what to be learned dr gsc rao - stai online 3rd india sugar expo presentations.pdf · what to be...
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WHAT TO BE LEARNED FROM INDIAN SUGAR
INDUSTRY
Dr GSC RaoPresidentSugar Technologist Association of India
AGENDA
Indian Sugar Industry
Cane Cultivation
Technology Advancement
Policy
Industry’s Experience
Relevance to Indonesian/ASEAN sugar industry
Sugarcane•4.8 M ha; •50 M farmers
Harvest•70 t/ha•335 Mt
INDIAN SUGAR INDUSTRY AT A GLANCE
Processing•650 sugar mills•240 Mt
Sugar•24 Mt•6 Mt Refining Capacity
Molasses•350 distilleries•2.2 billion liters•30% ethanol•40% industrial•30% potable
Bagasse•2500 MW export to national grid
Animal Fodder 70 Mt
JaggeryProd
SUGARCANE PRODUCTIONOutgrowers
•100%
Avg land holding •0.1 to 2 ha
Irrigation•100% in Tropical <<rain 500-1000 mm rain>> 20-30 irrigation/crop•95% in Subtropical <<rain 500 mm>> 4-6 irrigation/crop
Crop Duration•Tropical –> 12-18 months•Subtropical –> 9-11 months
Sugarcane Yield•Tropical –> 80 t/ha•Subtropical –> 55 t/ha
Sugar Content•Tropical –> 11%•Subtropical –> 9.2%
SUGARCANE PRODUCTIONCane Production Constraints• Water availability >> Tropical States• Sunsine >> Subtropical States
Cane Supply Issues• Govt regulates cane pricing• High cane cost due to stagnated yields• Harvesting labour• Mechanization constraint
IT Interventions• Cane Management System for Outgrowers• Production forecast and harvesting plans• Web based cane procurement and payment system for
paperless work
MILLING CAPACITY
0
1
2
3
4
5
6
7
8
Uttar Pradesh
Maharashtra
Karnataka
Tamilnadu
Gujarat
Andra Pradesh
Punjab
Haryana
Bihar
Uttrakhand
Others
mln mt
6
Private Sector14.448%Cooperativ
e Sector14.147%
Govt Sector
1.55%
DISTRIBUTION OF CRUSHING CAPACITY
PRODUCTION TECHNOLOGYTotally indigenously developed with machinery manufacturers and support services
Most Modern Plant
<40% Steam Consumption
<1.7% total pol loss
27 kW/t power
consumption
Complete DCS
Operated
Process Technology
Double Sulphitation• 600 Plants• 95%
Production• >100 IU Sugar
Raw to refining• 30 Plants• 5% Production• <45 IU Refined
Sugar
Stand Alone Refineries• 4 Plants• Refining
Capacity 3 million tons
Overseas Turnover = $100 Million
Total Turnover = $500 Million
INDIAN SUGAR MACHINERY MANUFACTURER
Section No.Boiler 12+
Turbo Generator 5+
Mills 10+
Boiling House Equipments 2000+
Automation 10+
Electrical Equipments 1000+
Material Handling 100+
Pumps 100+
General Equipmets 1000+
Technical Consultancy Services 10+
Process Chemical Manufactures 2000+
Cane Management System (IT) 10+
8
Turnkey Sugar Plant Suppliers15
SME to support industry5000+
Countries Representation60
Sugar technologists, Engineers, Cane Experts provides overseas services
1000+
Philippines
Thailand
Cambodia
Fiji
Sri Lanka
China
Indonesia
Mauritius
South Africa
Kenya
Mozambique
Ethiopia
Iran Pakistan
Uganda
Nigeria
Ghana
Zimbabwe
Tanzania
Guatemala
GLOBAL PRESENCE OF SUGAR INDUSTRY MACHINERY MANUFACTURES FROM INDIA
UAE
Sudan
Bangladesh
Myanmar
9
Vietnam
NepalEgyptSyria
Labanon
Romania
Zaire
Zambia
Colombia
USA
Mexico
West IndiesGuyana
Philippines
Thailand
Cambodia
Fiji
Sri LankaIndonesia
Kenya
Ethiopia
Iran Pakistan
Uganda
Nigeria
Ghana
Zimbabwe
Tanzania
GLOBAL PRESENCE OF INDIAN SUGAR PROFESSIONALS
UAE
Sudan
Bangladesh
10
Vietnam
NepalSyria
Labanon
Romania
Zaire
Zambia
West Indies
TECHNOLOGY ADVANCEMENT IN SUGAR ENGINEERING
Cane Unloading Manual Unloading
Hydraulic Grab (3-4 tons/grab)
Chain Sling Unloading
Truck Tippler (15-
20 tons)
Cane Preparation Cutter (PI: 80+)
Shredder (PI: 85+)
Swinging Hammer Fibrizors(PI: 90+)
MillingConventional Mills (RME:
90+) Self Setting
Mills GRPF/ TRPF Two Roller Mills (RME:
95+)
Mill Drives Drop Valve Engine
Steam Turbines
Hydraulic Drive
DC/ AC Variable
Frequency Drive
Complete DCS operated automation from cane feeding to milling
Milling efficiencies at 96.5 with sugar loss in bagasse to 0.4% with moisture 48%
11
TECHNOLOGY DEVELOPMENT IN SUGAR TECHNOLOGY
Steam Consumption From 60-70% To 35-40%
Evaporator Robot Type Falling Film Evaporator
Pans Batch Continuous
Process Technology Double Sulphitation Defeco Remelt Phosphitationand Decolorization
Centrifugal Machine Batch type Batch/ Continuous type
Sugar Plantation White Sugar Refined sugar, PharmaSugar, value added products
Automation Manually Operated Fully Automated
12
CONTINUED…
• from <0.6 to 2.4 mm
Sugar Grain Size
• Utilization of flash vapors, molasses conditioners with non condensable gasses, melt evaporator, juice heating with vapor condensate etc
• Boiling house steam consumption 33 to 40% and BHR at 85%
Steam Economy
• VFD for fans, pumps, centrifugals, planetary gears for crystallisers and mixers , continuous crystallizers, fluidized bed sugar dryers to reduce the power
Variable Frequency Drives
• Complete automation of processing though DCS
Automation
• Capability to produce sugar without added chemicals
Sugar types
13
COGENERATION OF POWERCogeneration
Installed at 150 mills (25%)Capacity = 3050 MWPotential = 8500 MW
Efficiency
Back pressure -450 kW/t of BagasseCondensing -650 kW/t of Bagasse
Power generation
Increased from 18 kWh/TCH to 135 kWh/TCH
New Model
Biomass based cogen for round the year
Additional Benefits
Renewable energy certificatesCDM benefits
14
Bagasse + Wood Fired Boiler
(11 Kg/cm2 boiler)
Bagasse Fired Boiler(21-32 Kg/cm2 Boiler
Saving of Bagasse [7-8%]
(32-67 Kg/cm2 boiler)
Multifuel Boiler
(67-110 Kg/cm2)
DEVELOPMENT IN BOILER TECHNOLOGY
Energy Saving• Saving by adopting VFD, • ESP• Automation of blowers, pumps
Automation• Ease monitoring• Steam temperature & Draught
control• Fuel feeding• Combustion control• Ash handling
