4 425,7 610,9 603,2

m/crop 89.523 88.546 127.067 125.466

Prod. sugar V.H.P. t/d 869,3 857,8 579,1 572,4

t/crop 180.814 178.422 120.457 119.059

Proc. vaporconsumpt. kg/TC 318,6 313,7 285,7 292,1 303,1 298,7 276,0 277,5


Bagasse humidity % 50,0 52,0 50,0 52,0 50,0 52,0 50,0 52,0

Bagasse per hour t/h 104,26 113,09 104,45 112,79 104,06 112,94 104,45 113,23

Vapour total t/h 207,79 217,13 193,39 206,53 207,40 216,81 193,38 206,26

Vapour for process t/h 132,75 130,69 119,04 121,70 126,30 124,45 115,01 115,61

Vapour forcondensation t/h 63,13 72,95 62,67 71,65 68,50 78,10 66,16 76,73

Installed capacity MW 30+20 30+23 30+20 30+23 30+20 30+23 30+20 30+23

Eletr. energy backpres. MW 27,9 27,8 25,2 26,0 26,8 26,8 24,5 24,9

Eletr. energy

condens. MW 18,0 20,8 17,9 20,4 19,5 22,3 18,9 21,9Eletr. energy total MW 45,9 48,6 43,0 46,4 46,3 49,0 43,3 46,8

Eletr. energy cons. MW 10,4 10.4 12,5 12,5 10,4 10,4 12,5 12,5

Eletr. energy sold MW 35,5 38,2 30,5 33,9 35,9 38,6 30,8 34,3

Power potential Kwh/t cane 110,2 116,6 103,3 111,1 111,2 117,6 104,0 112,3

Eletr. energy soldcrop MWh/crop 177.216 190.694 152.256 169.229 179.213 192.691 153.754 171.226


Humidity of bagasse comparison 50% / 52%

ART Split:

[60% sugar/40% ethanol] +[40%sugar/60% ethanol]

Notes:

1- Fiber mean on cane = 11,66%


3- 5% storage of bagasse for

stops and start up


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Fiber

(influence on the generation of electric power)


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Milling

Total cane t 2.080.000 2.080.000






Fiber on cane % 12,17 13,44




Prod. ethanol hidr. m/d 409,9 409,8

m/crop 85.259 85.238

Prod. Sugar V.H.P. t/d 826,8 826,56

t/crop 171.974 171.924Proc. vapor consumpt. kg/TC 293,9 285,4


Bagasse per hour t/h 108,2 118,8

Vapour total t/h 206,0 228,4

Vapour for process t/h 122,5 118,9

Vapour for condensation t/h 70,5 92,9


Eletr. energy back pres. MW 26,1 26,1

Eletr. energy condens. MW 20,1 26,5

Eletr. energy total MW 46,2 52,6

Eletr. energy cons. MW 12,5 12,5

Eletr. energy sold MW 33,7 40,1Power potential Kwh/t cane 110,9 126,3

Eletr. energy sold crop MWh/crop 168.230 200.179

Conceitual study for a new10.000 tc/d factory:

Fiber comparison:

12,17% and 13,44%

ART split:


Notes:

1- Fiber on cane (mean) =12,17% / 13,44%




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Modern Concepts


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Destillery with modern concepts Start up September 2010


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Modern Concepts

New sugar Factory

Evaporation station -(Roberts and FallingFilms)

Drawing in 3D


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Modern Concepts New Sugar Factory


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Cogeneration in cane sugar factories some aspects

Power export proves nowadays as a substantial source of revenue

and has become possible in the last years in most cane sugarproducing countries.

Power export potential between 100 125 kWh/t cane up to 200kWh/t cane.

1800 2000 cane sugar factories can export 156 179 TWh/a or

20 MW/factory.

Prices of 50 60 /MWh (Brazil, India) and carbon credits of 5-10 /tCO2 make power export attractive.

Factory models have been investigated that allow steam on cane

demands between 26 34 % steam on cane.Plants of this type have been already implemented in Brazil, Indiaand Pakistan.


