ISSCT Workshop June to to 4 July. Warren Lawlor July 2008

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1 ISSCT Workshop June to to 4 July Warren Lawlor July 2008

2 Background Venue Technical Sessions Visits Conclusion Contents

3 Background ISSCT Congress every 3 years Workshops held between Congresses Workshops: Less formal Mainly slide show presentations Discussion encouraged Includes site visits Workshop theme: Design, Manufacturing and maintenance of sugar mill equipment

4 Background Workshop held in conjunction with SIMTEC: (Symposium and Technology Exhibition on the Sugar & Alcohol Industry)

5 Brazil Venue

6 Venue Peracicaba, Brazil

7 Venue The Old Sugar Mill, Peracicaba, Brazil

8 Technical Sessions Four technical sessions keynote address Presentations Discussion Over 25 presentations 4 Site visits

9 1. Overview of Brazilian Industry (Edgard Gomes Beauclair of STAB) Sugar Cane In Brazil million hectares 470 million tonnes of cane 29 million tonnes of sugar 17 billion liters of ethanol 83 tonnes sugarcane per hectare

10 1. Overview of Brazilian Industry (Edgard Gomes Beauclair of STAB) Brazillian Plants 357 plants produce sugar, ethanol, and some cogeneration 88 more mills planned by 2010 (US$ 17 Billion)

11 1. Overview of Brazilian Industry (Edgard Gomes Beauclair of STAB) Million tonnes % % % % % % % % % % % % / / / / / /11 Increase of 30 millions t/year For sugar For Ethanoll

12 1. Overview of Brazilian Industry (Edgard Gomes Beauclair of STAB) Environmetal issues Cane for ethanol is not replacing food production (previously unproductive land) New cane land not within Amazon region Amazon forest Pantanal wetlands Atlantic coastal forest

13 1. Overview of Brazilian Industry (Edgard Gomes Beauclair of STAB) Summary Brazilian industry is focused on sugarcane as an energy crop Products include: Ethanol from juice products Ethanol from biomass (Hydrolysis) Biodiesel from biomass Electricity Sugar products Bioediesel Plant Barralcool Mill (First in Brazil to produce sugar, ethanol, electricity and biodiesel)

14 2. Factory and factory system design (Jose Oliverio of Dedini) Vision for future of sugar industry Sustainable development based on producing biofuels and bioenergy from sugarcane. Vision of sugarcane as energy One tonne of sugar cane = 1.2 barrels of oil (1/3 bagasse, 1/3 trash, 1/3 sugar) Bioelecticity from bagasse, trash, dunder Bioethonol from juice, bagasse and trash Biodiesel from integrated sugar and bioethanol mill

15 2. Factory and factory system design (Jose Oliverio of Dedini) Traditional Technology CANE RECEPTION/ PREPARATION EXTRACTION JUICE SUGAR PROCESS SUGAR MOLASSES B A G A S S E STEAM GENERATION (BOILER) SURPLUS BAGASSE PRODUCT FLOW ELECTRICITY GENERATION (TURBOGENERATOR) HIGH ORESSURE STEAM FLOW (DRIVING PURPOSE) LOW PRESSURE STEAM FLOW (THERMAL PURPOSE)

16 2. Factory and factory system design (Jose Oliverio of Dedini) Traditional Technology Optimised CANE RECEPTION/ PREPARATION EXTRACTION B A G A S S E JUICE J U I C E SUGAR PROCESS MOLASSES SUGAR BIOETHANOL BIOETHANOL PROCESS STILLAGE STEAM GENERATION (BOILER) ELECTRICITY GENERATION (TURBOGENERATION) BIOELECTRICITY

17 2. Factory and factory system design (Jose Oliverio of Dedini) Future (Electricity optimised)

18 2. Factory and factory system design (Jose Oliverio of Dedini) Future (Ethanol optimised)