Efficiency• Stringent water quality• LP and HP heaters• High enthalpy steam• Membrane type water wall
15
TECHNOLOGICAL ADVANCEMENT IN BIO-ETHANOL PRODUCTION
Produces average 10 mln mt molasses corresponds to 2.3 billion liter of alcohol
Accomplish Nation’s 0.8 billion liter potable alcohol demand
Capable to supply 1.4 billion liter of ethanol to meet country’s 10% of ethanol blending
16
ALCOHOL/ ETHANOL
Fermentation
Batch type
Cascading
Continuous fermentation with 92% efficiency
Technology Change
Atmospheric distillation
Multipressure distillation
Product Mix
Single product plant
Multiproduct <<RS, ENA, Ethanol>>
Steam and Power
Steam reduced from 6 kg/lit to 3 kg/l
Power 0.5 kWh/l to 0.25 kWh/l
17
Land
Resources
System
Management
Agriculture Sector
& Industrial
Sector
Sugar
Bio-Ethanol
Bio-Electricity
Bio-ManureBio-Diesel
Animal Fodder
Edible Oil Expeller Refinery
Horticultural Products for IQF (Individual Quick
Freezing) Cold Storage Food Processing
“4B” BUSINESS MODEL
18
POLICY
Most controlled to decontrolled
industry
Sugarcane price
determined by Central
and Provincial Govt
Cane area reservation
Rehabilitation and
Modernization Fund (SDF)
Agri/ soft loans for farmers
Sugar import/export
INDUSTRY EXPERIENCETechnology upgradation eg. Cogeneration and Distillery
Neglecting sugarcane will cost deeply fatal
Burrowing for growth leads to death trap
Continuous growth in small steps is better
Need to integrate with global market
•Ethanol Blending Program•Raw-Refining model for export-import switch•4B Business Model
Future drivers
RELEVANCE TO INDONESIA/ ASEANOutgrowers model should be socially relevant and sustainable
Small units should grow regularly by balancing cane area vis-v-vis cane production growth
Focus on cane development yield and quality improvement through varietal change
Sugarcane and sugar price should be linked
Automation/mechanization
Byproduct utilization
THANK YOU
22
• High Pressure and High Temperature Steam Cycles are Important for
• The choice of pressure and temperature levels for steam cycle depends on thefollowing factors
• Thermodynamically the Energy Recovery from Rankine Cycle depends more onSteam Temperature
However, increase in Steam Temperature must be accompanied by increase inSteam Pressure to ensure optimum extraction of useful energy from the workingmedium
Fuel and Ash Properties
Quality of Feed Water and Water Treatment Systems available
Cost of Boiler and Steam Turbine System
Level of Confidence of Plant Operators
Increasing Cycle Efficiency of the Plant
Increasing Power Output from Co-Generation Plant
Development of High Pressure Boilers - Co-Generation
33
- AdvantagesHigh Pressure and High Temperature Boilers
• Higher Power Generation Per Ton of Bagasse
• Higher Cycle Efficiency of Plant
• Saving in Bagasse, hence Extended period of Operation
• Lower Fuel and Steam Consumption for the same Power Output, hence Reduced Boiler Capacity
44
Parameters Unit45 Kg/cm2 (a) 66 Kg/cm2 (a) 87 Kg/cm2 (a) 110
Kg/cm2 (a) 540 0C
125Kg/cm2 (a)
540 0C 440 0C 515 0C 485 0C 515 0C 515 0C 540 0C
Feed Water temp to boiler
0C 105 ( without HP
Heater)
150 ( with 1 HP
Heater)
170 ( with 1 HP
Heater)
220 (with 2 HP
Heater)
230(with 2/3 HP
Heaters)
Bagasse Quantity TPH 43.51 46.18 41.78 42.89 41.2 42.2 38.6 37.5
Steam /Fuel ratio - 2.29 2.16 2.39 2.33 2.42 2.36 2.59 2.67
Gross Power output MW 24.8 28.8 26.5 28.9 28.5 29.3 29.4 29.8
Net Power Output MW 22 25.2 23.4 25.3 25.1 25.7 25.9 26.1
Specific Steam consumption
Kg/KW-hr 4.03 3.46 3.77 3.46 3.51 3.41 3.40 3.36
Power Generation per ton of Bagasse
KW/Ton Base +9.5% +11.4% +18.3% +21.4%
+22.0% +33.6% +39%
Heat Rate Kcals /KW-hr
3983 3640 3579 3370 3281 3258 3000 2875
Plant Efficiency % 21.6 23.6 24.0 25.5 26.2 26.4 28.7 29.9
Higher the Cycle Parameters – Higher the Output
(Calculations shown above are based on a 100 TPH Travelling Grate boilerwith 69% efficiency (on GCV 2270 Kcal / Kg Basis) and Turbine exhaust at 0.1 Kg / Cm2 (a)
- AdvantagesHigh Pressure Boilers
55
High Pressure Boilers
ISGEC HIGH PRESSURE TRAVELLING GRATE BOILERS (Above 105 Kg/cm2 Pressure)
S. No. Customer / Site No. of Units Capacity Pressure
RatingTemperature
Rating Fuel
TPH Kg/cm2 (g) ± 5 oCA) Travelling Grate Boilers (Total 27 Boilers)1 M/s Rana Power 1 130 125 548 100% Bagasse, 80% Imported
Coal2 M/s Dharni Sugars & Chemicals
Limited, Thiruvannamalai, Tamil Nadu.
1 145 125 545 100% Bagasse, 85% Imported Coal
3 Shree Datta SSKL (Unit of DalmiaBharat Sugars Limited), Kohlapur, Maharashtra
1 120 125 545 100% Bagasse, 82.3% Imported Coal
4 M/s Kesar Enterprises Limited Barielly, Uttar Pradesh
1 190 115 542 100 % Bagasse, 80% Imported Coal, 70% Indian Coal
5 Santa Ana Sugar Mill, Gautemala 1 220 109 540 Bagasse / Coal6 Ingenio Magdalena S.A. Guatemala 1 220 109 540 Bagasse / Coal7 Lizitex S.A., Guatemala 1 220 109 540 Bagasse / Coal8 Ingenio Chaparrastique S.A. de
C.V, El Salvador1 220 109 540 Bagasse / Coal
9 Biomass Energy S.A., Guatemala 2 220 109 540 Bagasse / Coal10 Shree Datta SSK Ltd., Kolhapur,
Maharashtra1 180 109 540 100% Bagasse / 100% Imported
Coal11 Dhampur Sugars Ltd., Asmoli
(U.P.)1 170 105 540 100% Bagasse / 70% Coal
12 Chadda Sugars Ltd., Dhanaura(U.P.)
1 170 105 540 100% Bagasse / 70% Coal
13 Ingenio La Union S.A. Guatemala 1 165 109 540 Bagasse/ Coal
Contd…
66
ISGEC HIGH PRESSURE TRAVELLING GRATE BOILERS(Above 105 Kg/cm2 Pressure)
S.No. Customer / Site No. of Units Capacity Pressure
RatingTemperature
Rating Fuel
TPH Kg/cm2 (g) ± 5 oCA) Travelling Grate Boilers (Total 27 Boilers)14 Ingenio Palo Gardo S.A. Guatemala 1 165 109 540 Bagasse / Coal15 Sunil Hitech Engineers Ltd.,
