ISSCT Workshop 2008 30 30 June to to 4 July Warren Lawlor July 2008
Background Venue Technical Sessions Visits Conclusion Contents
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
Background Workshop held in conjunction with SIMTEC: (Symposium and Technology Exhibition on the Sugar & Alcohol Industry)
Brazil Venue
Venue Peracicaba, Brazil
Venue The Old Sugar Mill, Peracicaba, Brazil
Technical Sessions Four technical sessions keynote address Presentations Discussion Over 25 presentations 4 Site visits
1. Overview of Brazilian Industry (Edgard Gomes Beauclair of STAB) Sugar Cane In Brazil 2007 6 million hectares 470 million tonnes of cane 29 million tonnes of sugar 17 billion liters of ethanol 83 tonnes sugarcane per hectare
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)
1. Overview of Brazilian Industry (Edgard Gomes Beauclair of STAB) Million tonnes 600 500 400 300 403 198 49% 427 200 47% 455 203 45% 487 210 43% 521 217 42% 559 225 40% 200 100 205 51% 227 53% 252 55% 277 57% 304 58% 334 60% 0 2005/06 2006/07 2007/08 2008/09 2009/10 2010/11 Increase of 30 millions t/year For sugar For Ethanoll
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
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)
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
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)
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
2. Factory and factory system design (Jose Oliverio of Dedini) Future (Electricity optimised)
2. Factory and factory system design (Jose Oliverio of Dedini) Future (Ethanol optimised)
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
2. Factory and factory system design (Jose Oliverio of Dedini) Vision for future of sugar industry
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
5. Concept of an energy efficient 6000 t/day sugar factory (Boris Morgenroth) Results (Benchmarking): Steam demand: 26 34 % on cane (raw / refined) Power demand: 25 32 kwh/t cane Power export: 90 125 kwh/t cane at 14 % fiber on cane Extraction recovery: ~ 98 % Overall recovery: ~ 87 % Sugar color: < 35-45 IU
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
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.
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
11. Development of pinionless mill (DK Goel from ISGEC) ISGEC has developed a range of mills up to 340 t/h
11. Development of pinionless mill (DK Goel from ISGEC) Stress distribution Pinionless vs conventional
11. Development of pinionless mill (DK Goel from ISGEC) Displacement Pinionless vs conventional
11. Development of pinionless mill (DK Goel from ISGEC) Shear force and bending moment diagram Pinionless vs conventional
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%
11. Development of pinionless mill (DK Goel from ISGEC) In operation
13. High Pressure Cogeneration (AK Subramanian of ISGEC)
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.
13. High Pressure Cogeneration (AK Subramanian of ISGEC)
13. High Pressure Cogeneration (AK Subramanian of ISGEC)
13. High Pressure Cogeneration (AK Subramanian of ISGEC)
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
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
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)
20. Novel and unconventional equipment designs (Dave Meadows of Tongaat Hulett) Examples: TH Cylindrical continuous pan
20. Novel and unconventional equipment designs (Dave Meadows of Tongaat Hulett) Examples: Rock and sand removal
20. Novel and unconventional equipment designs (Dave Meadows of Tongaat Hulett) Examples: Two roll mill
20. Novel and unconventional equipment designs (Dave Meadows of Tongaat Hulett) Examples: Bosch chainless diffuser
20. Novel and unconventional equipment designs (Dave Meadows of Tongaat Hulett) Examples: Fives Cail multitube sugar drier
20. Novel and unconventional equipment designs (Dave Meadows of Tongaat Hulett) Examples: Cane cleaning
20. Novel and unconventional equipment designs (Dave Meadows of Tongaat Hulett) Examples: BMA OVC
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)
20. Novel and unconventional equipment designs (Dave Meadows of Tongaat Hulett)
22. SRI swirl spreaders (Anthony Mann and Geoff Kent of SRI) Bagasse distribution
22. SRI swirl spreaders (Anthony Mann and Geoff Kent of SRI) SRI Swirl Spreader System Swirl spreaders Modifications to air distribution system
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
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
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 100 000 holes per meter
24. Jigger systems to improve vacuum pan performance (Ross Broadfoot of Queensland University of Technology) Air test after 15 000 hours of operation
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
Site Visits Usina Mandu Sugar Factory and distillery 12 000 tc/d A lot of TGM equipment
Site Visits Dedini One of 6 large manufacturing facilities visited Design and construction of complete sugar factories and distilleries Services: Sugar Brewaries Mining Steel
Site Visits Usina Da Barra white sugar factory and distillery 38 000 tc/d (3 lines) Produces: White, amorphous and liquid sugar
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
Acknowledgements All presenters at the 2008 ISSCT Workshop Booker Tate Limited
Obrigado / Thank you Visit our website www.booker-tate.co.uk