19 2. Factory and factory system design (Jose Oliverio of Dedini) Future (Biodiesel optimised) TECHNOLOGY OPTIMIZATION TO INTEGRATED BIODIESEL PRODUCTION 3 rd GENERATION LAND GRAIN OIL GRAIN MEAL RESOURCES SYSTEMS MANAGEMENT INTEGRATED FARMING SUGARCANE + GRAIN BIODIESEL CANE SUGARCANE + GRAIN INTEGRATED PROCESSES MILL BIODIESEL GLYCERIN BIOETHANOL STILLAGE BIOELECTRICITY

20 2. Factory and factory system design (Jose Oliverio of Dedini) Vision for future of sugar industry

21 5. Concept of an energy efficient 6000 t/day sugar factory (Boris Morgenroth) Emerging technologies Diffuser technology & return of clarifier underflow to diffuser Falling Film Evaporators Increased 5th effect vapour temperature (0,15 bar (a) to 0,55 bar (a)) Vapour bleeding from all effects All pans are supplied with vapour 3 of ~ 100 C Continuous pans for A, B and C product A-Seed cooling massecuite plant A Syrup wash for A-Sugar Stepwise flashing of condensates and reuse of flash Using condensate for pre-heating of limed juice High g factor continuous centrifugals High pressure boiler and turbine High level of automation

22 5. Concept of an energy efficient 6000 t/day sugar factory (Boris Morgenroth) Results (Benchmarking): Steam demand: % on cane (raw / refined) Power demand: kwh/t cane Power export: kwh/t cane at 14 % fiber on cane Extraction recovery: ~ 98 % Overall recovery: ~ 87 % Sugar color: < IU

23 6. Simple innovative, proven equipment and processes for improving energy efficiency (Bruce Moor of Bosch) Modifications can be made to an existing 80 s factory for efficiency improvements: High pressure boilers Continuous pans using V2 or V3 Diffusers Mud recycle to diffuser Electric drives on shredder and mills Increased boiler efficiency (air heaters / economisers) Long tube rising film evaporators Result: Export power potential increased from 10.7 MW to 47.7 MW

24 7. Fives Cail equipment and designs for reduced maintenance and improved efficiency (Simon Trancart of Fives Cail) In line whole stick shredder Power reduced by 15 to 20% compared to traditional knives and shredder.

25 7. Fives Cail equipment and designs for reduced maintenance and improved efficiency (Simon Trancart of Fives Cail) MillMax 3 roll mill 12% lower capital cost 40% lower maintenance cost 30% lower power consumption compared to 4 roll mill

26 11. Development of pinionless mill (DK Goel from ISGEC) ISGEC has developed a range of mills up to 340 t/h

27 11. Development of pinionless mill (DK Goel from ISGEC) Stress distribution Pinionless vs conventional

28 11. Development of pinionless mill (DK Goel from ISGEC) Displacement Pinionless vs conventional

29 11. Development of pinionless mill (DK Goel from ISGEC) Shear force and bending moment diagram Pinionless vs conventional

30 11. Development of pinionless mill (DK Goel from ISGEC) Drive efficiency Sl No Equipment Pinionless Drive Conventional Drive 1 VFD 96% 96% 2 AC Motor 96% 96% 3 Reduction Gearing 95% 92% 4 Tail Bar/Rope Coupling Not Applicable 97% 5 Mill Roll Crown pinion Not Applicable 92% Total Drive Efficiency 88% 76%

31 11. Development of pinionless mill (DK Goel from ISGEC) In operation

32 13. High Pressure Cogeneration (AK Subramanian of ISGEC)

33 13. High Pressure Cogeneration (AK Subramanian of ISGEC) Reason 45 bar to 105 bar = 32% more power generation per tone of bagasse Features Pressurised feedwater (220 Deg.C) Travelling grate (alternative fuels) Electrostatic precpitators On line steam and water analysis Claims 65 bar to 105 bar 10% increase in capital cost All boilers with pressure greater than 45 bar require dedicated water circuit.