Gangakhed, Maharashtra1 150 109 540 100% Bagasse / 80% Imported
Coal16 M/s KPR Sugar Mills Limited,
Coimbatore (T.N.)1 135 109 540 100% Bagasse / 80% Imported
Coal17 M/s NSL Sugars (Formely SCM
Sugars)1 135 109 540 100 % Bagasse, 100% Imported
Coal & 80 % Indian Coal18 EMPEE Sugars & Chemicals Ltd.,
Ambasamudram, TN2 135 109 540 100% Bagasse, 80% Imported
Coal19 M/s Bannari Amman Sugars Ltd.,
Kollegal, Karnataka 1 135 109 540 100% Bagasse 80% Imported
Coal20 Core Green Sugars, Gulbarga,
Karnataka1 130 109 540 100 % Bagasse, 76 % Coal
21 Vijaynagar Sugar, Gadag, Karnataka
1 120 109 540 100% Bagasse, 100% Imported Coal
22 M/s Chincholi Sugars Ltd., ChandanNagar, A.P.
1 120 109 540 100% Bagasse / 80% Imported Coal
23 Sar Senapati Santaji GhorpadeSugar Factory Ltd., Kagal, Kolhapur
1 120 109 540 100 % Bagasse
24 M/s Hindusthan Petroleum Corporation Limited, Lauriya Bihar
1 110 109 540 100% Bagasse,
25 M/s EID Parry Ltd. , Pattavathalai, Tamil nadu
1 100 109 540 100% Bagasse 100% Imported Coal
High Pressure Boilers
77
• Boilers for Co-Generation and generating power on sustainable basis must have
• The essential features of High Pressure Boilers for ensuring reliable operation onyear round basis are
High Uptime
High Efficiency
Low Power Consumption
Environment Friendly
Low O & M Cost
Multi Fuel Firing Capability
Ability to give trouble free service throughout the year
High Pressure Boilers - Features
88
• Wood Chips
• Olive Wood Trimmings
• Coconut Shell
• Groundnut Shell
• Subabul Wood
• Red Gram Husk
• Bengal Gram Husk
• Cashewnut Shell
• Woody Biomass
• Cane Top & Trash
• Cane Pith
• Other agricultural wastes, individually or in combinations
• Coal
• Supplementary Fuel - Oil, Natural Gas and Bio-Gas
- Multi Fuel Firing CapabilityBiomass and Fossil Fuels
99
• Of the several Technologies available, Travelling Grate Boilers canefficiently burn the following:
Biomass Fuels: Fossil Fuels:
Bagasse
Rice Husk
Wood Chips
Cotton Stalk
Mustard Stalk
Paddy Stalk
Coconut Shell
Olive Wood Trimmings
Groundnut Shells
Coal
Lignite
Oil
Gas
Travelling Grate Boilers - Multi Fuel Firing Capability
1010
Bi Drum Design Travelling Grate Boiler with Boiler Bank
[For Steam pressure up to 87 Kg / cm2 (a)]
Single Drum Design Travelling Grate Boiler with Modular Evaporator Bank
[For Steam pressure >87 Kg / cm2 (a)]
1111
High Pressure Boiler
95 TPH, 62 Kg / sq.cm (g), 500 Deg. CTravelling Grate Boiler, Mid Siam Sugar Co., Thailand
1212
170 TPH, 105 Kg / sq.cm (g), 540 Deg. CTravelling Grate Boiler, Dhampur Sugar Mills, India
High Pressure Boiler
1313
Single Drum Design(For Steam Pressure >87 Kg / sq.cm a)
• High ligament efficiency of drum (85 – 90%), hence lower drum thickness.
• Better circulation due to non-heateddown comers
• No tube expansion
Bi Drum Design (For Steam Pressure <87 Kg / sq.cm a)
• With single pass boiler bank whicheliminates eddies and minimises erosion
Generous Grate area loading (<2.5 M Kcals / hr - sq.m)
• Ensures efficient combustion of fuel
Generous Furnace Volumetric loading (<0.25 M Kcals / hr - cubic m)
• Ensures adequate residence time(2.5 to 3.0 seconds) for efficient fuelcombustion
• Reduces unburnt Carbon loss• Ensures optimum furnace exit
flue gas temperature (<900 0C)
Contd…
Features of High Pressure Boilers
High Uptime
- Design and Construction
1414
Water Cooled Membrane wall construction for furnace
• Minimum maintenance• High structural rigidity• Maximum absorption of heat
Convective Super heater Design(Shielded by nose)
• Lower metal temperatures • Avoids fouling
Wide Pitching for Super heater Tubes • Avoids fouling due to Alkali (Na2O + K2O) content in ash
Double Casing for Economiser • Protects Tube bends from erosion
Ferrules for Air heater Inlet Tubes • Minimises Erosion
Corten Steel Material for Air heater at the cold end
• Minimises Corrosion
Features of High Pressure Boilers - Design and Construction
High Uptime
Contd…
1515
RUGGED, EFFICIENT & EASY TO MAINTAIN
Continuous Ash Discharge Travelling Grate Stoker
1616
All Pressure Part Tubes of Seamless Construction
• Eliminates Leakages• Higher Life
Travelling Grate Bars of Spheroidal Graphite Iron Metallurgy
• Resistance to Wear and Tear at ElevatedTemperatures
• High Durability
Use of SA 213 T91 Material for Final Elements of Secondary Super heater
• High Creep Resistance• High Fatigue Resistance• High Corrosion Resistance
Optimum Steam side Pressure drop in Super heater Circuit
• Ensures proper Steam distributionand Cooling of Super heater Coils
Optimum Flue Gas Velocity Levels in Pressure Parts
• Minimises Erosion due to Ash Particles
Features of High Pressure Boilers
Contd…
High Uptime
- Design and Construction
1717
Efficient drum Internals (Cyclone Separators, Demisters)
• Ensures High Steam Purity at all loads
Pre dust Collector at the upstream of Electrostatic Precipitator
• Reduces Particulate loading on ESPand ID Fans
• Reduces Unburnt carryover to ESP,Eliminating Fire Hazards
Higher frame size for Motors with VFD
• Minimises Heat Losses
Features of High Pressure Boilers - Design and Construction
1818
Tall Furnace • Provides High Residence time,hence lower unburnt carbon loss
Over fire Air with High Pressure Secondary Air with Staggered Arrangement of Nozzles
• Proper Turbulence for Efficient Combustion
• Better Air Penetration across furnace cross
section. The above ensures lower unburnt
carbon loss
Soot Blower in Superheater and Economiser
• For Efficient on-load cleaningthereby Keeping Heating SurfacesClean for Proper Heat Transfer
High Efficiency
Contd…
1919
Optimum Excess Air Level • Reduces Dry Gas Loss
Use of High Pressure Feed Water Heaters • Fuel Economy
Grit Refiring • Reduces Unburnt Carbon loss
High Efficiency
2020
Optimum Flue Gas Velocities across
Pressure Parts
• Low draft loss, hence Low PowerConsumption in ID Fans
Variable Frequency Drives for Fans, Pumps, Feeders
• Low Auxiliary Power Consumption
Low Power Consumption
2121
Electrostatic Precipitators • To limit particulate emission up to 50 mg / Nm3
Silencers for Safety Valves, Start
Up Vent, FD Fan and SA Fan
• To meet noise levels as per OSHA norms
Dense phase Fly Ash handling
system
• Closed System, avoids dust nuisance
Environment Friendly
2222
Automated Operation with DCS • Less Manpower
• Accurate Controls
On line Steam and Water Analyser System • Ensures Strict Control of Water
Chemistry
On line Vibration Monitoring System for
Critical Rotating Equipment
• Preventive Maintenance
• Avoids Failures
Seamless Steel Tubes for Boiler Pressure
Parts
• Eliminates Tube Leakages
• Higher Life
Alloy Steel Tubes for Super heaters • Resistance to Corrosion, Fatigue
and Creep
Corten Steel Tubes for Cold end of Air heater • Prevents Corrosion
Low O & M Cost
Contd…
2323Contd…
Low O & M Cost
2424
Wear Liners for ID Fan Blades • Resistance to ErosionSoot Blowers (Long Retractable and Rotary) at Strategic Locations
• Avoids deposition and Fouling in
Pressure Parts
Air heater Air bypass Arrangement • Avoids Cold end Corrosion during Boiler Start-up, Part load operation and during Low Ambient Air Temperature
Stoker Shaft with Self Lubricated Graphite Bearings
• Maintenance Free• High Reliability
Low O & M Cost
2525
• To Eliminate Corrosion
• To Avoid Scaling
• To Control Steam Quality
• On-line Monitoring of Condensate and Boiler Feed Water Quality using SWAS
• Fully Automatic DM / RO Plant for achieving the Recommended Feed Water
Quality
Feed Water Quality Management In High Pressure Boilers
2626
Parameters Unit45
Kg/sq.cm (a)
66 Kg/sq.cm
(a)
87 Kg/sq.cm
(a)
110 Kg/sq.cm
(a)
125 Kg/sq.cm
(a)
pH 8.8 – 9.2 8.8 – 9.2 8.8 – 9.2 8.8 – 9.2 8.8 – 9.2
Hardness ppm Nil Nil Nil Nil Nil
Specific Electrical Conductivity after Cation Exchanger
µs / cm 2.0 0.5 0.5 0.3 0.2
Dissolved Oxygen ppm 0.20 0.007 0.007 0.005 0.005
Total dissolved solids ppm 1.0 0.25 0.25 0.15 0.10
Silica ppm 1.0 0.02 0.02 0.02 0.02
Total iron ppm 0.05 0.01 0.01 0.005 0.005
Total Copper ppm 0.01 0.01 0.01 0.005 0.005
Recommended Feed Water Quality
2727
Parameters Unit 45 Kg/sq.cm
(a)
66 Kg/sq.cm
(a)
87 Kg/sq.cm
(a)
110 Kg/sq.cm
(a)
125 Kg/sq.cm
(a)
pH 9.8 – 10.2 9.0 – 10.0 9.0 – 10.0 9.0 – 10.0 9.0 – 10.0
Total Dissolved Solid ppm 150 100 100 50 50
Specific Electrical
Conductivity
µs/cm 300 200 200 100 100
Silica ppm 10 5 * 2.5 * 1.5 * 1.5 *
Residual Phosphate ppm 15 – 25 5 – 20 5 – 20 5 – 20 5 – 10
* To be controlled based on drum operating pressure so as to maintain silica less than 0.02 ppm in the steam leavingthe boiler drum.