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Base data for the process calculations

Cane crushing rate 10.000 t cane/day

Effective crop length 180 daysSugar & Fibre content in cane 14%

Imbibition rate 35 or 44% on cane

Bagasse moisture 50%

Sugar recovery extraction 97 or 98%

Exhaust steam pressure 240 kPa(a) [2,4 bar(a)]

Evaporators 4 or 5 effect Falling film tubular with multistage distributor

Boiler steam pressure/temperature 10 900 kPa(a), 535 C [~109 bar(a)]

Sugar colour < 45 IU in case of the concepts with attached refinery

350 - 600 IU in case of the raw sugar factory concepts

Factory powerconsumption for:

Refined sugar production (1)Raw sugar production (2)

(1) 25 kWh/t cane for diffuser concepts and 30 kWh/t cane for millextraction concepts

(2) 20 kWh/t cane for diffuser concepts and 25 kWh/t cane for millextraction concepts

Overall sugar recovery 89.5 90.5% at 30 % molasses purity


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Technologies employed

Diffuser plus dewatering mills or milling tandem (6 mills) Recycling of clarifier underflow in case of the diffuser models

Defecation in the juice purification Partly direct contact heaters and plate/platular heaters for liquid/liquid

applications Optimum usage of heating with condensate Tubular Falling Film Evaporators (FFE) Stepwise flashing of condensates by condensate cigars CIP (clean in place) system for heaters and evaporators Minimisation of evaporator condenser loss Batch pans for seed massecuite and refinery products R1, R2 and R3 Continuous pans for the raw house operation Syrup/molasses wash layer system for A sugar Crystal seed technology in the raw house High pressure boilers with 109 bar and 535C

Extraction/condensing turbo alternators Fully electrified drives (no steam turbines) Reasonable degree of automation


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Tube/plate heaters versus direct contact heaters

R

3205-0

R

3105-0

3020

9

3025

3035

9

3040

3005

9

3010

R

3305-3

1. DC heaters are inexpensive and easy to integrate with low space demand2. Allow an approach temperature of 0.5 2 K while tubular or plate heatersrequire 4 8 K

3. Almost no cleaning or down time4. Constant performance5. High load flexibility with minimum performance change6. Drawback in the juice dilution and 2-3 % o.c. higher steam demand


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Falling Film Evaporators

Defecation or sulfitation are bothsuitable

Sugar hydrolysis and colour formationare similar or lower than inconventional Robert plants

Five effect plants of Tubular or Plate FFEhave been installed in Brazil (3),

India (4), Pakistan (1) in totalapprox. 250 300 FFE includingother installations

The most crucialaspects are the

juice distributordesign and CIPsystem.

Five effect FFE evaporation plant

at Almoiz, Pakistan


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Results of the diffuser scenarios

Scenario 1Diffuser (refinedsugar)

Scenario 2Diffuser (refinedsugar)

Scenario 3Diffuser (rawsugar)

Sugar extraction % 98 97 98

Imbibition rate % o.c. 44 35 44

Process steam on cane(during crop)

% 34,2 33,5 30

Excess bagasse for off-crop operation

t 182.015 194.778 221.364

Annual sugar production(pure sucrose)

t 227.86690,4 % recovery

225.54389,5 % recovery

228.33990,6 % recovery

Power production (crop) MW 34,305 33,38 30,12

Power production off-crop MW 32,454 34,746 39,49

Total annual power export MWh 205.525 209.240 220.093

Specific total power export kWh/tcane

114 116 122


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Scenario 4Mills (refinedsugar)

Scenario 5Mills (refinedsugar)

Scenario 6Mills (rawsugar)

Sugar extraction % 98 97 98

Imbibition rate % o.c. 44 35 44

Process steam on cane(during crop)

% 31,7 29,4 26

Excess bagasse for off-cropoperation

t 171.420 194.534 221.832

Annual sugar production(pure sucrose)

t 226.86090 % recovery

224.83689,2 % recovery

227.11790,1 % recovery

Power production (crop) MW 31,61 29,72 26,33

Power production off-crop MW 31,05 35,17 40,18

Total annual power export MWh 180.139 185.855 197.046

Specific total power export kWh/tcane

100 103 109

Results of the mill scenarios


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Evaporation plant operation Scenario 4 (Sugars)


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Ing. Helgo Ackermann

IPROSUCAR Consultoria e Engenharia Ltda

IPRO do Brasil

Piracicaba, So Paulo, Brasil

Tel. (55) (19) 3402-1100

[email protected]

Thank you for listening !

ackermann - 2010 - mass and energy balance – production of sugar , ethanol and energy comparison...

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