To evaluate the software tool UNISIM in. To evaluate the software ... Semicontinuous High grade A. 02 CENT_B ... Semicontinuous Low grade. Characteristics of ...
A new approach for short term scheduling g in the production of sugar from cane. cane •Raúl Raúl Sabadí •Jordi Cantón •Carlos de Armas •Leopoldo Rostgaard •Moises Graells •Luis Puigjaner
ICIDCA Camilo Cienfuegos Sugar Factory UPC
Objectives • To evaluate the software tool UNISIM in the short term scheduling of operations in the production of sugar from cane. cane • To do this evaluation through a real case study in a sugar factory in which the milling capacity was reduced.
Case study: “Camilo Camilo Cienfuegos” g Sugar g Factoryy • Material balance. balance • Recipes construction. • Selection of a feasible schedule. • Schedule optimisation (SA).
Material balance for a three th massecuites it processing system.
U N I S I M
Characteristics of the equipment Characteristics of vacuum pans. No. Label
Volume (m3)
Process
Minimum Maximum Operating
01 TACHO_01
13.0
51.3
36.8
Low grade (C)
02 TACHO_02
14.6
53.0
38.5
Low g grade (C) ( )
03 TACHO_03
15.1
53.6
38.8
High grade (A, B)
04 TACHO_04 _
13.5
47.6
41.1
High g grade g (A, ( , B))
05 TACHO_12
13.0
47.6
38.5
High grade (A, B)
06 TACHO_13 TACHO 13
13.3
47.6
38.5
High grade (A, B)
07 TACHO_14
13.3
47.6
38.5
High grade (A, B)
08 TACHO_15 TACHO 15
13.3
47.6
38.5
High grade (A)
Characteristics of the equipment Characteristics of intermediate storage vessels. No Label No. 01 02 03 04
GRAN_502 GRAN_504 GRAN 504 GRAN_506 GRAN_507
Material
Capacity (m3) Maximum Minimum Fine grain 200.0 0.0 Improved fine grain 200.0 200 0 00 0.0 Material S1 150.0 0.0 Material S2P 150.0 0.0
Process Low grade Low grade High grade High grade
Characteristics of crystallisers. No. Label 01 02 03
CRIST_A CRIST_B CRIST B CRIST_C
Material Massecuite A Massecuite B Massecuite C
Capacity (m3) Process Maximum Minimum 168.0 168 0 168.0 312.0
0.0 00 0.0 0.0
High grade A High grade A Low grade
Characteristics of the equipment Characteristics of centrifugals. No.
Label b l
01 02 03
CENT_A CENT_B CENT_C
Material i l Massecuite A Massecuite B Massecuite C
Capacity C i (m3/hr) 48.0 62.0 44.0
Type Semicontinuous Semicontinuous Semicontinuous
Characteristics of vessels. No. Label
Material
01 02 03 04
Molasses A 40.0 Molasses B 40.0 Final molasses 1000.0 Syrup 80.0
TANQUE_MA TANQUE_MB Q _ TANQUE_MF TANQUE_MP
Capacity (m3) M i Maximum Minimum Mi i 0.0 0.0 0.0 0.0
Process High grade A High grade B Low grade
Materials in process. No.
Material
Label
Initial stock (m3) ( )
01 Prepared syrup
MP
0.0
02 Seed magma
MS
0.0
03 Material S1
M_S1
0.0
04 Material S2P
M_S2P
0.0
05 Material S2
M_S2
0.0
06 Material S3
M_S3
0.0
07 Fine grain
M_GF
0.0
08 Improved d fi fine grain i
M_GFM
0.0
09 Massecuite A
M_MCA
0.0
10 Massecuite B
M_MCB
0.0
11 Massecuite C
M_MCC
0.0
12 Molasses A
MA
0.0
13 Miolasses Mi l B
MB
00 0.0
14 Final molasses
MF
0.0
15 Sugar A
AA
0.0
16 Sugar B
AB
0.0
17 Sugar C
AC
0.0
Utilities and resources. No.
Utility or resource
Type
Units
Max.
Min.
Initial
01 Steam
Renewable
ton/hr
40.0
0.0
02 Electricity
Renewable
kWh
03 Level of material S1
Storage
m3
150.0
0.0
0.0
04 Level of material S2P
Storage
m3
150.0
0.0
0.0
05 Level of fine grain
Storage
m3
200.0 200 0
0.0 00
0.0 00
06 Level of improved fine grain
Storage
m3
200.0
0.0
0.0
07 Level of massecuite A
Storage
m3
168.0
0.0
0.0
08 Level of massecuite B
Storage
m3
168.0
0.0
0.0
09 Level of massecuite C
Storage
m3
312.0
0.0
0.0
10 Level of molasses A
Storage
m3
40.0
0.0
40.0
11 Level of molasses B
Storage
m3
40.0
0.0
40.0
12 Level of final molasses
Storage
m3
1000.0 0.0
0.0
13 Level of syrup
Storage
m3
14 Level of sugar A
Storage
15 Level of sugar B
Storage
4500.0 0.0
80.0
0.0
80.0
m3
1000.0 0.0
0.0
m3
1000.0 0.0
0.0
Process level representation
High grade massecuites processing (COMERCIALES)
Low grade massecuites processing (AGOTAMIENTO)
Production gy strategy COMERCIALES
Camilo Cienfuegos Sugar Factory
U N I S I M
COMERCIALES Recipes
Flows No.