Recommended Boiler Water Quality
2828
• Use of Drum Coil Heaters for Minimising Cold end Corrosion in Economiser due
to Sulphur in Fuel
• Use of Steam Coil Air Preheater and Airheater Air by pass Arrangement for
Minimising Cold end Corrosion in Air heater during Start up and Low Ambient
Temperature
Prevention of Cold End Corrosion
2929
Parameters Unit
87 Kg/sq.cm (a), 515 Deg C
105 Kg/sq.cm (a), 540 Deg C
Design Values
Achieved Values
Design Values
Achieved Values
PlantNizam Deccan Sugars, India
Dhampur Sugars, India
Steam flow at Main steam stop valve Tph 110 110 170 171.4Steam temperature at Main steam stop valve
Deg.C 515 ± 5 515 540 ± 5 540
Steam pressure at Main steam stop valve
Kg / sq. cm (a)
87 87.2 105 105.4
Feed water temperature at Economiser inlet
Deg.C 170 168 220 218
Back end temperature Deg.C 150 148 150 146Boiler Efficiency on GCV basis % 71.5 72.7 71.1 71.4Auxiliary power consumption KW 1096 1025 1912 1754Particulate Emission at ESP outlet mg /
N.cu.m115 115 150 150
Noise level of rotating equipment at 1 meter distance
dB 85 < 85 85 < 85
Boiler Availability % - 97 - 97
Boiler Performance
3030
ENERGY SAVING IN SUGAR INDUSTRY
To achieve the higher cogeneration
Need of energy saving in sugar industry.
To support the cogeneration for saving of fuel.
Lower power consumption for more power output.
3131
FEW EQUIPMENTS FOR ENERGY SAVING IN SUGAR INDUSTRY
Chain Less cane Diffuser of 3500 TCD capacity for HPCL Bio-fuels Ltd., Sugauli - India
CANE DIFFUSERS
3232
FEW EQUIPMENTS FOR ENERGY SAVING IN SUGAR INDUSTRY
Evaporator Station with Falling Film Evaporators for 5000 TCD sugar plant for KPR Sugar Mills India
STEAM EFFICIENT PROCESSHOUSE WITH FALLING FILM EVAPORATORS
3333
Milling Tandem for 5000 TCD expandable to 7500 TCD capacity Sugar Plant in India
MILLS WITH ENERGY EFFICIENT DRIVES
FEW EQUIPMENTS FOR ENERGY SAVING IN SUGAR INDUSTRY
3434
Milling Plants with Pinion less Drives
Isometric view of Pinionless mill assembly
MILLS WITH ENERGY EFFICIENT DRIVES
FEW EQUIPMENTS FOR ENERGY SAVING IN SUGAR INDUSTRY
3535
• Recovers the heat from various condensate streams ofEvaporator sets, Pans and heaters
• Reduces steam consumption by 2-3 % on cane
• Eliminates several condensate pumps
EFFICIENT BLEEDING ARRANGEMENT WITH FLASH RECOVERY SYSTEM
FEW EQUIPMENTS FOR ENERGY SAVING IN SUGAR INDUSTRY
3636
• Spray Nozzles Condense vapour
• Jet nozzles increase momentumof water flow in the tailpipe venturito evacuate air bubbles trappedin the system
• Water required is only30-40 kg/kg vapours
• Automation further reduces needof water
POWER AND WATER EFFICIENT MULTI JET CONDENSERS
FEW EQUIPMENTS FOR ENERGY SAVING IN SUGAR INDUSTRY
3737
• Utilization of Non Condensable Gases
• Reduces steam consumption
• Inbuilt static mixer; no mechanicalagitation
• Installation on pan floor or atcentrifugal station
• No cleaning required
• No water required for conditioning
STEAM AND POWER EFFICIENT DIRECT CONTANT CONDITIONERS
FEW EQUIPMENTS FOR ENERGY SAVING IN SUGAR INDUSTRY
3838
• Excellent Massecuiteexhaustion due to strongcirculation of Massecuite
• Uniform Crystal growth
• Provides flexibility ofoperation with minimumoperators
• Low Massecuite boilinghead
• Horizontal pan layoutcomprising well mixed cells
• State of art multi-bafflearrestor to avoid anyentrainment
CONTINUOUS VACUUM PANS
FEW EQUIPMENTS FOR ENERGY SAVING IN SUGAR INDUSTRY
3939
Decanter System for Mud Filtration at KPR Sugar Mills, India
DECANTER SYSTEM FOR MUD REMOVAL WITHOUT USING BAGACILLO
FEW EQUIPMENTS FOR ENERGY SAVING IN SUGAR INDUSTRY
4040
ENERGY SAVING IN SUGAR INDUSTRY
4141
Overview
Indonesian Sugar Industry and Market
Indonesian Sugar Association/AGI
Surabaya, 21 May 2014
Outline1.Strategic Roles and Highly Intervened
2.Dynamic of Domestic Sugar Market (2008-2013)
3.Domestic Sugar Market Outlook and Opportunities
4.Concluding Remark
Historically strategic
Year 1930th• 179 Mills• Sugar Content 12%• Output 3 million ton• Export 2.4 million ton
Year 2000th• 62 Mills • Sugar Content 7%• Output 2.5 million ton• Import 2.5 million ton
It looks a gloomy evolution but it means also opportunities
Importance of Sugar in Indonesia
• Household expenditure: 4%• Number of farmers: 220,000 farmers• Number of mill : 62• Source of employment in rural areas
Therefore, it is considered as a basic food and accordingly highly intervened (production, distribution, and trade)
Main Policy: The Decree of Ministry of Industry and Trade No 527/2004 and Import tariff
Regulating almost all aspect of sugar market including• Import quota based sugar balance• The importer (producer and registered importer)• Time of import (two months after harvest season and one
month before harvests season)• Port for import: selected ports• Reference rice for sugar produced by farmers (HPP) and
related loan: minimum price and trigger for import• Market segmentation between refined sugar and
plantation white sugar (not very effective)• Import tariff (Rp 790/kg for refined and Rp 550/kg for
raw)
7,500
8,000
8,500
9,000
9,500
10,000
10,500
11,000
11,500
12,000
12,500
