ISSCT Workshop 2008 ISSCT Workshop 2008 - sasta

ISSCT Workshop Workshop 2008 2008 ISSCT 30June Juneto to44July July 30

Warren Lawlor July 2008

Contents

Background Venue Technical Sessions Visits Conclusion

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)

Venue

Brazil

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


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

559

600 487 427

500

521

455

403 400 300

198 49%

200 47%

203 45%

210 43%

217 42%

200 100

205 51%

227 53%

252 55%

277 57%

2005/06

2006/07

2007/08

2008/09

304 58%

2009/10

225 40%

334 60%

0

Increase of 30 millions t/year

2010/11

For sugar For Ethanoll


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


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


Traditional Technology

CANE

RECEPTION/ PREPARATION

EXTRACTION

JUICE

SUGAR PROCESS MOLASSES

B A G A S S E STEAM GENERATION (BOILER)

PRODUCT FLOW

SURPLUS BAGASSE

ELECTRICITY GENERATION (TURBOGENERATOR)

HIGH ORESSURE STEAM FLOW (DRIVING PURPOSE) LOW PRESSURE STEAM FLOW (THERMAL PURPOSE)

SUGAR


Traditional Technology Optimised

CANE

RECEPTION/ PREPARATION

JUICE

EXTRACTION

J U I C E

B A G A S S E

SUGAR PROCESS MOLASSES

BIOETHANOL

BIOETHANOL PROCESS

STEAM GENERATION (BOILER)

ELECTRICITY GENERATION (TURBOGENERATION)

SUGAR

BIOELECTRICITY

STILLAGE


Future (Electricity optimised)


Future (Ethanol optimised)

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

TECHNOLOGY TECHNOLOGY OPTIMIZATION OPTIMIZATION TO TO INTEGRATED INTEGRATED BIODIESEL BIODIESEL PRODUCTION PRODUCTION rd GENERATION 33rd GENERATION OIL LAND

GRAIN GRAIN MEAL

RESOURCES SYSTEMS

INTEGRATED FARMING SUGARCANE + GRAIN

BIODIESEL

SUGARCANE + GRAIN INTEGRATED PROCESSES MILL

BIODIESEL GLYCERIN BIOETHANOL

MANAGEMENT

CANE

STILLAGE BIOELECTRICITY


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: Power demand: Power export:

26 – 34 % on cane (raw / refined) 25 – 32 kWh/t cane 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


Stress distribution

Pinionless vs conventional


Displacement



Shear force and bending moment diagram



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%

88%

76%

Total Drive Efficiency


In operation

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.




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


Capital cost is significant for pumps < 10 kW Over 150 kW capital cost is negligible


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


Examples: Rock and sand removal


Examples: Two roll mill


Examples: Bosch chainless diffuser


Examples: Fives Cail multitube sugar drier


Examples: Cane cleaning


Examples: BMA OVC


… 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 1st and 2nd 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) …


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

Bagasse distribution


SRI Swirl Spreader System

Swirl spreaders Modifications to air distribution system


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


Laser drilled stainless steel tubing Holes of 0.2 mm diameter 100 000 holes per meter


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 Thank you you Obrigado Visitour ourwebsite website Visit www.booker-tate.co.uk www.booker-tate.co.uk