The Digital Sugar Mill

Seminar on Sugar & Ethanol Automation

Process House Automation

Mr. Israr Hussain

General Manager (Production)

Habib Sugar Mills

Process House

Automation

Agenda

Introduction

Automation Strategy

Role of Automation in Sugar Processing

Scope of Automation

Automation for Utilities

System Architecture

HMI Displays

Maintenance

Impact of Automation

Falling Film Evaporators Automation

Continuous/Batch Pan Automation

Remelt Phosphatation Process Automation

Multi-Bed Filters Automation

Skills and Training

Conclusions

3

Introduction

Worldwide sugar factories are being modernized and automated in responseto the need for efficient production and the ability to compete globally.

Continuous control and precise handling of all parameters is required toensure consistent product quality and reduce production costs.

Automation Strategy

Selection of automation strategy:

Centralized Control System (CCS)

Decentralized Control System (DCS)

Which strategy to choose?

Automation Strategy

Merits and Demerits:

Correct selection of automation equipment

Correct selection of instruments

Right automation partner

Choose wisely

Role of Automation in Sugar Processing

Key issues:

Perishable raw material

Heat sensitive product

pH sensitive product

Flow Rate

Fuel and Energy

Impact of operating parameters on sugar recovery and quality

Role of Automation in Sugar Processing

Impact of Operating Parameters on sugar recovery and quality:

Flow Rate pH TemperatureRetention

TimeLevel

IndicationPressure Vacuum

Automation for Utilities

Control of Key Parameters in Boiler Operations

Drum LevelSteam

PressureSteam

TemperatureSteam

QuantityFeed Water

TemperatureFlue Gas Analysis

Flue Gas Temperature

System Architecture

HMI Displays

HMI Displays

HMI Displays

Maintenance

Monitoring

Temperature PressureAxial Floats of

Rotors

Impact of Automation

Implementation of a need-based process control system leads to:

Capacity Optimization

Improved Plant Efficiency

Reduced Energy Cost

Improved Product Quality

Reduced Production Cost

Reduced Maintenance Cost

Reduced Down Time

Man-Power Savings

Falling Film / Conventional Evaporators Automation

Feed juice enters at the top of the tubes through distributors and flows down with the tube walls as a thin film. Since the film ismoving in the direction of gravity, a finer and faster moving film results, yielding high heat transfer coefficient and reducedcontact time. The flow of vapors and juice maybe concurrent or countercurrent where the liquid is drawn from bottom and vaporfrom the top. Forced circulation is applied.

Automation of Falling Film Evaporators is critical in the sense that its malfunction can cause accidents. We should understand thecriticality and dangers of this process and ensure safe and reliable operation through automating the process including:

Juice Flow

Juice Level

Emergency Hot Water

Sugar Losses through inversion

Salt Scaling

Caramelization in case of dry tubes

Falling Film / Conventional Evaporators Automation

Better control of these parameters affects sugar recovery and quality.

The way an evaporator plant works has a crucial impact on heat economy of thesugar factory.

Continuous / Batch Pan Automation

Efficient crystal growth requires accurate monitoring and control of all parameters (throughautomation) of the concentration of sugar solution in each compartment of the continuous vacuumpan.

Each compartment of the continuous vacuum pan is controlled through individual set points in orderto establish the required Brix profile along the pan.

The continuous vacuum pan permits constant level of vapor bleeding from the operator station. Thisresults in more even running of evaporator station and consistent dry substance content of the thickjuice.

The low massecuite level above calandria keeps the heating steam pressure. Moreover, circulation andhomogeneity of the massecuite improved. The heating steam can therefore be taken from adownstream effect of the evaporators station and fully used in upstream effect.

Remelt Phosphatation Process Automation

Monitoring and control of:

Liquor Flow Rate

Liquor Brix

Liquor Heating

Process Chemical Dosing

pH Control

Level Control

Retention Time

Continuous and precise monitoring and control of all the parameters is required to ensure consistentproduct quality and sugar losses.

Multi-Bed Filters Automation

Monitoring and Control

Flow Rate PressureBackwash

CycleLevel

Indicators

Skills and Training

Present day process control systems are interactive

It is imperative that Automation Solution Providers also facilitate the training andguidance for Sugar Mill operators, through:

Training Modules

Operational Support

Operational Manuals

Conclusions

22

The surest mantra to achieve cost reduction in the shortest time

Return on Investment can be phenomenal and quick

Move towards becoming internationally competitive

Question & AnswersThank You for Your Valuable Time