Jan
Mar
Mei Ju
l
Sep
Nop Ja
n
Mar
Mei
Juli
Sep
Nov Jan
Mar
Mei Ju
l
Sep
Nop Ja
n
Mar
Mei Ju
l
Sep
Nov Jan
Mar
Rp/
Kg
Import Parity Price
Retail Price and Import Parity Price
Retail Price
The decree has induced the market to be oligopoly/ oligopsony, specially at big trader/distributor (D1) level less competitive, 6-8 big players
20142013201220112010
Description 2008 2009 2010 2011 2012 2013 RataanHPP (Rp/kg) 5100 5350 6350 7000 8100 8100 6667
Auction (Rp/kg) 5262 7056 8478 8191 9707 9434 8021
Retail (Rp/kg) 6510 8577 10090 10144 11351 11884 9759Difference between Auction and HPP (%) 3.2 31.9 33.5 17.0 19.8 16.5 20.3Difference between retail and Auction (%) 23.7 21.6 19.0 23.8 16.9 26.0 21.8
Reference Price (HPP), Auction Price, Retail Price
Source: AGI (2004)
No well defined and consistent approach to formulate HPP , mostly based onProduction costs leading to consistent increase.Therefore, auction and retail price has consistently increased
No Company Status Province Number of Mill Capacity (TCD)
1 PTP Nusantara II SOE North Sumatera 2 7400
2 PTP Nusantara VII SOE Lampung and South Sumatra 2 12303
3 PTP Nusantara IX SOE Central Jawa 8 17590
4 PTP Nusantara X SOE East Jawa 11 39150
5 PTP Nusantara XI SOE East Jawa 16 43750
6 PTP Nusantara XIV SOE Sulawesi Selatan 3 7600
7 PT PG Rajawali I SOE East Jawa 2 16500
8 PT PG Rajawali II SOE West Jawa 5 14300Total SOE 49 158593
9 PT Madu Baru Private Jogjakarta 1 3500
10 PT Kebon Agung Private East Jawa 2 12000
11 PT Gunung Madu Plantation Private Lampung 1 12500
12 PT Garuda Panca Arta Private Lampung 3 27000
13 PT PG Gorontalo Private Gorontalo 1 8000
14 PT Industri Gula Nusantara Private Central Jawa 1 1800
15 PT PG Candi Baru Private East Jawa 1 2500
16 PT Pemuka Sakti Indah Private Lampung and Centra Java 1 4500
17 PT Laju Perdana Indah Private South Sumatra 2 11000Total Private 13 82800Indonesia 62 241393
Description of Sugar Companies in Indonesia
Year Area Cane ProductionSugar
Content Production(ha) (ton) (ton/ha) % (ton) (ton/ha)
2008 434127 32279323 74.4 7.97 2574236 5.93
2009 416335 30248204 72.6 7.60 2299504 5.52
2010 432737 35458022 81.9 6.46 2290130 5.29
2011 432830 28856722 66.7 7.40
21358254.93
2012 442478 31888930 72.7 8.13
25916875.86
2013 470198 35526064 75.6 7.18
25509655.40
(% per annum) 1.6 1.9 0.3 -2.1 -0.2 -1.9
Area, Sugar Content, and Production
The decree was effective to promote area and production in the beginning, but not in the last five yearLow productivity at on farm and off farm level (OVR = 80%, below efficient 87%)
No Company Capacity (Ton/Year)
2008 2009 2010 2011 2012 2013
1 PT. Angels Product 500,000 269,447 330,809 304,379 315,969 288,606 305,236
2 PT. Jawamanis Rafinasi 533,200 270,519 303,392 332,405 302,973 286,807 318,233
3 PT. Sentra Usahatama Jaya 540,000 321,367 424,693 435,085 378,849 478,226 527,566
4 PT. Permata Dunia Sukses Utama 396,000 326,534 363,403 372,362 312,500 330,977 363,938
5 PT. Dharmala Usaha Sukses 250,000 40,384 112,167 163,457 119,966 192,536 185,997
6 PT. Sugar Labinta 540,000 28,184 192,009 230,140 250,969 345,959 490,685
7 PT. Duta Sugar International 300,000 - 91,800 145,685 175,784 251,660 291,374
8 PT. Makasar Tene 462,000 - 213,570 373,293 335,098 296,093 337,858
9 PT. Berkah Manis Makmur 600,000 117,687
10 PT. Andalan Furnindo 400,000 76,587
11 PT. Medan Sugar Industry 495,000 21,980
Total 5,016,200 1,256,435 2,031,843 2,356,806 2,192,109 2,470,865 3,037,141
Refined Sugar Industry
Growth rate : 19% per annum
Refined Sugar Year
2009 2010 2011 2012 2013 2014
Small Industry , ton 300,026 315,027 330,778 347,317 364,683 382,917
Big and Medium Industry , ton 1,567,537 1,645,914 1,728,210 1,814,620 1,905,351 2,000,619
Use of Refined Sugar 1,867,563 1,960,941 2,058,988 2,161,937 2,270,034 2,383,536
5% annual growth rate
White Sugar Year
2009 2010 2011 2012 2013 2014
Household, kg per kapita 7.91 7.69 7.38 7.38 6.48 6.48
Hotel, kg per kapita 2.14 2.14 2.14 2.14 3.06 3.21Restautant , kg per kapita 1.16 1.16 1.16 1.16 1.56 1.67Total (kg) 11.21 10.99 10.68 10.68 11.10 11.36
Population 231,370,000 237,641,000 241,095,953 243,530,400 248,818,000 252,351,216
Consumption 2,593,658 2,611,675 2,574,905 2,600,905 2,761,880 2,867,265Total Refined and White 4,461,221 4,572,616 4,633,893 4,762,842 5,031,914 5,250,801
Source: Kantor Menko, 2014
Consumption or Use of Refined and White Sugar, 2009-2014
2% annual growth rate
Year White Refined
Raw Sugar for Total Inc
Refined White (Idle Capacity) MSGTotal MSG
2008 49,025 453,743 1,213,470 5,300 320,675 1,539,445 2,042,213
2009 13,000 149,838 2,237,489 149,060 203,482 2,590,031 2,752,869
2010 446,894 158,384 2,468,735 110,225 230,655 2,809,615 3,414,893
2011 143,479 60,412 2,267,092 127,842 186,577 2,581,511 2,785,402
2012 121,996 *) 99,271 2,579,842 433,188 **) 213,346 3,226,376 3,447,643
2013 0 98,577 3,019,000 537,000 395,530 3,951,530 4,050,107
Growth
(% p.a) (100.0) (26.3)20.0 151.8
4.3 20.7 14.7
Import of Sugar, 2008-2013
Outlook:Important issues should be considered• Cost of land, especially in Java, has been increasing.