Flow
Recipe COM_04 Label Coefficient
01 Seed magma
MS
-0.44
02 Prepared syrup
MP
-1.56
03 Material S1
M_S1
0.50
04 Material S2P
M_S2P
0.50
05 Massecuite A
M_MCA
1.00
Tasks No Task No.
Label
Size factor
Equipment
01
Boiling of massecuite A
MCA(IV)
1.0
TACHOS_A
02
Storage of material S1
ALM_S1
0.5
G_506
03
Storage of material S2P
ALM S2P ALM_S2P
05 0.5
G 507 G_507
04
Storage of massecuite A
ALM_MCA1
1.0
CRIST_A
Tasks in recipe COM_04 No. Task
a
b
c
TW
01- Load footing
0.0
0.007
1.0
0.0
02- Boiling S1
4.0
0.0
1.0
1.0
03- Discharge S1
0.25
0.0
1.0
0.0
04- Boiling S2P
1.0
0.0
1.0
1.5
05- Discharge S2P
0.25
0.0
1.0
0.0
06- Boiling MCA
1.5
0.0
1.0
1.5
07- Discharge MCA 0.25
0.0
1.0
0.0
02 ALM_S1
01- Get S1
0.25
0.0
1.0
0.0
03 ALM_S2
01- Get S2P
0.25
0.0
1.0
0.0
0.25
0.0
1.0
0.0
01 MCA(IV)
Subtask
04 ALM_MCA 01- Get MCA
TOP = a + bQc
TF = TI + TOP + TW
ES
02/01
03/01
04/01
Use of utilities and resources in recipe COM_04 No. Task 01 MCA(IV)
Scheduling for vacuum pan TACHO_02 No. Batch Recipe
Task
Subtask
From
To
TOP
TW
01 01
MCC(I)
01 Load 01L d ffooting ti
0 00 0.00
0 26 0.26
0 26 0.26
0 00 0.00
02- Boiling GF
0.26
4.26
4.00
0.00
03- Discharge GF
4.26
4.51
0.25
0.00
04 Boiling 04B ili GFM
4 51 4.51
8 51 8.51
4 00 4.00
0 00 0.00
05- Discharge GFM
8.51
8.76
0.25
0.00
06- Boiling MCC
8.76
13.76
5.00
0.00
07- Discharge MCC
13.76
14.01
0.25
0.00
01- Load GFM
14.01
14.26
0.25
0.00
02- Boiling MCC
14.26
19.26
5.00
0.00
03- Discharge MCC
19.26
19.51
0.25
0.00
19.51
21.04
0.00
1.53
01- Load footing
21.04
21.30
0.26
0.00
02- Boiling GF
21.30
25.30
4.00
0.00
03- Discharge GF
25.30
25.55
0.25
0.00
04- Boiling GFM
25.55
29.55
4.00
0.00
05- Discharge GFM
29.55
29.80
0.25
0.00
06- Boiling MCC
29.80
34.80
5.00
0.00
07- Discharge MCC
34.80
35.05
0.25
0.00
01- Load GFM
35.05
35.30
0.25
0.00
02- Boiling MCC
35.30
40.30
5.00
0.00
03- Discharge MCC
40.30
40.55
0.25
0.00
02 05
AGOT 01 AGOT_01
AGOT_03
MCC(III)
03 04 46
05 71
OFF AGOT_01
AGOT_03
MCC(I)
MCC(III)
Gantt Chart. Case 1 for launch Arbol_05.
Gantt Chart. Case 1 for launch Arbol_05.
Gantt Chart. Case 2 for launch Arbol_05. _
Gantt Chart. Case 2 for launch Arbol_05. _
Utilisation rates of vacuum pans for launch Arbol_05 C Case 1 Pan
C Case 2
Horizon
Off
UR(%)
Off
UR(%)
TACHO 01 TACHO_01
24 0 24.0
0 00 0.00
100.00 100 00
1 53 1.53
93 60 93.60
TACHO _02
24.0
4.26
82.30
5.79
75.90
TACHO_03
24.0
0.00
100.00
0.00
100.00
TACHO_04
24.0
0.35
98.50
3.54
85.30
TACHO_12
24.0
1.96
91.80
1.68
93.00
TACHO_13
24.0
3.25
86.50
7.13
70.30
TACHO_14
24.0
4.73
80.30
6.18
74.30
TACHO_14
24.0
4.56
81.00
7.45
69.00
192.0
19.11
90.00 33.30
82.70
Total
Conclusions • A new approach for description and scheduling of the process in the boiling house for sugar production from cane is used and its advantages and limitations d demonstrated. t t d
Conclusions • The process for building such a model over the software package UNISIM is described through a real case study in a sugar factory. It was demonstrated the f ibilit off using feasibility i this thi tool t l for f the th analysis.
Conclusions • In this study not only the pans stage was included; but also the crystallisation and centrifugation areas of the factory factory. The use of utilities and resources, including i inventory t off allll intermediate i t di t materials, t i l were analysed.
Conclusions • The utilisation rates of vacuum pans as well as the influence of the production planning on the steam consumption profile were studied looking for fulfilling sugar production d ti requirements i t in i this thi factory.
Conclusions • The use of simulated annealing technique for optimisation of the schedule was not efficient for this case case, in which the feasible Gantt chart was near the th optimum. ti F Further th d developments l t of this tool should take this into account.
Conclusions • Based on this experience a software tool oriented to process scheduling in sugar industry from cane will be developed. developed
