ISSCT Workshop 2008 ISSCT Workshop 2008 - sasta

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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

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Background Venue Technical Sessions Visits Conclusion

Background

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ISSCT Congress every 3 years Workshops held between Congresses Workshops:

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Less formal Mainly slide show presentations Discussion encouraged Includes site visits

Workshop theme:

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Design, Manufacturing and maintenance of sugar mill equipment

Background

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Workshop held in conjunction with SIMTEC:

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(Symposium and Technology Exhibition on the Sugar & Alcohol Industry)

Venue

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Brazil

Venue

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Peracicaba, Brazil

Venue

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The Old Sugar Mill, Peracicaba, Brazil

Technical Sessions

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Four technical sessions

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keynote address Presentations Discussion

Over 25 presentations 4 Site visits

1. Overview of Brazilian Industry (Edgard Gomes Beauclair of STAB)

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Sugar Cane In Brazil 2007

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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)

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Brazillian Plants

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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)

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Environmetal issues

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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)

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Summary

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Brazilian industry is focused on sugarcane as an energy crop Products include:

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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)

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Vision for future of sugar industry

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Sustainable development based on producing biofuels and bioenergy from sugarcane.

Vision of sugarcane as energy

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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)

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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)

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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)

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Future (Electricity optimised)

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

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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)

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Vision for future of sugar industry

5. Concept of an energy efficient 6000 t/day sugar factory (Boris Morgenroth)

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Emerging technologies

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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)

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Results (Benchmarking):

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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

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Extraction recovery:

~ 98 %

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Overall recovery:

~ 87 %

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Sugar color:

< 35 - 45 IU

6. Simple innovative, proven equipment and processes for improving energy efficiency (Bruce Moor of Bosch)

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Modifications can be made to an existing “80’s” factory for efficiency improvements:

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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:

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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)

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In line whole stick shredder

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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)

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MillMax 3 roll mill

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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)

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ISGEC has developed a range of mills up to 340 t/h

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

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Stress distribution

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Pinionless vs conventional

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

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Displacement

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Pinionless vs conventional

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

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Shear force and bending moment diagram

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Pinionless vs conventional

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

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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)

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In operation

13. High Pressure Cogeneration (AK Subramanian of ISGEC)

13. High Pressure Cogeneration (AK Subramanian of ISGEC)

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Reason

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45 bar to 105 bar = 32% more power generation per tone of bagasse

Features

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Pressurised feedwater (220 Deg.C) Travelling grate (alternative fuels) Electrostatic precpitators On line steam and water analysis

Claims

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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)

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Pump selection criterion should be based on lifecycle cost – not capital cost Selection criteria should include:

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Pump material and shaft sealing arrangement Pump efficiency Maintenance cost Quality

15. Selection use and maintenance of process pumps (Michael Yang of Sulzer)

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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)

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Variable frequency drive vs. valve control

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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)

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Examples: TH Cylindrical continuous pan

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

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Examples: Rock and sand removal

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

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Examples: Two roll mill

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

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Examples: Bosch chainless diffuser

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

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Examples: Fives Cail multitube sugar drier

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

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Examples: Cane cleaning

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

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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)

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Bagasse distribution

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

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SRI Swirl Spreader System

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Swirl spreaders Modifications to air distribution system

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

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Benefits

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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)

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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)

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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)

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Air test after 15 000 hours of operation

Site Visits ƒ

TGM: Gearbox and Turbine manufacturer

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Wide range of conventional and planetary gearboxes From 85 kNm to 4000 kNm capacity Wide range of turbines up to 250 MW

Site Visits ƒ

Usina Mandu Sugar Factory and distillery

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12 000 tc/d A lot of TGM equipment

Site Visits ƒ

Dedini

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One of 6 large manufacturing facilities visited Design and construction of complete sugar factories and distilleries Services:

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Sugar Brewaries Mining Steel

Site Visits ƒ

Usina Da Barra white sugar factory and distillery

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38 000 tc/d (3 lines) Produces:

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White, amorphous and liquid sugar

Conclusion

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Well attended

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62 participants 15 countries

Increased focus on energy products

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Driving innovation

Brazillian industry has a forward looking vision

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Thinking big Thinking energy

Exciting times for the Sugar Industry worldwide

Acknowledgements ƒ ƒ

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