For an example, the cost in 2012 was around Rp 12.2 million/ha, increasing to Rp 13.5 million in 2013, about 10% increase (competing with other crops and sectors)
• Increasing costs of labour and transportation, main costs component;
• Improved consumer awareness about the quality of sugar
• Changes in domestic sugar policy including price stabilization policy, roles of Bulog, and integration of white and refined sugar market
• More fluctuated of international sugar price
No Variable Unit 2013 2014-2019
1 HPP (Rp/kg) 8100 8100 – 8500
2 Auction Price (Rp/kg) 9434 9600-10000
3 Retail Price (Rp/kg) 11884 11750-12300
4 Production (juta ton) 2.55 2.50-2.90
5 Consumption (juta ton) 2.70 2.87-3.18
6 Import (juta ton) 0 0.10-0.40
Outlook of Domestic White Sugar Market
Source: Susila (2014)
Domestic market is expected to be deficit ant it tends to increase
OpportunitiesDomestic market is expected to be deficit and tend to
increase investment opportunities to increase productivity and expansion
Increasing Productivity/Intensification• On Farm Level
– Variety and on farm technology• Off Farm Level
– Technology to improve productivity investment and cooperation with SOE
– Product diversification– Energy efficiency
Expansion: especially outside Java
Expansion Outside JavaIt is inevitable because expansion in Java has been very costly mainly due to sharp increase in cost of landTo attract investment outside Java, then the government should provide various supports and incentive including:Well defined and accurate data related to suitable land
for sugar cane. It needs collaboration with local government and research institute to conduct surveys
Supports on land acquisition processes including clear land status
Fiscal incentive mainly on tax and infrastructure supports
Concluding Remark• Sugar is and will continue to be a strategic commodity
such that government interventions (supports and protection) are expected to be continued
• Under heavily government intervention, the production tend to be stagnant in the last five years and this trend is expected to be continued in the medium term.
• Demand tend to consistently increase due to population and income increase leading to deficit.
• This deficit is indeed an investment opportunities to increase production through productivity increase/intensification (on farm, off farm, and product diversification) and expansion, especially outside Java.
• Under deficit and highly regulated market, best time for investors to invest !
Terima Kasih
Dr. Wayan R. SusilaSenior Adviser
Indonesian Sugar Association+62 811 989 433, [email protected]
Role of Enzymes AndADY (Active Dry Yeast)toIncrease production efficiencies in Ethanol Production
Outline Introduction
Parameters impacting the Fermentation efficiencies
Performance parameters for Alcohol production
What are Enzymes and its role?
What are ADY (Active Dry Yeast)? Results in the plant
Impact of Enzyme and ADY on Efficiencies
Introduction Development in Bio-technology changing the molasses
fermentation for alcohol production to meet thefollowing requirements:
Higher Alcohol % in mash (beer) Contamination issues during fermentation Lower Spent wash (Vinasse)/ Per Liter of Alcohol Lower water consumption Lower Steam consumption Additional Yield by converting unfermentable sugars
Parameters impacting the fermentation efficiencies
Feedstock Quality issues
F/N Ratio Ratio of Fermentable sugar to non-fermentable substance will limit
the alcohol% in the wash Inhibits the Yeast growth
Volatile Acid Volatile acids in molasses < 2500 ppm Fermentation rate and yeast
growth is not much affected. Fermentation rate is reduced when volatile acids are in the range of
2500 – 7500 ppm and any further increase is not desirable
Parameters impacting the fermentation efficiencies
Caramel Content Caramel is toxic in nature to yeast and may affect the specific growth
rate and specific productivity. Retention time of fermentation may increase with high caramelized
molasses.
FAN (Free amino Nitrogen) Content Low yeast count and Low cell viability Low Fermentation reaction rate and Higher retention time Lower alcohol yield per ton molasses
Feedstock qualities
S. No.
Parameters Molasses "Class-I"
Molasses-C "Class-II"
Molasses-C "Class-III"
1 Total Solids, % w/w 78 - 82 76 - 80 76 - 80
2 Fermentable Sugars, %w/w 48 to 52 42 to 48 40 to 42
3 F/N ratio 1.40 1.20 1.0
4 Settleable sludge % w/w 3 3 3
5 Titrable volatile acidity,ppm 3000 3000 - 5000 5000 - 7500
6 FAN 1500 1500 1500
7 Butyric Acid content, ppm 150 150 150
8 Total Viable count, cfu/gm 1000 1000 1000
Fermenter Operating parameters
Yeast Cell Count and Viable count
Minimum yeast cell count of 250-300 million/ml to be maintained in the fermenter Viable Yeast of 85% is necessary Contamination to be controlled to maintain viable count and increase of VA in the fermenter Level of oxygen in the Prefermenter and Yeast cell count before transfer to main fermenter Poor Yeast growth is caused by low level of Nitrogen/Amino acids
Sugar and Alcohol % in the Fermentation and Feed dilution
Sugar concentration and Alcohol % affects the yeast growth rate The alcohol% in fermenter- to be gradually increased from 6.5% v/v to 10-12% v/v by starting with
low sugar feed ie dilution rate
Temperature Temperature of the fermenters to be kept at 32- 34 degC to get best results Temperature above 34 degC leads to increase of sugar Summer months- it becomes difficult as WBT (wet bulb temperature) goes above 32 degC
Parameters impacting the fermentation efficiencies
Performance parameters?
Higher Recovery Liter per ton molasses
Lower Steam consumption
Lower water consumption
Less Spent wash (vinasse) production to manage environmental issues
What are Enzymes? Enzymes are proteins, consist of long chains of amino acids held together by
peptide bonds, present in all living cells.
Enzymes are catalysts, means that by their mere presence, and withoutbeing consumed in the process, enzymes can speed up chemical processesthat would otherwise run very slowly, if at all.
Enzymes work only on renewable raw materials and finds usage inindustries like Fruit Juice, Cereals & Food, Milk, Starch & Sugar, Alcohol,Brewery, Meat, Textile, Leather, Paper & Pulp, Detergents, Animal feed andpharmacy.
Impact on Molasses Fermentation Ensure more sugars in fermentation by hydrolyzing sugars from
Starch, Dextrin, Cellulose and other polysaccharides.
Control bacterial contamination; ensuring sugars are notconsumed by bacteria producing acids.
Hydrolyze proteins into FAAN (free-alpha amino nitrogen) ensuringhealthier and robust yeast growth.
Increased Additional Yield by 8-10 liters/ton of molasses.
Increased alcohol percentage thus reduction in spent-wash ratio(Reducing energy required for distillation and evaporation).
Elimination of di-acetyl odour and improving the ENA quality.
What are ADY? ADY is Active Dry yeast strain of improved strain of saccharomyces cerevisiae to
achieve following:
Higher alcohol tolerance Higher cell count to maintain 350-400 million cells/ml in the wash Higher viability count High gravity fermentation
Cerevisiae and pombe are the two species of yeast used for alcohol fermentation. Pombe are osmo tolerant
Grain (starch) based alcohol fermentation is operating at 18%+ v/v alcohol with use of ADY, high alcohol tolerant yeast.
Grain (starch) Feedstock has high F/N ratio as compared to Molasses
Molasses F/N ratio varies from 1.0 to 1.4. Lower F/N Ratio limits the alcohol% in wash.
Advantages and consumption of ADY Advantages:
Eliminates tedious culture propagation and bacterial proliferation in culture vessels.
Faster growth rate ofYeast along with application OF ENZYMES
Restricts bacterial growth in Pre-fermenter and production fermenters
Consumption issues:
Not practiced widely in molasses distillery due to system of yeast propagation through lab slant.