34 13. High Pressure Cogeneration (AK Subramanian of ISGEC)

35 13. High Pressure Cogeneration (AK Subramanian of ISGEC)

36 13. High Pressure Cogeneration (AK Subramanian of ISGEC)

37 15. Selection use and maintenance of process pumps (Michael Yang of Sulzer) Pump selection criterion should be based on lifecycle cost not capital cost Selection criteria should include: Pump material and shaft sealing arrangement Pump efficiency Maintenance cost Quality

38 15. Selection use and maintenance of process pumps (Michael Yang of Sulzer) Capital cost is significant for pumps < 10 kw Over 150 kw capital cost is negligible

39 15. Selection use and maintenance of process pumps (Michael Yang of Sulzer) Variable frequency drive vs. valve control 25 to 30% energy saving (If highly throttled) (Sulzer has software available to analyze pumping systems and determine savings)

40 20. Novel and unconventional equipment designs (Dave Meadows of Tongaat Hulett) Examples: TH Cylindrical continuous pan

41 20. Novel and unconventional equipment designs (Dave Meadows of Tongaat Hulett) Examples: Rock and sand removal

42 20. Novel and unconventional equipment designs (Dave Meadows of Tongaat Hulett) Examples: Two roll mill

43 20. Novel and unconventional equipment designs (Dave Meadows of Tongaat Hulett) Examples: Bosch chainless diffuser

44 20. Novel and unconventional equipment designs (Dave Meadows of Tongaat Hulett) Examples: Fives Cail multitube sugar drier

45 20. Novel and unconventional equipment designs (Dave Meadows of Tongaat Hulett) Examples: Cane cleaning

46 20. Novel and unconventional equipment designs (Dave Meadows of Tongaat Hulett) Examples: BMA OVC

47 20. Novel and unconventional equipment designs (Dave Meadows of Tongaat Hulett) if you are building, expanding or modifying a sugarcane factory, and you are installing: Knives and a heavy duty shredder rather than an inline, whole-stick shredder, or A tandem of 4-roll mills rather than a diffuser, 2-roll mills or both, or Robert evaporators on 1 st and 2 nd effects rather than long-tube film or plate, or Batch pans rather than continuous pans on all boilings, or Lower pressure boilers (< 45 bar) rather than high pressure boilers (> 86 bar)

48 20. Novel and unconventional equipment designs (Dave Meadows of Tongaat Hulett)

49 22. SRI swirl spreaders (Anthony Mann and Geoff Kent of SRI) Bagasse distribution

50 22. SRI swirl spreaders (Anthony Mann and Geoff Kent of SRI) SRI Swirl Spreader System Swirl spreaders Modifications to air distribution system

51 22. SRI swirl spreaders (Anthony Mann and Geoff Kent of SRI) Benefits 10% increase in boiler capacity Improved flame stability Reduces sensitivity to bagasse moisture

52 24. Jigger systems to improve vacuum pan performance (Ross Broadfoot of Queensland University of Technology) Incondensible gasses used as jigger steam Improves circulation (20%) Improves heat transfer (5 to 30%) Shorter cycle times Reduced calandria pressure Applicable to Batch and Continuous pans

53 24. Jigger systems to improve vacuum pan performance (Ross Broadfoot of Queensland University of Technology) Laser drilled stainless steel tubing Holes of 0.2 mm diameter holes per meter

54 24. Jigger systems to improve vacuum pan performance (Ross Broadfoot of Queensland University of Technology) Air test after hours of operation

55 Site Visits TGM: Gearbox and Turbine manufacturer Wide range of conventional and planetary gearboxes From 85 knm to 4000 knm capacity Wide range of turbines up to 250 MW

56 Site Visits Usina Mandu Sugar Factory and distillery tc/d A lot of TGM equipment

57 Site Visits Dedini One of 6 large manufacturing facilities visited Design and construction of complete sugar factories and distilleries Services: Sugar Brewaries Mining Steel

58 Site Visits Usina Da Barra white sugar factory and distillery tc/d (3 lines) Produces: White, amorphous and liquid sugar

59 Conclusion Well attended 62 participants 15 countries Increased focus on energy products Driving innovation Brazillian industry has a forward looking vision Thinking big Thinking energy Exciting times for the Sugar Industry worldwide

60 Acknowledgements All presenters at the 2008 ISSCT Workshop Booker Tate Limited

61 Obrigado / Thank you Visit our website

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