Jun 30, 2009 ... ISSCT Congress every 3 years. ▫ Workshops held between Congresses. ▫
Workshops: ▫ Less formal. ▫ Mainly slide show presentations.
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
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
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
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 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
2. Factory and factory system design (Jose Oliverio of Dedini)
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
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 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
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: 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
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%
88%
76%
Total Drive Efficiency
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 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) …
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 Thank you you Obrigado Visitour ourwebsite website Visit www.booker-tate.co.uk www.booker-tate.co.uk