Zero cost in yeast propagation system: Not entirely true as sugar is consumed duringpropagation and also low cell count per ml as compared to ADY
Consumption of ADY 0.2 Kg/KL are achieved with Pre-fermenter stage
Can be further optimised by adding one stage propagation before Pre-Fermenter stage,
ADY Plant trials
Impact of Enzymes and ADY on EfficienciesComparison for F/N Ratio- 1.0
Parameters Normal Operation Fermentation with Enzymes and ADY
Alcohol% in wash, % v/v 7.5 8.5
Yield, Liter/ton 235 242
Spent wash Production, Liters per Liter of alcohol
10.0 8.5
Water requirement for molasses dilution, m3/KL
9.2 7.7
Steam Consumption Reduction of 0.2 Kg/liter
Impact of Enzymes and ADY on EfficienciesComparison for F/N Ratio- 1.2
Parameters Normal Operation Fermentation with Enzymes and ADY
Alcohol% in wash, % v/v 8.0 10.5
Yield, Liter/ton 260 268
Spent wash Production, Liters per Liter of alcohol
9.2 6.5
Water requirement for molasses dilution, m3/KL
8.8 6
Steam Consumption Reduction of 0.30Kg/liter
Impact of Enzymes and ADY on EfficienciesComparison for F/N Ratio- 1.4
Parameters Normal Operation Fermentation with Enzymes and ADY
Alcohol% in wash, % v/v 8.5 12.0
Yield, Liter/ton 284 294
Spent wash Production, Liters per Liter of alcohol
8.5 5.5
Water requirement for molasses dilution, m3/KL
8.4 5
Steam Consumption Reduction of 0.35 Kg/liter
Conclusion1. Increase of chemical cost by 0.006 US$/LiterAdvantages1. Average increase in yield by 7-8 Liter per ton mol.2. Reduction in steam consumption by 20-35%3. Reduction in water consumption by 25-40%4. Reduction in spent wash generation by 20-40%
Savings in operation cost is 5-6 times the additional chenical cost apart from easier
environmental management for vinasse
STEAM ECONOMY AND ENERGY CONSERVATION A.K. SRIVASTAVAPRINCIPAL CONSULTANTGLOBAL CANE SUGAR SERVICES LTD,
1
Civilization and Energy
Sugar cane having highest bio-conversion efficiency to capture sunlight through photosynthesis and able to fix around 40-50 tons of dry matter per hectare of land annually on a renewable basis
Steam Electrical Nuclear
Energy Source
Non-Renewable (Fossil Fuel) Renewable (Bio-mass, Wind, Solar, Tidal)
Civilization Started 10,000 Years Ago
Energy Human Brain
Without Energy and without our brain what we are today was impossible
2
Indian Sugar Industry
India has an ancient history of Sugarcane right from the RIGVEDA ( 5000 BC),
Now Sugarcane is grown in more than 110 countries mostly migrated from India by the various travelers.
Sugar is derived from Sanskrit (Original language of india) world SHARKARA ( AZUCAR, SUCRE, SUIKER, ZUCKER)
India discovered how to crystallize the sugar first time around 300 AD
India is the largest consumer and second largest producer of sugar after Brazil
1
2
3
4
5
3
Steam power scenario*
Year Steam Consumption %
cane
Power Generation
kwh/tc
Power Consumption
kwh/tc
1930 +65 30 -
1950 60 40 -
1975 55 - -
2000 46 - 35
2005 43 - 32
2008 38-42 100 28
Today 34 140 22
*With double sulphitation process
4
Advantages of steam economy
Surplus power generation to be exported to grid to replace powergenerated by fossil fuel ( Coal, Oil)
Saving of cellulosic fuel which can be diverted to other useful purpose likepaper making, pellets for house hold purpose, chemicals etc ( Cellulosicethanol is going to be a reality, US production this year is 45 mnl alcohol fromcellulosic waste)
Low energy concept also protects sugar and reducing sugar in the process, (less loss and less colour formation , higher yield )
Less colour formation in the plant ( good quality of sugar) Lower investment on steam and electrical power generation or Higher
crushing with (lower Boiler and TG set capacity) Existing plant can crush more with the same steam generation Integrate a Refinery for raw sugar conversion
5
Possible Scenario
Steam consumption can be brought down to < 30% oncane for production of very high pol raw sugar.
Steam consumption can be brought down to 36% on canefor complex converting cane to refined sugar.
Electrical power consumption can be brought down to 22KW per ton cane for sugar complex converting cane torefined sugar .
Steam consumption can be brought down to 0.80 ton perton of Refined sugar output in a autonomous refinery withrecovery house.
6
Action Plan- Sugar plant
Optimization of steam consumption for extraction of sugar from sugar cane
Optimization of electrical power consumption
Improvement in the bagasse/steam ratio(2.65)
Improvement in steam/power ratio(5.2 T/MWh back pressure mode, 3.7 T/MWh condensing mode)
7
Action Plan: Autonomous Refinery
Steam Re-boiler for avoiding cold water use at Boilers
Melt concentrator with extensive vapour bleeding , minimum double effect
DCH for various heating, low temp vapour for melting
Surface condenserFor hot water recovery , No cold water any where
8
Adopting New Process Technology and equipments
Modified Bleeding scheme at Evaporator No use of high pressure steam in Boiling House Maximum use of Condensate Heat Use of NCG heat for molasses conditioning Flash heat Recovery Direct contact heaters to utilise later effects vapour Minimum use of water addition in the process Optimization of Drain and leakages and recycling of condensate from
drain Use of modern equipment which have higher heat transfer at lower
delta T coefficient and lower BPE
9
Case study of Raw juice heating
7.03
2.9
1.831.22
0.32
CASE 1 CASE 2 CASE 3 CASE 4 CASE 5
Steam economy in raw juice heatingExtra load on evaporator
Case 1: Heating with Exhaust steamCase 2: Heating with vapour IIICase 3: Hearing with VLJH and Vapour IIICase 4: Heating with VLJH + Vapour IV +vapour IIICase 5: Heating with VLJH + Condensate+ vapour IV
10
Waste Heat Recovery from VapourCondensate
Parameter Value UnitBasis 100 Tons cane/hr
Vapour Condensate 80 Tons/hrHeat Available 7.84 M KcalHeat Utilized in Process 3.31 M KcalHeat Recycle Back 4.10 M KcalHeat Released to Atmosphere 0.40 M KcalHeat Recovered 94.50 %Cooled Condensate Available 30 Tons/hrWater Recovered for cold water makeup
300 Liters/ton of cane
11
Vapour Condensate Heat Utilization
VapourCondensate
Heat Utilization
Condensate flashing
Defecated juice
heating
Raw juice heating
DM water heating Centrifugal
wash water heating
Make up water for cooling circuit,
Effluent load
reduction
12
Crystallization
A pan boiling
•Present status – I/II vapour
•Possibilities-III vapour
B pan boiling
•Present status –I/ II vapour
•Possibility –III vapour
C pan boiling
•Present status –Exhaust/I vapour
•Possibilities –II/III vapour
Refinery boiling
•Present status –Exhaust / I vapour
•Possibilities-II vapour
13
Eliminating Reduced Pressure Steam Requirement
Air for Sugar Drying• Replace 7 bar steam with Vapour condensate
Molasses Conditioning• Replace 7 bar steam with NCG
Sulphur melting• Use Thermic fluid to utilise exothermic heat from burner
and use for sulphur meltingSugar Melting• 7 bar steam with-3rd/4th vapor
1
2
3
4
14
Latest Equipment for Steam/power Economy
• low residence time, high heat transfer coefficient• No boiling point elevation
Thin film evaporation hence no loss oftemperature difference
• Negligible retention time, less heat injury and lessinversion of sugar or destruction of reducingsugars
• lower delta T with very low juice hold upvolume, Can give good evaporation rate even atlow delta T as low as 40C
Falling Film Evaporator
15
Latest Equipment for Steam/power Economy
• Minimization of vapour pressure requirement• Minimum temperature variation • Uniformity of the product
No fines, conglomerates etc.• Maximum exhaustion of the mother liquor
Key requirements
• Facilitate steam economy • Stabilise working of evaporator, • Consistent steam demand• Avoid heat injury to sugar • User friendly • Stabilise boiler working,
Role of continuous pans
• Horizontal tube keeping the heating media inside the tube and massecuite outside the tube• Horizontal continuous pan with vertical tubes (no of compartments 8-13)• Vertical continuous pan with vertical tubes ( no of compartments 5-6 )• Vertical tubes and vertical pan( Langraney)
Four main design features
16
Energy optimization in sugar factories adopted in India
1. Maximum utilisation of waste vapour for juiceheating.
2. Raw juice heating with last body vapour partialat full vacuum and full at reduced vacuum
3. Raw/defecated juice heating with vapourcondensate
4. Raw/defecated juice heating through IV/III/IIvapour
5. Clear juice heating with clarifier flash vapour6. Clear juice heating with second/first vapour7. Heating sequences utilises mix of Tubular/Plate
and direct contact heaters
17
Energy optimization in sugar factories adopted in India
1. Quintuple effect evaporator and Falling film bodies forall effect, Bleeding from all effects
2. Condensate flashing both Exhaust as well as vapour3. Clear juice concentration with Pan vapour4. A, B and C Massecuite boiling in Continuous vacuum
pan5. Pan Boiling on vapour III of Quintuple effect
evaporator6. Molasses conditioning with NCG7. Pan washing with second vapour8. Sugar melting with low grade vapour
18
Energy optimization in sugar factories adopted in India
1. Air heating through vapour condensate/First vapour/Second vapour2. No reduced pressure steam in the plant3. Bagasse drying through flue gasses4. Use of LP/HP heaters at boiler5. Wash water for centrifugal heating through exhaust steam
condensate6. Gravity flow of hot water from condenser to Spray
pond/cooling tower7. Installation of condensate polishing unit for reconditioning of
vapour condensate8. Flash vapour of blow down for de-arator/DM water heating9. DM water heating through vapour condensate
19
Energy Optimisation: Autonomous Refinery
Most of the refinery uses fossil fuel
Steam consumption range between 1.25 to
1.75 tons /ton RSO
Can be brought down< 0.80 ton/ton RSO
Higher production capacity with
existing steam & power generation
Lower cost of conversion
Saving of invoirnament
20
Energy Optimisation: Autonomous Refinery
Surface condenser for condensate
recovery
Double/triple effect Melt
concentratorDCH for Misc
heating
No Cold water &
Higher yield
Recovery Boiling on Melt
concentratorSteam
Transformer
21
Heating in Refinery
Traditionally, the following technology was employed: Direct injection of live steam Shell and tube heat exchangers Plate heat exchangers
All the above can be replaced with low cost/maintenance free directcontact heat exchangers
A shell and tube heaterfor melt showing sandaccumulation
A typical plateheat exchanger
Three direct contactheaters employed formolasses conditioning
22
DCH – Energy efficiency
Energy Efficiency1. The DCH is the necessary equipment to take advantage of
maximum bleeding of vapour from the melt concentratorsecond effect. The double effect has a ∆ T to 350C and the lastbody pressure at 47 kPa , providing vapour at 800C.y using 80%vapour for heating and conditioning, vapour sent to thecondenser is minimum
Advantages The cost of DCH is 40 - 50% of a tubular or plate heat
exchanger. Due to high head room requirement for sealing legprovision less floor space is required. Lower steel structurespecification due to less weight.Easy to automate and fullautomation is possible. No stand by equipment is required.Simpler pumping and piping requirement, e.g. No condensateextraction etc
23
DCH Application
Raw sugar melting Raw Sugar Melt heating for reaction Sweet Water Heating Make up Water Heating Surface Condenser Condensate heating Affinated Syrup Heating Run off/A,B, Molasses Conditioning
24
Melting and Molasses conditioning
Heating of the melt by direct contact heater requires a portion of theheated liquor to be recycled to the melter to provide heat fordissolution. Exhaust steam/Reduced pressure live steam is replacedwith low pressure vapour providing an opportunity for energyefficiency.
Molasses conditioning requires heating and dilution. Commonlydirect injection of exhaust/reduced pressure steam and also hotwater addition for conditioning with agitation has been practiced.The DCH heats, dilutes and agitates simultaneously, by applicationof low pressure vapour in a cascade body. The DCH conditions allrun off, 1st crop and 2nd crop molasses by adjusting the brix, raisingthe temperature and dissolving fine crystals.
25
Water and Affinated Syrup Heating
Process water, sweet water, make up water, AirCooled Condenser condensate heating and affinatedsyrup heating.
These are generally heated by surface heaters usingmostly exhaust steam.
However, DCH heaters are able to employ lowpressure vapour to achieve the same purpose.
26
Electrical Power Consumption*
Sl. No. Area KW/ton cane1. Cane preparation 5.02. Milling 7.03. Juice preparation 2.04. Evaporation/Crystallisation 1.05. Injection and Spray 3.06. Centrifugals 4.07. Others ( Lighting, workshop etc) 1.08. Total 23.09. Boiler and Utilities 7.010. Over all power consumption 30.0
27
Power Potential
Power Export
•115 kW per ton cane to grid
•5000 TCD plant exports 87,000 MWh in season and with surplus bagasse during off season
Power Revenue
•Extra revenue 7-8 MUSD @ 8-9 Cent/unit
•Clean Energy attracts CDM benefits
Bagasse Saving
•Diverted to Paper/ Particle Board/ Chemical Industry
• Commercial Conversion of bagasse into Ethanol will be reality in 10 years
28
Energy optimization in sugar factories adopted in India
AC variable frequency drives with Planetary gear box for speed reduction in single stage for Mill drives ( 40% plant load on ACVFD)
HT motors for preparatory units like shredder etc
Helical / bevel helical reduction gear box instead of worm reduction gear box
Antifriction bearing in place of GM liners to reduce frictional losses.Belt conveyers instead of Slat conveyers for bagasse conveying
Power factor improvement through capacitor banks
SCADA based process automation
29
Energy optimization in sugar factories adopted in India
SCADA based automation system
Belt conveyers for bagasse conveying in place of chain and slat carriers
Planetary drives for all crystallizers, Pug Mills , mixers, melter in place of geared motor or motor and worm reduction gear box
Energy efficient motors
Correct sizing of motors, pumps, piping and pipe routing, cables
Optimal use of Power generation system
30
Opportunity for Indonesian Sugar Industry
Indonesia produces just 45% of sugar from Sugar cane for domesticconsumption. 55% Raw sugar is imported and converted into refined/White sugar
A high energy efficient sugar plant can be integrated with a refineryto process both sugar cane as well as raw sugar
Fuel requirement for both facilities can be met with the sugar cane 12-16 USD/ton of refined sugar conversion cost can be saved Saved bagasse can run the refinery during off cane period A 2500 TCD energy efficient sugar plant can also support a 500 tpd
refinery in terms of sharing common utilities
31
Conclusion
Time has come to start sugar Industry to make them globally competitive which is possible only when we cut down the energy cost
Start generating revenue from the surplus power
Use the surplus bagasse for paper, particle board, chemicals/animal fodder etc
Convert raw sugar into refined sugar with lowest conversion cost
32
